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CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional Application No. 60/287,522 filed Apr. 30, 2001.
FIELD OF THE INVENTION
[0002] This invention relates to methods for preparing certain cholesteryl ester transfer protein (CETP) inhibitors and intermediates useful in the preparation of said CETP inhibitors.
BACKGROUND OF THE INVENTION
[0003] Atherosclerosis and its associated coronary artery disease (CAD) is the leading cause of mortality in the industrialized world. Despite attempts to modify secondary risk factors (smoking, obesity, lack of exercise) and treatment of dyslipidemia with dietary modification and drug therapy, coronary heart disease (CHD) remains the most common cause of death in the U.S.
[0004] Risk for development of this condition has been shown to be strongly correlated with certain plasma lipid levels. While elevated LDL-C may be the most recognized form of dyslipidemia, it is by no means the only significant lipid associated contributor to CHD. Low HDL-C is also a known risk factor for CHD (Gordon, D. J., et al.: “High-density Lipoprotein Cholesterol and Cardiovascular Disease”, Circulation, (1989), 79: 8-15).
[0005] High LDL-cholesterol and triglyceride levels are positively correlated, while high levels of HDL-cholesterol are negatively correlated with the risk for developing cardiovascular diseases. Thus, dyslipidernia is not a unitary risk profile for CHD but may be comprised of one or more lipid aberrations.
[0006] Among the many factors controlling plasma levels of these disease dependent principles, cholesteryl ester transfer protein (CETP) activity affects all three. The role of this 70,000 dalton plasma glycoprotein found in a number of animal species, including humans, is to transfer cholesteryl ester and triglyceride between lipoprotein particles, including high density lipoproteins (HDL), low density lipoproteins (LDL), very low density lipoproteins (VLDL), and chylomicrons. The net result of CETP activity is a lowering of HDL cholesterol and an increase in LDL cholesterol. This effect on lipoprotein profile is believed to be pro-atherogenic, especially in subjects whose lipid profile constitutes an increased risk for CHD.
[0007] No wholly satisfactory HDL-elevating therapies exist. Niacin can significantly increase HDL, but has serious toleration issues resulting in reduced compliance. Fibrates and the HMG-CoA reductase inhibitors raise HDL-C only modestly. As a result, there is a significant unmet medical need for a well-tolerated agent which can significantly elevate plasma HDL levels, thereby reversing or slowing the progression of atherosclerosis.
[0008] PCT application publication number WO 00/02887 discloses the use of catalysts comprising certain novel ligands for transition metals in transition metal-catalyzed carbon-heteroatom and carbon-carbon bond formation.
[0009] Commonly assigned U.S. Pat. No. 6,140,343, the disclosure of which is incorporated herein by reference, discloses, inter alia, the CETP inhibitor, cis-4-[acetyl-(3,5-bis-trifluoromethyl-benzyl)-amino]-2-ethyl-6-trifluoromethyl-3,4-dihydro-2H-quinoline-1-carboxylic acid isopropyl ester, and processes for the preparation thereof (e.g., procedure disclosed in Example 46).
[0010] Commonly assigned U.S. Pat. No. 6,197,786, the disclosure of which is incorporated herein by reference, discloses, inter alia, the CETP inhibitor, cis-4-[(3,5-bis-trifluoromethyl-benzyl)-methoxycarbonyl-amino]-2-ethyl-6-trifluoromethyl-3,4-dihydro-2H-quinoline-1-carboxylic acid ethyl ester, and processes for the preparation thereof (e.g., procedure disclosed in Example 7).
SUMMARY OF THE INVENTION
[0011] One aspect of this invention provides methods for preparing the compound of formula IA,
[0012] comprising combining the compound of formula VIIIA,
[0013] with a 3,5-bis(trifluoromethyl)benzyl halide in the presence of a base, wherein said base is preferably potassium t-butoxide.
[0014] In a preferred embodiment, said compound of formula VIIIA is prepared by a method comprising combining the compound of formula VIIA,
[0015] with ethyl chloroformate to form the compound of formula VIIIA. In a more preferred embodiment, said compound of formula VIIA is prepared by a method comprising reducing the compound of formula VI,
[0016] wherein R is methyl, with a reducing agent to form a reduced compound and cyclizing the reduced compound under acidic conditions to form a compound of formula VIIA. Even more preferably, said compound of formula VI is prepared by a method comprising combining the compound of formula IV,
[0017] with the compound of formula V,
[0018] wherein R is methyl, in the presence of a base to form the compound of formula VI. In an even more preferred embodiment, said compound of formula IV is prepared by a method comprising hydrolyzing the compound of formula III, III,
[0019] with a hydrolyzing agent selected from an acid and a base to form the compound of formula IV. Even more preferably, said compound of formula III is prepared by a method comprising coupling trifluoromethylbenzene para-substituted with a halogen or O-triflate with the compound of formula II,
[0020] to form the compound of formula III.
[0021] Another aspect of this invention provides methods for preparing the compound of formula VIIIB,
[0022] wherein R 1 is benzyl or substituted benzyl,
[0023] comprising combining the compound of formula VIIB,
[0024] wherein R 1 is as defined for formula VIIIB,
[0025] with isopropyl chloroformate in the presence of a base, preferably pyridine, to form the compound of claim VIIIB.
[0026] A further aspect of this invention provides methods for preparing the compound of formula IB
[0027] comprising the steps of:
[0028] a) reducing the compound of formula VIIIB,
[0029] wherein R 1 is benzyl or substituted benzyl,
[0030] with a reducing agent to form cis-4-amino-2-ethyl-6-trifluoromethyl-3,4,-dihydro-2H-quinoline-1-carboxylic acid isopropyl ester;
[0031] b) treating said cis-4-amino-2-ethyl-6-trifluoromethyl-3,4,-dihydro-2H-quinoline-1-carboxylic acid isopropyl ester first with 3,5-bis-trifluoromethyl-benzaldehyde under acidic conditions followed by a reducing agent to form cis-4-(3,5-bis-trifluoromethyl-benzylamino)-2-ethyl-6-trifluoromethyl-3,4,-dihydro-2H-quinoline-1-carboxylic acid isopropyl ester;
[0032] c) treating said cis-4-(3,5-3,5-bis-trifluoromethyl-benzylamino)-2-ethyl-6-trifluoromethyl-3,4,-dihydro-2H-quinoline-1-carboxylic acid isopropyl ester with an acetylating agent to form the compound of formula IB, wherein said compound of formula VIIIB is prepared by a method comprising combining the compound of formula VIIB,
[0033] with isopropyl chloroformate to form the compound of claim VIIIB.
[0034] In a preferred embodiment, said compound of formula VIIB is prepared by a method comprising reducing the compound of formula VI,
[0035] wherein R 1 is benzyl or substituted benzyl, with a reducing agent to form a reduced compound and cyclizing the reduced compound under acidic conditions to form the compound of formula VIIB. Even more preferably, said compound of formula VI is prepared by a method comprising combining the compound of formula IV,
[0036] with the compound of formula V,
[0037] wherein R 1 is benzyl or substituted benzyl, in the presence of a base to form the compound of formula VI. In an even more preferred embodiment, said compound of formula IV is prepared by a method comprising hydrolyzing the compound of formula III,
[0038] with a hydrolyzing agent selected from an acid and a base to form the compound of formula IV. Even more preferably, said compound of formula III is prepared by a method comprising coupling trifluoromethylbenzene para-substituted with a halogen or O-triflate with the compound of formula II,
[0039] to form the compound of formula III.
[0040] An additional aspect of this invention provides the compound of formula VIIIA,
[0041] Another aspect of this invention is methods for preparing the compound of formula VIIIA,
[0042] comprising combining the compound of formula VIIA,
[0043] with ethyl chloroformate in the presence of a base, preferably pyridine base, to form the compound of formula VIIIA.
[0044] The term “substituted benzyl” with respect to compounds of formula V, VI and VII means benzyl that is substituted on the benzene ring with one or more substituents such that such substitution does not prevent: (a) the reaction of the applicable formula V compound with the compound of formula IV to form the applicable formula VI compounds, (b) the reduction and cyclization of the applicable formula VI to form the applicable formula VIIB compound, (c) the acetylation of the formula VIIB compound to form the formula VIIIB compound or (d) the deprotection step to remove the applicable substituted benzyloxycarbonyl group in forming the formula IB compound from the compound of formula VIIIB. Preferred substituents are (C 1 -C 3 )alkyl and (C 1 -C 3 )alkoxy and halogens.
[0045] Chemical structures herein are represented by planar chemical structure diagrams that are viewed from a perspective above the plane of the structure. A wedge line ( ) appearing in such chemical structures represents a bond that projects up from the plane of the structure.
DETAILED DESCRIPTION OF THE INVENTION
[0046] Reaction Scheme A illustrates the process for preparing the chiral isomer of formula 11 from (R)-2-amino-1-butanol. Scheme B illustrates the process of preparing the cholesterol ester transfer protein inhibitors of formula IA and formula IB.
[0047] According to Scheme B, the formula III compound is prepared by combining the chiral isomer compound of formula II ((R)-3-amino-pentanenitrile) with trifluoromethylbenzene that is para-substituted with a halogen or O-triflate (—O—S(O) 2 CF 3 ) in the presence of a metal catalyst, preferably Pd. For optimal coupling, the coupling reaction occurs in the presence of a ligand, preferably a phosphine ligand, and a base. A preferred phosphine ligand is a dialkylphosphinobiphenyl ligand, preferably selected from 2-dicyclohexylphosphino-2′-(N,N-dimethylamino)biphenyl) and 2-dicyclohexylphosphino-2′-methylbiphenyl. The reaction is preferably performed at a temperature of about 60° C. to about 110° C. The formula II chiral isomer may be prepared from (R)-2-amino-1-butanol (CAS#005856-63-3) by methods known to those skilled in the art according to Scheme A and as described in Example 9 of the Experimental Procedures.
[0048] The formula IV compound is prepared by hydrolyzing the nitrile of the formula III compound. The hydrolysis may be performed in acidic or basic conditions. The preferred method of hydrolysis is under acidic conditions, preferably using sulfuric acid and water. For hydrolysis with base, preferred bases are hydroxy bases, preferably lithium hydroxide, sodium hydroxide and potassium hydroxide, or alkoxy bases, preferably methoxide and ethoxide. Also, for hydrolysis with base, it is preferably to use a peroxide. The hydrolysis reaction is preferably performed at a temperature of about 20° C. to about 40° C.
[0049] The formula VI compound is prepared by reacting the amide of the formula IV compound with a formula V chloroformate in the presence of a base, preferably lithium t-butoxide. The reaction is preferably performed at a temperature of about 0° C. to about 35° C. If the formula VI compound having R as methyl is desired, then methyl chloroformate is used as the formula V compound. If the formula VI compound having R as benzyl is desired, then benzyl chloroformate is used.
[0050] The formula VII compound is prepared by reacting the imide of the formula VI compound with a reducing agent, preferably sodium borohydride, in the presence of a Lewis acid activator, preferably calcium or magnesium ions to produce a reduced intermediate. The reaction to make the reduced intermediate is preferably performed at a temperature of about −20° C. to about 20° C. Under acidic conditions, the intermediate diastereoselectively cyclizes to form the tetrahydroquinoline ring of formula VII. The cyclization step is preferably performed at about 20° C. to about 50° C.
[0051] The CETP inhibitor of formula IA is prepared by acylating the compound of formula VII wherein R is methyl at the tetrahydroquinoline nitrogen with ethyl chloroformate in the presence of a base, preferably pyridine, to form the compound of formula VIIIA. The reaction is preferably performed at a temperature of about 0° C. to about 25° C.
[0052] The formula IA CETP inhibitor is prepared by alkylating the formula VIII compound, wherein R is methyl, with a 3,5-bis(trifluoromethyl)benzyl halide, preferably 3,5-bis(trifluoromethyl)benzyl bromide in the presence of a base, preferably an alkoxide or hydroxide, and more preferably potassium t-butoxide. The preferred temperature range of the reaction is about 25° C. to about 75° C.
[0053] The CETP inhibitor of formula IB is prepared by acylating compound VII wherein R is benzyl or substituted benzyl at the tetrahydroquinoline nitrogen with isopropyl chloroformate in the presence of a base, preferably pyridine, to form the compound of formula VIIIB. The preferred temperature of this reaction is about 0° C. to about 25° C.
[0054] The CETP inhibitor of formula IB may then be prepared from the formula VIIIB compound by first treating compound VIIIB with an excess of a hydrogen source (e.g., cyclohexene, hydrogen gas or ammonium formate) in the presence of a suitable catalyst in a polar solvent (e.g. ethanol) to remove the benzyloxycarbonyl group. The 3,5-bis-trifluoromethylbenzyl group of the formula IB compound may then be introduced by treating the amine and an acid, such as acetic acid, with 3,5-bis-trifluoromethyl-benzaldehyde followed by treatment with a hydride source, such as sodium triacetoxyborohydride. Then, the amino group is acetylated by methods known by those skilled in the art to form the formula IB compound. The procedure for preparing the compound of formula IB from the compound of formula VIIIB is further described in Example 46 of commonly assigned U.S. Pat. No. 6,140,343. The disclosure of U.S. Pat. No. 6,140,343 is incorporated herein by reference.
Experimental Procedures
[0055] Melting points were determined on a Buchi melting point apparatus. NMR spectra were recorded on a Varian Unity 400 (Varian Co., Palo Alto, Calif.). Chemical shifts are expressed in parts per million downfield from the solvent. The peak shapes are denoted as follows: s=singlet; d=doublet; t=triplet; q=quartet; m=multiplet; bs=broad singlet.
EXAMPLE 1
(3R)-3-(4-Trifluoromethyl-phenylamino)-pentanenitrile
[0056] A clean, dry and nitrogen gas purged 100 L glass tank was charged with (R)-3-aminopentanenitrile methanesulfonic acid salt (3000 g, 15.44 mol), sodium carbonate (2.8 kg, 26.4 mol), and methylene chloride (21 L). The heterogeneous mixture was stirred well for at least 2 hours. The mixture was filtered and the filter was rinsed with methylene chloride (3×2 L). The resulting filtrate was placed in a clean, dry, and nitrogen gas purged 50 L glass reaction tank. The methylene chloride was removed by distillation until the internal temperature reached 50-53° C. to afford the free-based amine as a thin oil. The tank was then cooled to room temperature and charged with toluene (20 L), chloro-4-(trifluoromethyl)benzene (4200 g, 23.26 mol), and cesium carbonate (7500 g, 23.02 mol). The solution was sparged with nitrogen gas for 1 hour. Near the time of completion of the sparging, fresh catalyst solution was prepared by charging a 2L round-bottom flask, equipped with stir bar and flushed with nitrogen gas, with 2-dicyclohexylphosphino-2′-(N,N-dimethylamino)biphenyl (68 g, 0.17 mol), phenylboronic acid (28 g, 0.23 g), and tetrahydrofuran (1.2 L) followed by palladium acetate (26 g, 0.12 mol). The catalyst solution was stirred at room temperature under nitrogen atmosphere for 15 minutes. The catalyst solution was added to the 50L reaction tank with the use of a cannula (excluding air). The mixture was heated to 79° C. internal temperature under nitrogen atmosphere for 16 hours. The reaction solution was cooled to room temperature and filtered through Celite®. The solids were rinsed with toluene (3×2L) and the filtrate was collected. All filtrates were combined to afford a crude solution of the title compound.
EXAMPLE 2
(3R)-3-(4-Trifluoromethyl-phenylamino)-pentanoic Acid Amide
[0057] Aqueous sulfuric acid (8.2 L sulfuric acid and 1.1 L water premixed and cooled to 35° C. or less) was added to the crude toluene solution of (3R)-3-(4-trifluoromethyl-phenylamino)-pentanenitrile from Example 1. The resulting bilayer was stirred well and heated to 35° C. for 17 hours. The lower aqueous layer was collected and quenched with aqueous sodium hydroxide (95 L water and 10.7 kg sodium hydroxide) and diisopropyl ether (IPE) (40 L). After extraction and removal of the aqueous layer, the organic layer was combined and extracted with saturated aqueous NaHCO 3 (10 L). The organic phase from the resulting bilayer was concentrated by distillation to a volume of 19 L. The solution was then cooled to room temperature and seeded with (3R)-3-(4-trifluoromethyl-phenylamino)-pentanoic acid amide and allowed to granulate for 3 hours while stirring. To the heterogenous mixture was added cyclohexane (38 L) and the mixture was granulated for an additional 11 hours. The solids were filtered, rinsed with cyclohexane (4 L), dried under vacuum at 40° C. to afford 3021 g (75%) of the title compound.
[0058] [0058] 1 H NMR (400 MHz, CDCl 3 ): 0.98 (t, 3, J=7.5), 1.60-1.76 (m, 2), 2.45 (d, 2, J=5.8), 3.73-3.80 (m, 1), 5.53(br s, 1), 5.63 (br s, 1), 6.65, (d, 2, J=8.7), 7.39 (d, 2, J=8.7)
[0059] [0059] 13 C NMR (100 MHz, CDCl 3 ): 10.74, 27.80, 40.02, 51.95, 112.63, 118.9 (q, J=32.7), 125.18 (q, J=271.0), 126.93 (q, J=3.8), 150.17, 174.26
EXAMPLE 3
(3R)-[3-(4-Trifluoromethyl-phenylamino)-pentanoyl]-carbamic Acid Methyl Ester
[0060] A clean, dry and nitrogen gas purged 100 L glass tank was charged with (3R)-3-(4-trifluoromethyl-phenylamino)-pentanoic acid amide (6094 g, 23.42 mol), isopropyl ether (30 L) and methyl chloroformate (2.7 kg, 29 mol). The resulting slurry was cooled to 2° C. The reaction tank was then charged with lithium t-butoxide solution (18-20% in THF, 24.6 kg, ˜58 mol) at such a rate as to maintain the internal temperature below 10° C. and preferably at a temperature of about 5° C. Ten minutes after addition of base was complete, the reaction was quenched by the addition of 1.5 M hydrochloric acid (36 L). The aqueous layer was removed, and the organic phase extracted with saturated NaCl/water solution (10 L). The aqueous layer was removed and the organic phase was concentrated by distillation under vacuum and at a temperature of about 50° C. until the volume was reduced to about 24 L. Cyclohexane (48 L) was added to the reaction vessel and distillation was again repeated at an internal temperature of about 45-50° C. under vacuum until the volume of solution in the vessel was reduced to 24 L. A second portion of cyclohexane (48 L) was added to the reaction vessel and distillation was again repeated at an internal temperature of about 45-50° C. under vacuum until the volume of solution in the vessel was reduced to 24 L. While holding the temperature at 50° C., the solution was seeded with (3R)-[3-(4-trifluoromethyl-phenylamino)-pentanoyl]-carbamic acid methyl ester and allowed to granulate while stirring for 2 hours. The solution was then cooled slowly (over 1.5 hours) to room temperature and allowed to granulate while stirring for 15 hours. The mixture was filtered. The resulting solids were rinsed with cyclohexane (10 L) and dried under vacuum at 40° C. to afford 7504 g of the title compound (94%).
[0061] m.p.=142.3-142.4° C.
[0062] [0062] 1 H NMR (400 MHz, d 6 -Acetone): 0.96 (t, 3, J=7.4), 1.55-1.75 (m, 2), 2.86 (dd, 1, J=6.6, 16.2, 2.96 (dd, 1, J=6.2, 16.2), 3.69 (s, 3), 3.92-3.99 (m, 1), 5.49 (br d, 1, J=8.7), 6.76 (d, 2, J=8.7), 7.37 (d, 2, J=8.7), 9.42 (br s, 1).
[0063] [0063] 13 C NMR (100 MHz, CDCl 3 ): 10.62, 28.10, 40.19, 51.45, 53.42, 112.54, 118.98 (q, J=32.70), 125.16 (q, J=270.2), 126.90 (q, J=3.8), 150.10, 152.71, 173.40.
EXAMPLE 4
(2R, 4S)-(2-Ethyl-6-trifluoromethyl-1,2,3,4-tetrahydro-quinolin-4-yl)-carbamic Acid Methyl Ester
[0064] A clean, dry and nitrogen gas purged 100 L glass tank was charged (3R)-[3-(4-trifluoromethyl-phenylamino)-pentanoyl]-carbamic acid methyl ester (7474 g) followed by 2B ethanol (46 L) and water (2.35 L). Sodium borohydride (620 g) was added to the solution in one portion. Nitrogen gas purging is maintained. The mixture was stirred at room temperature for 20 minutes and then cooled to −10° C. A solution of 3.3 M aqueous magnesium chloride solution (4.68 kg MgCl 2 .6H 2 O in 7 L water) was added at such a rate that the internal temperature did not exceed −5° C. Once addition was completed, the reaction solution was warmed to 0° C. for 45 min. The reaction was quenched by transferring the reaction mixture to a 200 L tank containing methylene chloride (70 L), and 1 M hydrochloric acid/citric acid solution (5.8 L concetrated hydrochloric acid, 64 L water, and 10.5 kg citric acid). The headspace of the tank was purged with nitrogen gas. This bilayer was stirred at room temperature for two hours. The phases were separated and the lower organic product layer was removed. After aqueous layer removal, the organic phase was returned to the reaction vessel and extracted with an aqueous citric acid solution (6.3 kg citric acid, 34 L water). The mixture was stirred for 1 hour and allowed to settle overnight. The layers were separated and to the organic was added Darco® activated carbon (G-60 grade, 700 g) (Atlas Powder Co., Wilmington, Del.) and the solution was stirred for 30 minutes. The mixture was then filtered through Celite®, and the carbon was rinsed twice with methylene chloride (14L and 8L). The filtrate was distilled while periodically adding hexanes so as to displace the methylene chloride with hexanes to a total final volume of 70 L (112 L total hexanes used). Product crystallized during the displacement. Once a stable distillation temperature was reached, the solution was cooled and granulated while stirring at room temperature for 10 hours. The solids were filtered off, rinsed with hexanes (14 L), and dried at 40° C. under vacuum to afford the title compound (5291 g). (80%).
[0065] m.p.=139.0-140.5° C.
[0066] [0066] 1 H NMR (400 MHz, d 6 -Acetone): 1.00 (t, 3, J=7.5), 1.51-1.67 (m, 3), 2.19 (ddd, 1, J=2.9, 5.4, 12.4), 3.44-3.53 (m, 1), 3.67 (s, 3), 4.89-4.96(m, 1), 5.66 (br s, 1), 6.56 (br d, 1, J=8.7), 6.65 (d, 1, J=8.7), 7.20 (d, 1, J=8.7), 7.30 (br s, 1).
[0067] [0067] 13 C NMR (100 MHz, CDCl 3 ): 9.88, 29.24, 35.47, 48.09, 52.42, 52.60, 113.66, 118.90 (q, J=33.1), 121.40, 124.08 (q, J=3.8), 125.08 (q, J=270.6), 125.70 (q, J=3.8), 147.68, 157.30.
EXAMPLE 5
(2R, 4S)-2-Ethyl-4-methoxycarbonylamino-6-trifluoromethyl-3,4-dihydro-2H-quinoline-1-carboxylic Acid Ethyl Ester
[0068] A clean, dry and nitrogen gas purged 100 L glass tank was charged with (2R, 4S)-(2-ethyl-6-trifluoromethyl-1,2,3,4-tetrahydro-quinolin-4-yl)-carbamic acid methyl ester (5191 g, 17.17 mol), methylene chloride (21 L), and pyridine (4.16 L, 51.4 mol). The reaction vessel was cooled to −10° C. Ethyl chloroformate (4.10 L, 42.9 mol) was slowly added at such a rate that the internal temperature did not exceed −5° C. The reaction solution was brought to 0° C. and held for 20 hours. The reaction was quenched by adding to a mixture of diisopropyl ether (IPE) (36 L), methylene chloride (6.2 L) and 1.5M hydrochloric acid solution (52 L). The resulting phases were separated and the organic layer was extracted with 1 M sodium hydroxide solution (15 L). The resulting phases were separated and the organic layer was washed with saturated aqueous sodium chloride NaCl (15 L). The resulting phases were separated and the organic layer was concentrated by distillation to a volume of 40 L. Crystallization initiated at lower volume. The methylene chloride was displaced with IPE by distilling the mixture and periodically adding IPE to maintain a constant volume at 40L until a temperature of 68° C. was maintained (46 L total IPE used). The mixture was cooled and allowed to granulate with stirring at room temperature for 19 hours. The solids were filtered, rinsed with IPE (8 L), and dried under vacuum at 40° C. to afford 5668 g of the title compound (88%).
[0069] m.p.=157.3-157.6° C.
[0070] [0070] 1 H (400 MHz,d 6 -Acetone): 0.84 (t, 3, J=7.5), 1.26 (t, 3, J=7.0), 1.44-1.73 (m, 3), 2.59 (ddd, 1, J=4.6, 8.3,12.9), 3.67 (s, 3), 4.14-4.28 (m, 2), 4.46-4.54 (m, 1), 4.66-4.74 (m, 1), 6.82 (br d, 1, J=9.1), 7.53 (s, 1), 7.58 (d, 1, J=8.3), 7.69 (d, 1, J=8.3).
[0071] [0071] 13 C NMR (100 MHz, CDCl 3 ): 9.93, 14.55, 28.46, 38.08, 46.92, 52.64, 53.70, 62.42, 120.83 (q, J=3.4), 124.32 (q, J=271.7), 124.36 (q, J=3.4), 126.38, 126.46 (q, J=32.7), 134.68,139.65,154.66, 156.85.
EXAMPLE 6
(2R, 4S)-4-[(3,5-Bis-trifluoromethyl-benzyl)-methoxycarbonyl-aminol-2-ethyl-6-trifluoromethyl-3,4-dihydro-2H-quinoline-1-carboxylic Acid Ethyl Ester
[0072] A clean, dry and nitrogen gas purged 100 L glass tank was charged with (2R, 4S)-2-ethyl-4-methoxycarbonylamino-6-trifluoromethyl-3,4-dihydro-2H-quinoline-1-carboxylic acid ethyl ester (5175 g, 13.82 mol), CH 2 Cl 2 (20 L), and potassium t-butoxide (1551 g, 13.82 mol) at room temperature. The mixture was stirred for five minutes. 3,5-Bis(trifluromethyl)benzylbromide (3.50 L, 19.1 mol) was added to the mixture in one portion. The internal temperature was maintained between 20-25° C. for 1.5 hours. After 2.3 hours of reaction time, an additional charge of potassium t-butoxide (46.10 g, 0.41 mol) was added. After a total reaction time of 4.5 hours, the reaction was quenched. 1,4-Diazabicyclo[2.2.2]octane (DABCO) (918 9, 8.18 mol) was added to the reaction solution and the mixture was stirred for 1 hour. IPE (40 L) and 0.5 M hydrochloric acid (30 L) were added to the reaction mixture. The resulting organic and aqueous phases were separated and the organic layer was extracted with 0.5M hydrochloric acid (2×30 L). The resulting organic and aqueous phases were then separated and the organic layer was extracted with saturated aqueous sodium chloride (15 L) and the resulting organic and aqueous phases were separated. Anhydrous magnesium sulfate (3.5 kg) was added to the organic layer and the mixture was stirred for 30 minutes. The mixture was then filtered (0.5 micron filter) into a 50 L glass tank with IPE wash (8 L) in two portions. The filtrate was concentrated under vacuum to a total volume of 12 L with internal temperature of 35° C. resulting in an oil. 2B Ethanol (25 L) was added to the oil and the solution was concentrated under vacuum to a volume of 12 L. To the solution was added 2B ethanol (15 L) and the solution was again concentrated under vacuum to a volume of 12 L. The solution was cooled to room temperature and seeded with (2R, 4S)-4-[(3,5-bis-trifluoromethyl-benzyl)-methoxycarbonyl-amino]-2-ethyl-6-trifluoromethyl-3,4-dihydro-2H-quinoline-1-carboxylic acid ethyl ester (3 g). The solution was granulated for about 38 hours, filtered, and rinsed with 2B ethanol (4 L+2L). The solids were dried under vacuum (no heat) to afford 4610 g (55%) of the title compound. The mother liquor from the above filtration was concentrated under vacuum (solution temp=62° C.) to a final volume of 6 L and cooled to 38° C. The solution was seeded with (2R, 4S)-4-[(3,5-bis-trifluoromethyl-benzyl)-methoxycarbonyl-amino]-2-ethyl-6-trifluoromethyl-3,4-dihydro-2H-quinoline-1-carboxylic acid ethyl ester (0.5 g) and allowed to cool and granulate while stirring for 19 hours. The mixture was filtered and the solids rinsed with 2B EtOH (2.5 L). The resulting cake was dried under vacuum (no heat) to provide 1422 g (17%) of the title compound as the second crop. Combined recovery was 6032 g (73%).
EXAMPLE 7
(3R)-[3-(4-Trifluoromethyl-phenylamino)-pentanoyl]-carbamic Acid Benzyl Ester
[0073] A clean, dry and nitrogen gas purged flask was charged with (3R)-3-(4-trifluoromethyl-phenylamino)-pentanoic acid amide (20.11 g, 77.27 mmol) and isopropyl ether (100 mL) and the mixture was cooled to −12° C. Benzyl chloroformate (13.25 mL, 92.8 mmol) was then added followed by the slow addition of 1.0 M lithium tert-butoxide in THF solution (185.5 mL). The lithium tert-butoxide solution was added at such a rate that the internal temperature remained below 0° C. Fifteen minutes after the completion of base addition, the reaction was quenched by adding the mixture to isopropyl ether (100 mL) and 1.5 M hydrochloric acid (130 mL). The phases were separated and the organic layer was washed with saturated aqueous sodium chloride solution (130 mL). The phases were separated, the organic layer was dried (MgSO 4 ), filtered, and concentrated under partial vacuum (at 40° C.) to a total volume of 100 mL. Additional isopropylether (200 mL) was added and the solution was again concentrated under partial vacuum (at 40° C.) to a total volume of 100 mL. After cooling, the solution was seeded with (3R)-[3-(4-trifluoromethyl-phenylamino)-pentanoyl]-carbamic acid benzyl ester and allowed to stir at room temperature overnight. The remaining solvent was displaced with cyclohexane using partial vacuum distillation (45° C. bath, 200 mL followed by 100 mL), the resultant slurry was cooled and stirred for 40 minutes, filtered, and dried to provide 25.8714 g (85%) of the title compound.
[0074] m.p. 100.6-101.4° C.
[0075] [0075] 1 H NMR (400 MHz d 6 -acetone): 0.96 (t, 3, J=7.5), 1.57-1.75 (m, 2), 2.87 (dd, 1, J=6.6, 16.2), 2.97 (dd, 1, J=6.2, 16.2), 3.94-4.00 (m, 1), 5.16 (s, 2), 5.50 (br s, 1), 6.75 (d, 2, J=5.7), 7.33-7.43 (m, 7), 9.52 (br s, 1).
[0076] [0076] 13 C NMR (100 MHz CDCl 3 ): 10.66, 28.13, 40.28, 51.47, 68.25, 112.52, 118.91 (q, J=32.3), 125.21 (q, J=269.9), 126.92 (q, J=3.8), 128.64, 128.98, 129.04, 135.05, 150.12,152.12, 173.52.
EXAMPLE 8
(2R, 4S)-(2-Ethyl-6-trifluoromethyl-1,2,3,4-tetrahydro-quinolin-4-yl)-carbamic Acid Benzyl Ester
[0077] A clean, dry and nitrogen gas purged flask was charged with (3R)-[3-(4-trifluoromethyl-phenylamino)-pentanoyl]-carbamic acid benzyl ester (11.51 g, 29.18 mmol) and 95% ethanol (80 mL) and the solution was cooled in an ice/acetone bath (˜−12° C.). Sodium borohydride (0.773 g, 20.4 mmol) was then added to the solution. The internal temperature of the reaction was −11.5° C. To the reaction flask was slowly added a solution of MgCl 2 .6H 2 O (6.23 g, 30.6 mmol, in 13 mL H 2 O). The internal temperature was maintained below −5° C. by adjusting the addition rate. Once all of the magnesium solution was added, the solution temperature was raised to 0° C. and stirred for 30 minutes. The reaction was then quenched by the addition of methylene chloride (115 mL), 1N hydrochloric acid (115 mL) and citric acid (14.02 g, 72.97 mmol). This bilayer was stirred at room temperature. After 3.75 hours, the cyclization reaction was found to be complete by HPLC analysis and the phases were separated. Water (58 mL) and citric acid (8.41 g, 43.77 mmol) were added to the organic layer and the mixture was stirred at room temperature for 45 minutes. The phases were separated and g-60 Darco® activated charcoal (1.52 g) (Atlas Powder Co., Wilmington, Del.) was added to the organic layer. After stirring for 45 minutes, the solution was filtered through Celite® and washed with methylene chloride (2×15 mL). The filtrate was then displaced with hexanes (approximately 350 mL) by distillation under atmospheric pressure and concentration of the mixture to a total volume of 230 mL. The mixture was stirred at room temperature for 14 h, filtered, and dried to afford 9.0872 g (82%) of the title compound.
[0078] m.p. 154.0-155.2° C.
[0079] [0079] 1 H NMR (400 MHz d 6 -acetone): 1.00 (t, 3, J=7.5), 1.51-1.69 (m, 3), 2.17-2.26 (m, 1), 3.46-3.54 (m, 1), 4.96 (ddd, 1, J=5.4, 9.5, 11.6), 5.14 (d, 1, J=12.9), 5.20 (d, 1, J=12.9), 5.66 (br s, 1), 6.65 (d, 1, J=8.3), 6.71 (br d, 1, J=9.1), 7.20 (dd, 1, J=1.9, 8.9), 7.30-7.43 (m, 6).
[0080] [0080] 13 C NMR (100 MHz CDCl 3 ): 9.89, 29.24, 35.34, 48.16, 52.44, 67.27, 113.70, 118.85 (q, J=32.7), 121.37, 124.12 (q, J=3.8), 125.14 (q, J=270.6), 125.72 (q, J=3.8), 128.38, 128.51, 128.86, 136.57,147.71, 156.74.
EXAMPLE 9
(R)-3-Aminopentanenitrile Methanesulfonic Acid Salt
[0081] Step 1: Methanesulfonic Acid 2-tert-butoxycarbonylamino-butyl Ester.
[0082] Run #1: BOC anhydride (515.9 g) in ethyl acetate (400 mL) was added to a solution of R-(−)-2-amino-1-butanol (200.66 g) in ethyl acetate (1105 mL) via an addition funnel. The reaction mixture was stirred for approximately 30 minutes. Tetramethylethylenediamine (TMEDA) (360 mL) was added and the reaction mixture was cooled to approximately 10° C. Methanesulfonyl chloride (184.7 mL) was added to the reaction mixture over a 30-minute period. After stirring for 1 hour, the reaction mixture was filtered and the filtrate was collected.
[0083] Run #2: BOC anhydride (514.5 g) in ethyl acetate (400 mL) was added to a solution of R-(−)-2-amino-1-butanol (200.12 g) in ethyl acetate (1101 mL) via an addition funnel. The reaction mixture was stirred for approximately 30 minutes. Tetramethylethylenediamine (TMEDA) (359.1 mL) was added and the reaction mixture was cooled to approximately 10° C. Methanesulfonyl chloride (184.1 mL) was added to the reaction mixture over a 30-minute period. After stirring for 1 hour, the reaction mixture was combined with the filtrate from Run #1 and filtered. The solids where washed with 400 mL ethyl acetate. Hexanes (12 L) were added to the filtrate. The mixture was cooled in an ice/water bath. After about 2.5 hours the solids were isolated by filtration, washed with hexanes (2 L) and dried under vacuum to afford the title compound (971.57 g).
[0084] Step 2: (1-Cyanomethyl-propyl)-carbamic acid tert-butyl ester. Sodium cyanide (24.05 g) was added to dimethylformamide (DMF) (500 L) and the mixture was stirred at 35° C. for 30 minutes. Tetrabutyl ammonium bromide was added and the reaction mixture was stirred at 35° C. for two hours. Methanesulfonic acid 2-tert-butoxycarbonylamino-butyl ester (101.23 g) was added and the reaction mixture was stirred at 35° C. overnight. The mixture was then partitioned between two liters water and one liter isopropyl ether. The resulting organic and aqueous phases were separated and washed sequentially with water and a saturated solution of sodium chloride in water. The organic layer was dried over magnesium sulfate, filtered and concentrated to afford a solid (65.22 g). The solid (61.6 g) was transferred to a flask equipped with an overhead stirrer. Hexane was added and the flask was heated to 65° C. After all the solids were in solution, the mixture was cooled to ambient temperature. The mixture was stirred overnight. The resulting solids were isolated by filtration to afford the title compound (52.32 g).
[0085] Step 3: (R)-3-Aminopentanenitrile methanesulfonic acid salt. Methane sulfonic acid (71 g) was added to a solution of (1-cyanomethyl-propyl)-carbamic acid tert-butyl ester in tetrahydrofuran (530 mL). The reaction mixture was heated to 40° C. for approximately 30 minutes. The temperature was raised to 45° C. and stirred for approximately one hour. The temperature was raised again to 65° C. and the reaction mixture was stirred for five hours. The mixture was allowed to cool to ambient temperature. The resulting solids were isolated by filtration to afford the title compound (41.53 g). | This invention relates to methods for preparing certain cholesteryl ester transfer protein (CETP) inhibitors and intermediates useful in the preparation of said CETP inhibitors. | 2 |
BACKGROUND OF THE INVENTION
[0001] The invention is in the field of plectrums, or “picks”, for stringed musical instruments, and more particularly a die-cut, snap away pick for guitars and other stringed musical instruments that can be easily detached from a card, sheet, strip and the like.
[0002] Many stringed instruments such as guitars, mandolins, basses are played with picks, which consist of small generally flat pieces of material that are usually (but not always) flexible. Picks come in many sizes and are made of many kinds of materials including plastics (e.g. PVC, acetal polyoxymethylene (POM) resins (i.e. Delrin®), Nylon, etc), shell, metal, stone, wood, paper, composite materials, and other materials. Picks are manufactured in a variety of thicknesses and stiffnesses, depending on a user's preferences. Picks are often shaped to have one or more rounded points, and can have a generally ogive shape at one or more ends. Picks come in numerous colors and can have graphics appearing thereon. Indeed, picks are collected by musicians and non-musicians alike.
[0003] Picks are often displayed at music stores in bulk in plastic bags, in open containers, displayed on paper displays, and the like.
[0004] Although picks can last a long time, they are frequently lost or misplaced, and users may wish to use different picks for different songs, instruments and conditions. Lacking a proper pick, a musician can improvise and use another object, such as a coin, as a pick if required. It would be useful for musicians to have a convenient way to carry extra picks so that they are available anytime and any place.
[0005] Comfort in use and slip resistance are two additional important factors in choosing picks, and it would therefore be desirable to have picks that are comfortable to hold and which do not have any sharp edges, and also picks which are designed to be firmly gripped without slipping or sliding in the fingers.
[0006] It would also be useful to provide a readily accessible supply of picks to musicians during performances that can easily be taken when needed, yet will not be misplaced or lost.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] Further advantages of the invention will become apparent upon a reading of the following detailed description taken in conjunction with the accompanying drawings.
[0008] FIG. 1 is a top plan view of a first exemplary embodiment of a wallet-sized card of detachable picks.
[0009] FIG. 2 is a top plan view of the card of FIG. 1 with pick removed.
[0010] FIG. 3 is a top view of the pick removed from the card of FIG. 2 .
[0011] FIG. 4 is a top plan view of a second exemplary embodiment of a wallet-sized card of detachable picks.
[0012] FIG. 5 is a top plan view of the card of FIG. 4 with one piece removed.
[0013] FIG. 6 is a top plan view of one removed pick from the card of FIG. 3 .
DETAILED DESCRIPTION OF THE INVENTION
[0014] Referring to FIG. 1 , there is shown a top plan view of a first exemplary embodiment of a wallet-sized card 10 of detachable picks and FIG. 2 is a top plan view showing the wallet-sized card 10 of FIG. 1 with pick 14 D removed. The card has a card body 12 with four detachable picks 14 A, 14 B, 14 C, and 14 D, which are attached to the card body 12 by webs 18 separating cut line sections 16 A and 16 B. The cut lines 16 A and 16 B have end sections 20 that turn into the interior of the picks such that the webs 18 are located inwardly of the generally rounded triangular outline of the picks created by the cut lines 16 A and 16 B. Although four picks are shown, a greater or lesser number of picks can be used. In order to provide a wallet-sized card having standard “business card” dimensions of 85.7 mm×54.0 mm (3.375″×2.125″) and picks that are about 31.8 mm to 35 mm (1.25″ to 1.375″) long, four picks can be accommodated. If larger picks are desired, fewer picks will fit on the card footprint. Also, while the wallet-sized card is convenient to carry, larger sized cards that accommodate more cards can be used. Also, while two cut line sections 16 A and 16 B are shown, a single cut line can be used, in which case there will be just one web 18 .
[0015] The card 10 can be made of material such as plastic (e.g., polyvinyl chloride (PVC), acetal polyoxymethylene (POM) resins (i.e. Delrin®.), polycarbonate, Nylon, etc., Teslin® (a synthetic dimensionally stable, highly filled, single layer, microporous film that is polyolefin-based with 60% of its weight comprised of non-abrasive filler and 65% of its volume comprised of air), laminated paper, composite materials, etc., and the like. The picks 14 A, 14 B, 14 C, and 14 D can be conveniently die-cut from the card leaving the webs 18 intact so that the picks remain integral with the card until the webs are broken or cut (e.g. by pushing on the pick, twisting the picks relative to the card body 12 , or slicing the webs with a blade.) The width and size of the webs 18 can be varied depending on how much force is desired to remove a pick from the card body 12 . Although two webs 18 are shown bridging between each pick and the card body 12 , a lesser or greater number of webs can be used depending on how secure the picks need to be carried on the card. Depending on the materials used, the card thickness (and thus pick thickness) can be varied to control the stiffness of the pick. Using PVC and Teslin® sheet material, good results have been achieved with 0.51 mm thickness material (0.02″ or 20 mil), 0.76 mm thickness material (0.03″ or 30 mil), 1.02 mm thickness material (0.04″ or 40 mil), and 1.27 mm thickness material (0.05″ or 50 mil). Other thicknesses can be used, and these thicknesses apply to all of the embodiments disclosed herein.
[0016] Referring again to FIG. 2 , it is a top plan view showing the wallet-sized card 10 of FIG. 1 with pick 14 D removed, leaving an opening 22 in the card body 12 . As can be seen, after pick 14 D is removed from the card body 12 , the webs 18 will break between the end sections 20 along a bridging cut 24 interior of the general outline of the removed pick.
[0017] FIG. 3 is a top plan view of the snapped off pick 14 D. The removed pick 14 D has as its outline the cut line sections 16 that defines its wider top 32 which extends down at its left and right sides to the upper ends of the turned in cut lines 20 , and its lower half has left and right side 34 and a lower narrower end 30 , which is generally used for contact with strings when plucking and picking. As can be seen, the inwardly turn ends 20 of the cut lines generally extend into the body of the pick 14 D, and the areas where the webs 18 are broken 28 lie inwardly of the general outline of the side edges 34 of the pick. So, if there are any sharp edges or projections that might have resulted when the picks were removed from the card body, they will lie inwardly of the general outward edges of the pick, and any such sharp edges or projects would not be in contact to cause discomfort with the user's fingers or create a projection which might inadvertently rasp on a musical instrument string. The result is a pick that is comfortable to hold and use and which is smooth at all possible contact surfaces.
[0018] The cut lines are made to be relatively thin, so that even after a pick, e.g., 14 D is removed from the card body 12 , the pick 14 D can be reinserted in the opening 22 with the tight fit of the pick 14 D forming an interference fit with the opening, thereby allowing reinsertion of the pick and storage therein.
[0019] FIG. 4 is a top plan view of a second exemplary embodiment of a wallet-sized card 40 of detachable picks that is very similar to the embodiment of wallet-sized card 10 of FIG. 1 . Picks 44 A, 44 B, and 44 C are integral with a card body 42 , and each pick is connected to the card body 42 by two webs 48 which are uncut areas between the inwardly angled ends 50 of cut lines 46 A and 46 B. Wile a total of four picks 44 A, 44 B, and 44 C are shown, a greater or lesser number of picks can be arranged on a card body, as discussed with reference to FIGS. 1 and 2 . Also, while two cut line sections 46 A and 46 B are shown, a single cut line can be used, in which case there will be just one web 48 . The material and construction of this card can be as described with the card of FIGS. 1 and 2 . Each pick, in addition, preferably includes an inwardly located grip 60 . The grip 60 is formed by a cut line 62 which can define, for example, a generally triangular cut line through the pick with two terminated spaced apart ends 64 , leaving an uncut gap region 66 . The cut line 62 can follow other contours and can form other shapes as desired. Due to the flexibility of the material used to form the pick, the grip can pivot slightly on its uncut gap region 66 . The cut lines 62 create a discontinuity in the surface of the pick, which discontinuing provides a gripping area for the user's fingers to help the pick avoid slipping when in use.
[0020] FIG. 5 is a top plan view showing the wallet-sized card 40 of FIG. 4 with pick 44 D removed, leaving an opening 52 in the card body 42 . As can be seen, after pick 44 D is removed from the card body 42 , the webs 48 will break between the end sections 50 along a bridging cut 54 interior of the general outline of the removed pick.
[0021] FIG. 6 is a top plan view of the snapped off pick 44 D. The removed pick 44 D has as its outline the cut line sections 46 that defines its wider top 52 which extends down at its left and right sides to the upper ends of the turned in cut lines 50 , and its lower half has left and right side 54 and a lower narrower end 60 , which is generally used for contact with strings when plucking and picking. As can be seen, the inwardly turn ends 50 of the cut lines generally extend into the body of the pick 44 D, and the areas where the webs 48 are broken 58 lie inwardly of the general outline of the side edges 54 of the pick. So, if there are any sharp edges or projections that might have resulted when picks were removed from the card body, they will lie inwardly of the general outward edges of the pick, and any such sharp edges or projects would not be in contact to cause discomfort with the user's fingers or create a projection which might inadvertently rasp on a musical instrument string. These inturned areas provide further grip areas with which to hold the piece. The result is a pick that is comfortable to hold and use and which is smooth at all possible contact surfaces.
[0022] The cut lines are be made to be relatively thin, so that even after a pick, e.g., 44 D is removed from the card body 42 , the pick 44 D can be reinserted in the opening 52 with the tight fit of the pick 44 D forming an interference fit with the opening, thereby allowing reinsertion of the pick and storage therein.
[0023] With respect to the card bodies of FIGS. 1 , 2 , 4 , and 5 , they can be conveniently sized to be the same or similar to charge cards, credit cards or business cards (e.g. from about 50.8 mm to 54 mm (2″ to 2.125″) by about 85.7 mm to 88.9 mm (3.375″ to 3.5″) so that it can be conveniently carried in a user's wallet or handbag along with other similar sized cards. Naturally, other sizes can be used. Also, as noted above, other sizes of card bodies can be provided.
[0024] If desired, the cut lines can be made to be relatively thin, so that even after a pick, e.g., 14 D or 44 D is removed from the card body 12 or 42 , respectively, the pick 14 D and 44 D can be reinserted in the opening 22 or 52 with the tight fit of the pick 14 D or 44 D forming an interference fit with the opening, thereby allowing reinsertion of the pick and storage therein. With modern die cutting equipment, very thin die cut lines can be formed such that the cut line does not remove much, if any, material along the cut line. Accordingly, with use of the proper die cutting equipment, the object being die cut (“die cut object”) from a section of material (“base material”) may be snapped back into place and frictionally retained with an interference fit in the opening in the base material from which the die cut object was cut. In such cases, interruption(s) in the die cut line to form webs between the die cut object and the base material can be made to be very thin so that the dimensions and number of webs can be adjusted as desired to adjust the amount of force necessary to be applied to detach a die cut object from the base material. Also, depending on the thickness of the blade used and angle of the cutting edge of the blade, when die cutting the object from the base material, the perimeter edge of the pick may become somewhat rounded off and become very smooth.
[0025] Although a preferred embodiment of the present invention has been described, it should not be construed to limit the scope of the appended claims. For example, the present invention may be implemented to include a variety of different pick sizes, shapes, thicknesses and layouts.
[0026] In addition, those skilled in the art will understand that various modifications may be made to the described embodiment. Moreover, to those skilled in the various arts, the invention itself herein will suggest solutions to other tasks and adaptations for other applications. It is therefore desired that the present embodiments be considered in all respects as illustrative and not restrictive, reference being made to the appended claims rather than the foregoing description to indicate the scope of the invention. | Snap away musical instrument picks. A sheet of material is provided that has a plurality of musical instrument picks formed therein by cut lines around the perimeter of the picks except for uncut web areas around each pick. The ends of the cut lines turn into the picks. A pick can be detached from the card body by severing the web to remove a pick when desired, and any rough edges formed by breaking the web are not located along the outer perimeter of the pick. The sheet of material can be sized to be carried in a purse or wallet and the like for easy access. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of Korean Patent Application No. 10-2012-0027185, filed on Mar. 16, 2012, in the Korean Intellectual Property Office, the disclosure of which is incorporated herein by reference.
BACKGROUND
[0002] 1. Field
[0003] Embodiments of the present disclosure relate to a refrigerator having a rotating bar configured to seal a gap formed between a pair of doors thereof.
[0004] 2. Description of the Related Art
[0005] In general, a refrigerator is a household appliance having a storage compartment to store food, and a cool air supplying apparatus to supply cool air to the storage compartment to store the food in a fresh manner. The refrigerator, according to the storage compartment and a door thereof, may be classified into different types.
[0006] A TMF (Top Mounted Freezer)-type refrigerator is provided therein with a storage compartment that is divided into an upper side and a lower side by a horizontal partition while a freezing compartment is formed at the upper side and a refrigerating compartment is formed at the lower side, and a BMF (Bottom Mounted Freezer)-type refrigerator is provided with a refrigerating compartment formed at the upper side while a freezing compartment is formed at the lower side.
[0007] In addition, a SBS (Side By Side)-type refrigerator is provided therein with a storage compartment that is divided into an left side and a right side by a vertical partition while a freezing compartment is formed at one side and a refrigerating compartment is formed at the other side, and a FDR (French Door Refrigerator)-type refrigerator is provided therein with a storage compartment that is divided into an upper side and a lower side by a horizontal partition while a refrigerating compartment is formed at the upper side and a freezing compartment is formed at the lower side, as the refrigerating compartment at the upper side is open/closed by a pair of doors.
[0008] Meanwhile, a gasket is provided at a door of a refrigerator to seal a gap which is formed between the door and the body of the refrigerator when the door is closed. However, with respect to the FDR-type refrigerator, the refrigerating compartment at the upper side is open and closed by a pair of doors, but the refrigerating compartment is not provided therein with a vertical partition, and thus a gap formed between the pair of doors may not be sealed by the gasket. In order to seal the gap between the pair of doors, a rotating bar rotatably installed at one of the pair of the doors is suggested.
[0009] The rotating bar as such, when the pair of doors is closed, is being rotated in a horizontal state with respect to the pair of doors to seal the gap in between the pair of doors, and when one door provided with the rotating bar installed thereto is open, the rotating bar is being rotated to a vertical state with respect to the other door, so that the rotating bar is not being interfered at the other door, which is not provided with the rotating bar installed thereto.
[0010] Meanwhile, the rotating bar includes a heat insulation member configured to block cool air from being discharged from a storage compartment, a metal plate formed of metal so as to come into close contact with a gasket installed at a rear surface of the door, and a heat generating member configured to radiate heat to prevent the frost from being formed at the plate.
SUMMARY
[0011] Therefore, it is an aspect of the present disclosure to provide a structure of a rotating bar having an enhanced insulation performance.
[0012] It is another aspect of the present disclosure to provide a structure of a rotating bar enabling an insertion protrusion of the rotating bar to be inserted into a guide part regardless of the position of the rotating bar.
[0013] It is still another aspect of the present disclosure to provide a structure of a rotating bar capable of sealing a gap between the rotating bar and a body as well as a gap between one pair of doors.
[0014] Additional aspects of the disclosure 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 disclosure.
[0015] In accordance with one aspect of the present disclosure, a refrigerator includes a body, a storage compartment, a first door, a second door, a first gasket, a second gasket, a rotating bar and a guide part. The storage compartment may be formed at an inside of the body while having a front surface thereof open. The first door may be configured to open/close a portion of the front surface of the storage compartment that is open. The second door may be configured to open/close a remaining portion of the front surface of the storage compartment that is open. The first gasket may be installed at a rear surface of the first door to seal a gap formed between the first door and the body. The second gasket may be installed at a rear surface of the second door to seal a gap formed between the second door and the body. The rotating bar may be rotatably coupled to the first door to seal a gap formed between the first door and the second door in a state that the first door and the second door are closed. The guide part may be provided at the body to guide a rotation of the rotating bar, and may have a guide body part fixed to the body and a guide groove formed in the guide body part. The rotating bar may include a case, a heat insulation member, a metallic plate, a heat generating member, and an insertion protrusion. The case may be provided with an accommodating space therein. The heat insulation member may be accommodated in the accommodating space. The metallic plate may be coupled to the case. The heat generating member may be configured to prevent frost from being formed on the metallic plate. The insertion protrusion may be configured to be elastically biased toward an outer side of the case so as to be inserted into the guide groove, and upon exertion of external force, may be configured to move toward an inner side of the case.
[0016] If the first door is closed in a state of the rotating bar being rotated in perpendicular to the first door, the insertion protrusion may enter the guide groove through an entry of the guide groove and then may be rotated along a curved surface of the guide groove. If the first door is closed in a state of the rotating bar being rotated in parallel to the first door, the insertion protrusion may move toward the inner side of the case by the external force of the guide body part to avoid an interference with the guide body part, and then may move toward the outer side of the case by the elastic force so as to be inserted into the guide groove.
[0017] The insertion protrusion may include a protrusion part, an elastic member, and a stopper part. The protrusion part may be configured to be inserted into the guide groove. The elastic member may be configured to elastically support the protrusion part such that the protrusion part protrudes toward the outer side of the case. The stopper part may be configured to prevent the protrusion part from being separated to an outside the case.
[0018] The protrusion part may include an inclined surface. The inclined surface may be configured to allow the protrusion part to perform a vertical movement by a horizontal force exerted on the protrusion part.
[0019] The insertion protrusion may be provided on at least one of an upper end and a lower end of the rotating bar.
[0020] The case may be provided with a passage part provided in a form of a hole that allows the insertion protrusion to pass therethrough.
[0021] A support part configured to support the elastic member may be provided at the inner side of the case.
[0022] The rotating bar may further include a sealing member. The sealing member may have a blocking wall that protrudes to the outer side of the case so as to seal a gap formed between the body and the rotating bar.
[0023] The sealing member may be formed of rubber.
[0024] In accordance with another aspect of the present disclosure, a refrigerator includes a body, a storage compartment, a pair of doors, a rotating bar, and a sealing member. The storage compartment may be formed at an inside of the body while having a front surface thereof open. The pair of doors may be rotatably coupled to the body to open/close the front surface of the storage compartment that is open. The rotating bar may be rotatably coupled to one of the pair of doors to seal a gap formed between the pair of doors in a state that the pair of doors are closed. The sealing member may protrude from the rotating bar to seal a gap formed between the rotating bar and the body.
[0025] The refrigerator may further include a guide part and an insertion protrusion. The guide part may be provided at an upper side of the body to guide a rotation of the rotating bar. The insertion protrusion may protrude toward an upper side from the rotating bar so as to be rotated while being inserted into the guide part. The insertion protrusion may be provided so as to enable a vertical movement.
[0026] The refrigerator may further include an elastic member. The elastic member may be configured to elastically support the insertion protrusion to the upper side.
[0027] The insertion protrusion may include an inclined surface that allows the insertion protrusion to move to a lower side by a pressing force exerted in a horizontal direction.
[0028] As described above, with respect to the rotating bar for sealing a gap between one pair of doors, the doors are prevented from being incompletely closed due to an erroneous operation of the rotating bar, and the convenience of use is improved.
[0029] In addition, the rotating bar seals a gap between the rotating bar and the door as well as a gap between one pair of doors, thereby improving the heat insulation efficiency of the storage compartment.
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] These and/or other aspects of the disclosure will become apparent and more readily appreciated from the following description of the embodiments, taken in conjunction with the accompanying drawings of which:
[0031] FIG. 1 is a drawing illustrating a front of a refrigerator in accordance with one aspect of the present disclosure.
[0032] FIG. 2 is an exploded perspective view showing a structure of a rotating bar of the refrigerator of FIG. 1 .
[0033] FIG. 3 is an assembled perspective view of the rotating bar of the refrigerator of FIG. 1 .
[0034] FIG. 4 is a cross-sectional view of the rotating bar of the refrigerator of FIG. 1 .
[0035] FIG. 5 is a cross-sectional view of a rotating bar of a refrigerator in accordance with another aspect of the present disclosure.
[0036] FIGS. 6 to 9 are drawings to describe the operation of the rotating bar of the refrigerator of FIG. 1 .
[0037] FIG. 10 is a drawing showing a structure of an insertion protrusion of the rotating bar of the refrigerator of FIG. 1 .
[0038] FIGS. 11 to 12 are drawings to describe a vertical movement of the insertion protrusion of the rotating bar of the refrigerator of FIG. 1 .
DETAILED DESCRIPTION
[0039] Reference will now be made in detail to the embodiments of the present disclosure, examples of which are illustrated in the accompanying drawings, wherein like reference numerals refer to like elements throughout.
[0040] FIG. 1 is a drawing illustrating a front of a refrigerator in accordance with one aspect of the present disclosure. Referring to FIG. 1 , a refrigerator 1 in accordance with one embodiment of the present disclosure includes a body 10 , storage compartments 20 and 30 divided into an upper side and a lower side at an inside the body 10 , doors 31 , 40 , and 50 configured to open/close the storage compartments 20 and 30 , and a cool air supplying apparatus (not shown) to supply cool air to the storage compartments 20 and 30 .
[0041] The body 10 may include an inner case forming the storage compartments 20 and 30 , an outer case forming an exterior appearance by being coupled to an outer side of the inner case, and a heat insulation member foamed in between the inner case and the outer case and configured to thermally insulate the storage compartments 20 and 30 from each other.
[0042] The cool air supplying apparatus (not shown) may generate cool air by using a cooling circulation cycle configured to compress, condense, expand, and evaporate refrigerant.
[0043] The storage compartments 20 and 30 may be provided with a front surface thereof open, and may be partitioned into the refrigerating compartment 20 at the upper side and the freezing compartment 30 at the lower side. The refrigerating compartment 20 may be open and closed by a pair of doors 40 and 50 that are rotatably coupled to the body 10 , and the freezing compartment 30 may be open and closed by a sliding door 31 slidably mounted at the body 10 .
[0044] The pair of doors 40 and 50 configured to open and close the refrigerating compartment 20 may be disposed side by side. Hereinafter, for the sake of convenience, the left side door 40 on the drawing is referred to as the first door 40 and the right side door 50 on the drawing is referred to as the second door 50 .
[0045] The first door 40 is configured to open and close a left portion of the front surface of the refrigerating compartment 20 that is open, and the second door 50 is configured to open and close the remaining portion of the front surface of the refrigerating compartment 20 that is open. Door shelves 41 and 51 are provided at the rear surfaces of the first door 40 and the second door 50 , respectively, to store foods. In addition, at the rims of the rear surfaces of the first door 40 and the second door 50 , gaskets 42 and 52 are provided, respectively, to seal the gap with respect to the body 10 in a state that the first door 40 and the second door 50 are closed.
[0046] The gaskets 42 and 52 may be installed in a shape of a loop along the rims of the rear surfaces of the first door 40 and the second door 50 , respectively, and magnets ( 42 a and 52 a in FIGS. 4 and 5 ) may be included at an inside the gaskets 42 and 52 , respectively.
[0047] Meanwhile, in a state that the first door 40 and the second door 50 are closed, a gap may be formed between the first door 40 and the second door 50 , and in order to seal the gap as such, a rotating bar 100 is rotatably mounted at the first door 40 .
[0048] The rotating bar 100 as such is provided in a bar shape formed lengthwise along the height direction of the first door 40 , and may be rotated by a guide part 60 provided at the body 10 . The guide part 60 of the body 10 may include a guide body ( 61 in FIG. 6 ) coupled to the body 10 , and a guide groove ( 62 in FIG. 6 ) formed at the guide body 61 . Hereinafter, the structure and the operation of the rotating bar 100 as such will be described.
[0049] FIG. 2 is an exploded perspective view showing a structure of the rotating bar of the refrigerator of FIG. 1 , FIG. 3 is an assembled perspective view of the rotating bar of the refrigerator of FIG. 1 , and FIG. 4 is a cross-sectional view of the rotating bar of the refrigerator of FIG. 1 .
[0050] Referring to FIGS. 2 to 4 , the rotating bar 100 includes a case 110 having an accommodating space 110 a and provided with one surface thereof open, a heat insulation member 120 accommodated in the accommodating space 110 a of the case 110 , a cover 130 coupled to the one open surface of the case 110 , a metallic plate 150 coupled to an outer side of the cover 130 , and a heat generating member 140 disposed at a space in between the cover 130 and the metallic plate 150 .
[0051] The case 110 is configured to form an external appearance of the rotating bar 100 , and may be provided at an inside thereof with the accommodating space 110 a having one surface open, and the one open surface of the rotating bar 100 may be covered by the cover 130 . A hinge bracket coupling part 110 b to which a hinge bracket ( 70 in FIG. 6 ) is coupled may be provided at the case 110 .
[0052] The hinge bracket 70 may include a fixing part ( 71 in FIG. 6 ) fixed to the rear surface of the first door 40 , and a hinge bar ( 72 in FIG. 6 ) configured to connect the fixing part 71 to the rotating bar 100 , so that the rotating bar 100 is rotated on a rotation shaft ( 73 in FIG. 6 ). The fixing part 71 may be coupled to the rear surface of the first door 40 by use of a connecting member such as a screw.
[0053] In addition, at an upper surface of the case 110 , a passage part 112 may be provided, so that an insertion protrusion 161 being inserted into the guide groove ( 62 in FIG. 6 ) of the guide part ( 60 in FIG. 6 ) may be protruded to an outside the case 110 . The passage part 112 may be provided in the form of a hole having the same shape as the insertion protrusion 161 .
[0054] In the embodiment of the present disclosure, the guide part 60 is formed at an upper portion of the body 10 while the insertion protrusion 161 is protruded toward an upper side of the rotating bar 100 . However, the guide part 60 may be formed at a lower portion of the body 10 while the insertion protrusion 161 may be protruded toward a lower side of the rotating bar 100 . In this case, the passage part 112 of the case 110 may also be formed at a lower surface of the case 110 . The case 110 as such may be injection-molded using plastic material as an integrated body.
[0055] The heat insulation member 120 is configured to thermally insulate the refrigerating compartment 20 , and may be formed of EPS (Expanded PolyStyrene) material having superior insulation performance and light weight. The heat insulation member 120 , after being formed in an approximate shape to be inserted into the accommodating space 110 a of the case 110 , may be inserted into the accommodating space 110 a of the case 110 .
[0056] The cover 130 is configured to cover the one surface of the case 110 that is open, and may be coupled to the one open surface of the case 110 after the heat insulation member 120 is inserted into the accommodating space 110 a of the case 110 .
[0057] As illustrated on FIG. 4 , the cover 130 is provided with a cross section obtained by being bent several times, and forms a portion of the side surface and a portion of the rear surface of the rotating bar 100 . Here, the rear surface of the rotating bar 100 is referred to as a surface facing the gaskets 42 and 52 of the doors 41 and 51 .
[0058] In detail, the cover 130 includes a heat insulation member adhering part 131 making contact with the heat insulation member 120 , a second coupling part 132 to which the metallic plate 150 , which will be described later, is coupled, a heat conduction blocking part 133 protruded toward the metallic plate 150 , and a side surface forming part 134 forming at least one portion of the side surface of the rotating bar 100 . The cover 130 may be injection molded using plastic material having low heat conductivity as an integrated body.
[0059] The metallic plate 150 may be coupled to an outer side of the cover 130 as such, and the metallic plate 150 is formed of metallic material so as to come into close contact with the gaskets 42 and 52 by the magnetic force of the magnets 42 a and 52 a included in the gaskets 42 and 52 , and to provide rigidity to the rotating bar 100 .
[0060] The metallic plate 150 may include a first coupling part 151 being coupled to the second coupling part 132 of the cover 130 , and a gasket close-contact part 152 coming into close contact with the gaskets 42 and 52 . The first coupling part 151 of the metallic plate 150 is coupled to the second coupling part 132 of the cover 130 by a connecting member such as a screw or by an adhesive member.
[0061] Meanwhile, the heat generating member 140 , which is configured to generate heat to prevent frost from being formed on the metallic plate 150 due to the temperature difference between the inside and the outside the refrigerating compartment 40 , may be disposed at a space formed by the first coupling part 151 of the metallic plate 150 and the gasket close-contact part 152 of the metallic plate 150 .
[0062] Here, so as to prevent the heat generated from the heat generating member 140 from being excessively delivered to the metallic plate 150 , the heat generating member 140 may be implemented by a heating cable 140 , which includes a heating wire covered with non-conductive material such as silicon or an FEP (Fluorinated Ethylene Propylene).
[0063] Thus, the heat generating member 140 , so as to deliver the minimum amount of heat to the metallic plate 150 to prevent frost from being formed on the metallic plate 150 , may be disposed in a line-contacted manner with the metallic plate 150 instead of being surface-contacted with the metallic plate 150 .
[0064] Meanwhile, the heat conduction blocking part 133 of the cover 130 and the gasket close-contact part 152 of the metallic plate 150 , both of which were previously described, form the rear surface of the rotating bar 100 . The central portion of the rear surface of the rotating bar 100 is formed by the gasket close-contact part 152 of the metallic plate 150 , and both side edge portions of the rear surface of the rotating bar 100 are formed by the heat conduction blocking part 133 of the cover 130 .
[0065] In order to prevent the heat, which is being conducted along the gasket close-contact part 152 of the metallic plate 150 , from being conducted to the side surface of the rotating bar 100 , the heat conduction blocking part 133 of the cover 130 is needed to be provided for a predetermined length L.
[0066] The length L of the heat conduction blocking part 133 of the cover 130 is provided to be approximately larger than a thickness D of the cover 130 , and within the limit that the metallic plate 150 comes into close contact with the gaskets 42 and 52 by the magnetic force of the magnets 42 a and 52 a that are included in the gaskets 42 and 52 , the length of the gasket close-contact part 152 of the metallic plate 150 may be reduced while increasing the length L of the heat conduction blocking part 133 of the cover 130 .
[0067] According to the structure as the above, in a state where the first door 40 and the second door 50 are closed, the rotating bar 100 may seal the gap between the first door 40 and the second door 50 while coming into close contact with the gaskets 42 and 52 of the first door 40 and the second door 50 , and may also minimize the heat, which is generated from the heat generating member 140 of the rotating bar 100 , from penetrating to an inside the refrigerating compartment 20 .
[0068] Thus, the insulation performance of the rotating bar 100 is enhanced while the heat loss of the heat generating member 140 is minimized, thereby able to save the energy needed to prevent frost from being formed on the rotating bar 100 .
[0069] Meanwhile, sealing members ( 170 and 180 in FIG. 2 ) may be provided at an upper end and at a lower end of the rotating bar 100 , respectively, to seal a gap formed between the rotating bar 100 and the body 10 in a state that the doors 40 and 50 are closed.
[0070] The sealing member 170 of the upper end and the sealing member 180 of the lower end may include blocking walls 171 and 181 , respectively, which protrude to seal the gap in between the guide part 60 of the body 10 and the rotating bar 100 in a state that the door 40 is closed.
[0071] As illustrated in one embodiment shown in FIG. 12 of the present disclosure, in a case when the guide part 60 is provided at an upper portion of the body 10 , the sealing member 170 may seal the gap between the guide part 60 and the rotating bar 100 .
[0072] The sealing members 170 and 180 as such may be formed of flexible material such as rubber to seal the gap between the body 10 and the rotating bar 100 in a smooth manner without damage by a collision.
[0073] FIG. 5 is a cross-sectional view of a rotating bar of a refrigerator in accordance with another aspect of the present disclosure. Hereinafter, the structure of a rotating bar in accordance with another embodiment of the present disclosure will be described with reference to FIG. 5 . In the following description, the same reference numerals will be assigned to the parts of the present embodiment that are identical to those according to the previous embodiment, and details of parts will be omitted in order to avoid redundancy.
[0074] In accordance with another embodiment of the present disclosure, the rotating bar 100 includes a case 110 provided with an accommodating space formed at an inside thereof and having one surface thereof open, a heat insulation member 120 accommodated in the accommodating space of the case 110 , a metallic plate 150 coupled to the one open surface of the case 110 , a heat generating member 140 configured to radiate heat to prevent frost from being formed on the metallic plate 150 , and a heat insulation film 190 formed on a surface of the metallic plate 150 that is exposed to the outside.
[0075] The heat insulation film 190 is configured to increase the heat resistance of the metallic plate 150 so as to prevent the heat generated at the heat generating member 140 from penetrating to the refrigerating compartment 20 after being delivered along the metallic plate 150 to the both side surfaces of the rotating bar, and the heat insulation film 190 may be formed of material having a low heat conductivity.
[0076] The heat insulation film 190 may be formed on the surface of the metallic plate 150 through a method such as a coating, or may be formed by attaching processed material having a shape of a thin panel to the metallic plate 150 .
[0077] However, the heat insulation film 190 is needed to be provided with a thickness less than a predetermined thickness, so that, in a state of the first door 40 and the second door 50 are closed, the rotating bar may come into close contact with the gaskets 42 and 52 by the magnetic force of the magnets 42 a and 52 a that are included in the gaskets 42 and 52 .
[0078] As for the heat generating member 140 , a heating cable may be used, and by being line-contacted with the metallic plate 150 , may supply the minimum amount of heat needed to prevent frost from being formed at the metallic plate 150 . The heat generating member 140 , except for the area that is being line-contacted with the metallic plate 150 , is disposed in a way to be surrounded by the heat insulation member 120 , thereby minimizing heat loss.
[0079] FIGS. 6 to 9 are drawings to describe the operation of the rotating bar of the refrigerator of FIG. 1 . Referring to FIGS. 6 to 9 , the operation of the rotating bar of the refrigerator in accordance with one embodiment of the present disclosure will be described in brief.
[0080] FIG. 6 illustrates a normal position of the rotating bar 100 in a state that the door 40 is open, FIG. 7 illustrates a process of the first door 40 being closed from the state of FIG. 6 , and
[0081] FIG. 8 illustrates a state of the first door 40 and the second door 50 closed.
[0082] FIG. 9 illustrates an abnormal position of the rotating bar 100 in a state that the first door 40 is open.
[0083] As illustrated on FIG. 6 , in a state that the first door 40 is open, the normal position of the rotating bar 100 is a position at which the rear surface of the rotating bar 100 is approximately perpendicular to the longitudinal direction of the first door 40 . Hereinafter, the position as such is referred to as a vertical position.
[0084] In a state that the rotating bar 100 is at the vertical position, as the first door 40 is closed, as illustrated on FIG. 7 , the insertion protrusion 161 of the rotating bar 100 may enter an inside the guide groove 62 through a guide groove entry 63 of the guide part 60 that is provided at the body 10 .
[0085] The insertion protrusion 161 that enters an inside the guide groove 62 is rotated along the curved surface of the guide groove 62 , and as the insertion protrusion 161 rotates, the rotating bar 100 is also rotated.
[0086] Finally, as illustrated on FIG. 8 , when the first door 40 is completely closed, the rear surface of rotating bar 100 is disposed in an approximately horizontal to the longitudinal direction of the first door 40 and of the second door 50 , and thus the rotating bar 100 comes into close contact with the gaskets 42 and 52 , thereby able to seal the gap in between the first door 40 and the second door 50 . Hereinafter, the position of the rotating bar 100 as such will be referred to as a horizontal position.
[0087] Finally, in the process of the first door 40 being closed, the rotating bar 100 , in the order of sequence as illustrated on FIG. 6 , FIG. 7 , and FIG. 8 , is rotated in clockwise direction on the drawings.
[0088] In addition, on the contrary, in the process of the first door 40 being open, the rotating bar 100 , in the order of sequence of FIG. 8 , FIG. 7 , and FIG. 6 , is rotated in the counter-clockwise direction with respect to the drawings, and in the state of the first door 40 is completely open, the rotating bar 100 is disposed at the vertical position.
[0089] As the above, as the rotating bar 100 is disposed at the vertical position, the first door 40 , even in a state of the second door 50 being closed, may be closed without having the rotating bar 100 being interfered by the second door 50 , and in addition, the insertion protrusion 161 of the rotating bar 100 may enter the guide groove 62 through the guide groove entry 63 .
[0090] However, in a state that the first door 40 is open, the rotating bar 100 may be disposed at the horizontal position due to an erroneous operation by a user. In this case, in the process of the first door 40 being closed, the rotating bar 100 may be interfered by the second door 50 . In addition, even if the rotating bar 100 does not interfere with the second door 50 since the second door 50 is open, the insertion protrusion 161 may not be able to enter the guide groove 62 through the guide groove entry part 63 , and may collide with the guide body 61 .
[0091] Thus, the first door 40 is not being completed closed, and the cool air of the refrigerating compartment 20 may be discharged, thereby causing a damage on the insertion protrusion 161 .
[0092] Thus, the insertion protrusion 161 of the rotating bar 100 of the refrigerator in accordance with one embodiment of the present disclosure is configured to be vertically movable, so that the insertion protrusion 161 is inserted into the guide groove 62 without being collided with the guide body 61 even in a state of the rotating bar 100 being at the horizontal position. The structure of the insertion protrusion 161 as such will be described hereinafter.
[0093] FIG. 10 is a drawing showing a structure of the insertion protrusion of the rotating bar of the refrigerator of FIG. 1 , and FIGS. 11 to 12 are drawings to describe a vertical movement of the insertion protrusion of the rotating bar of the refrigerator of FIG. 1 .
[0094] Referring to FIGS. 10 to 12 , the insertion protrusion 161 includes a body part 166 disposed at an inside the rotating bar 100 , a protrusion part 164 protruded to the outside the rotating bar 100 through the passage part 112 of the rotating bar 100 , a stopper part 165 to prevent the insertion protrusion 161 from being separated to the outside the rotating bar 100 , and an inclined surface 163 formed at the protrusion part 164 .
[0095] The body part 166 is provided at an inside thereof with a hollowness into which an elastic member 162 may be inserted, and the insertion protrusion 161 is elastically biased by the elastic member 162 in a state of that the protrusion part 164 protrudes to the outside the rotating bar 100 .
[0096] At the case 110 of the rotating bar 100 , a supporting part 111 to support the elastic member 162 is provided, and also a supporting bar 111 a is protruded from the supporting part 111 . At the body part 166 , a supporting bar 166 a is provided to support the elastic member 162 .
[0097] The protrusion part 164 is provided with an approximately same shape as the passage part 112 while provided with a size smaller than the size of the passage part 112 so as to be able to pass through the passage part 112 . The protrusion part 164 may be provided with the stopper part 165 to limit the protrusion range of the protrusion part 164 to the outside of the protrusion part 164 .
[0098] The inclined surface 163 formed at the protrusion part 164 is configured to convert horizontal force into vertical force, and is configured in a way that the insertion protrusion 161 may move vertically by the horizontal pressing force of the guide body 61 in the process of the first door 40 being closed while the rotating bar 100 is at the horizontal position.
[0099] Thus, as illustrated on FIG. 9 , if the first door 40 is closed in a state of the rotating bar 100 is at the horizontal position, the insertion protrusion 161 is collided with the guide body 61 , and may descend by the pressing force of the guide body 61 .
[0100] In the state as such, when the first door 40 is completely closed, the insertion protrusion 161 is ascended by the restoration force of the elastic member 162 , and may be inserted into the guide groove 62 .
[0101] According to the structure as the above, the first door 40 of the refrigerator in accordance with one embodiment of the present disclosure, even in a state that the rotating bar 100 is rotated to the horizontal position, may be closed without interference. Thus, the user convenience is enhanced, and the cool air loss due to the incomplete closing of the doors 40 and 50 may be prevented.
[0102] Although a few embodiments of the present disclosure 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 disclosure, the scope of which is defined in the claims and their equivalents. | A refrigerator provided with a rotating bar configured to seal a gap between one pair of doors, capable of preventing the door from being incompletely closed due to an erroneous operation of the rotating bar, the rotating bar capable of sealing a gap formed between the rotating bar and a body as well as a gap formed between one pair of doors, the rotating bar being elastically supported by an elastic member so as to move by receiving an external force from a guide part provided on the body, the rotating bar including a sealing member protruding from the rotating bar so as to seal a gap between the rotating bar and the body. | 1 |
BACKGROUND OF THE INVENTION
1. Technical Field
The present invention relates to a method for producing a membrane which, following mechanical injury in the sense of a puncture or a bullet hole or penetration wound with a small-caliber weapon, is capable of closing this injury without external intervention.
2. History of the Related Art
The present invention is concerned with pneumatic structures such as have been known, for example, from the European Patent Specifications EP 1 239 756, EP 1 210 489, the European Patent Applications EP 03 700 039 and EP 03 764 875 and the international publication WO 2005/007991.
EP 1 239 756 discloses a pneumatic mattress or bench seat which requires no horizontal support as underlay. It can quickly be made ready for use and can be stowed away again with little space requirement. The arrangement of the supporting chambers can be configured in such a manner that the mattress itself is configured in the manner of a supporting structure.
EP 1 210 489 discloses a pneumatic structural element in the manner of an inflatable tubular hollow body which can absorb without buckling tensile and thrust forces which may arise. The structural elements can easily be joined together to form more complex components such as roofs or bridges, which may be erected very rapidly.
EP 1 554 158 (EP 1 210 489) discloses an adaptive pneumatic seat and backrest for vehicles and airplanes which, despite the given basic structure of the air chambers, offers high seat comfort corresponding to conventional foam cushions and brings a discernible saving in weight compared with these.
WO 2004/009400 (EP 03 764 875) discloses an adaptive pneumatic seat and backrests for vehicles and airplanes which, despite the given basic structure of the air chambers, offers high seat comfort corresponding to conventional foam cushions and brings a discernible saving in weight compared with these and in addition, can be simply designed onto existing seat shell structures.
WO 2005/007991 discloses a pneumatic support. The structural element can easily be joined together to form more complex components such as roofs or bridges which may be erected very rapidly. In addition, the structural element can easily be joined to conventional existing building constructions.
Among other things, such pneumatic structures have in common that they weigh comparatively little, i.e. they are easily transportable since their membrane takes up little space in the deflated state and can be stored and transported in a space-saving manner.
These pneumatic structures comprise on the one hand large-area structures having areas of several hundred to several thousand square meters with small excess pressures of the order of magnitude of 10 to 500 mbar, on the other hand small-volume and small-area structures having excess pressures of 50-200 mbar, as in the case of pneumatic seats for example.
In all these cases the escape of compressed gas, usually air, should be avoided in order to maintain said internal operating pressure at least at the necessary minimum.
SUMMARY OF THE INVENTION
The object of the present invention is to provide a method whereby a membrane used as an envelope in such said pneumatic structures can be prepared and processed in such a manner that a hole of said type in this membrane closes without intervention.
BRIEF DESCRIPTION OF THE DRAWINGS
A more complete understanding of the self-healing membrane of the present invention may be obtained by reference to the following Detailed Description, when taken in conjunction with the accompanying drawings, wherein:
FIG. 1 illustrates a cross-section through a membrane produced according to the invention;
FIG. 2 illustrates a first type of injury;
FIG. 3 illustrates FIG. 2 after removal of the injurious object;
FIG. 4 illustrates the first type of injury on an enlarged scale;
FIG. 5 illustrates a second type of injury during the self-healing process;
FIG. 6 illustrates a plan view of a film to be applied to the layer;
FIG. 7 illustrates, in plain view, a variant of the process step of FIG. 6 ;
FIG. 8 illustrates a cross-section of a second variant for the process step according to FIG. 6 .
DETAILED DESCRIPTION OF THE INVENTION
Reference is now made in detail to exemplary embodiments of the present invention illustrated in the accompanying drawings. Wherever possible, the same reference numerals are used throughout the drawings to refer to the same or similar parts.
FIG. 1 shows a membrane as an envelope of a pneumatic structure, the airtight membrane is designated by the reference numeral 1 . The membrane 1 can be, for example, fabric made of polyester, nylon, fiberglass, aramides coated with a plastic such as PVC, PU, silicone or Teflon® but also flexible films made of such materials if the tensile stresses which occur are within permissible material properties.
A thin layer 2 of a plastic containing a plurality of small gas bubbles 3 is applied to the inside of this membrane 1 by means of one of the known techniques, i.e., for example, by wiping, rolling or spraying. Polyurethane, for example, is used as the plastic here.
For example, PVC-coated polyester fabric from Duraskin® (Type III, Verseldag, Krefeld) was coated with different commercially available closed-pore polyurethane foams according to the manufacturer's instructions. The two-component polyurethane foam Polyfoam F5 (Polyconform GmbH) proved to be particularly suitable here.
The aforementioned gas bubbles 3 located in the plastic of the layer 2 can either be incorporated therein by a rapid mixing process of the plastic. However, they can also be formed by the polymerization process and then left in the plastic by omitting a vacuum treatment. Gas bubbles in the range of 10μ-200μ have proved successful for the desired self-healing process of an injury to the membrane 1 . (An arrangement comprising a stereomicroscope (Olympus, SZX9) and connected digital camera (Olympus DP12, Japan) was advantageous for studying the membrane 1 coated by the layer 2 ).
The membrane 1 was then polymerized at elevated pressure. However, the polymerization parameters such as pressure and temperature can vary, being specific to the plastic. The elevated pressure, typically 2 bar, is important.
An excess pressure over 5 bar leads to a deterioration in the self-healing or repair capability compared with an excess pressure of 2 bar, which lies in the range which is already attainable during polymerization without excess pressure. As has been mentioned, the best self-healing results were achieved during polymerization at an excess pressure in the range of 2 bar. Polymerization in an excess pressure range of 2 to 3 bar also yielded good results. Polymerization in the excess pressure range of 0.5 to 4 bar still yields significantly better results compared with polymerization without excess pressure.
The improved reaction properties can be attributed to the elevated internal pressure of the foam cells or bubbles ( 3 ) and also to conformational or structural changes inside the foam which have a positive influence on the repair, i.e. sealing, behavior merely as a result of a different arrangement of the material.
The repair behavior could also be further improved by determining the amount of plastic to be polymerized applied per unit area; better results in the self-healing or repair behavior were achieved with an amount of coating in the range of 1 to 2 g for an area of about 20 cm 2 (circular sample having a diameter of 5 cm) as compared with amounts of coating outside this range. A coating amount of 1.6 g proved to be particularly advantageous. This corresponds to a quantity per 100 cm 2 of 5 to 10 g or an optimal quantity of 8 g of coating material.
Finally, it has also proved favorable to store the coated membrane after polymerization or protect it from mechanical stressing, i.e. to delay the time before the possible first injury. An improvement in the repair capability of the coated membrane was already observed after a week, with eight weeks having proved to be particularly advantageous.
If the membrane 1 is injured by piercing with a pointed object, a hole thus formed will close partly by itself as a result of the elastic properties of the membrane 1 as shown in FIG. 2 . A fissure 5 as shown in FIG. 3 remains.
FIG. 4 shows a section of the uppermost part of the fissure 5 . Under the influence of the internal pressure of the gas bubbles or an internal stress of the layer 2 , a part of the layer 2 is pushed into the fissure 5 and is partially pressed therein by the escaping air; a process which can take seconds to minutes. The cross-section of the hole is thereby reduced and the leakage flow severely suppressed. Since the internal pressure can usually be maintained by external means such as compressors or, at low internal pressures of pneumatic structures, by fans, and in addition, this internal pressure is usually permanently monitored, there is sufficient time for an intervention in the sense of a repair to the envelope of the pneumatic structure.
For fissures 5 of small diameter, complete closure can occur merely as a result of the subsequent pushing of the layer 2 .
In the case of larger holes 4 or holes caused by blunt objects or by projectiles from firearms, however, the self-healing effect described with reference to FIGS. 2 to 4 does not result in complete closure of the hole 4 . With such an injury, the layer 2 is torn along a larger rim of a hole. In order to make self-healing possible even in said cases, pre-polymers in a suitable form, for example, are provided which polymerize on contact with air and the moisture contained therein. Typically, on contact with the moisture in the air, such polymers form bubbles which are drawn into the hole 4 and completely cure there. Moreover, since the structural forces are absorbed by the membrane, a hole in the membrane is not a weakening if the force flow is interrupted as a result of the lower strength of its filling. Alternatively, two-component plastics can also be used in a suitable form instead of pre-polymers.
FIG. 5 shows a first exemplary embodiment of a second step of this production method according to the invention. Here, a plurality of microcapsules 6 are mixed into the material of the layer 2 . Such microcapsules typically having a diameter of about 100μ, contain, for example, a monomer, others contain an accelerator and/or a catalyst for effecting the polymerization of the monomer. The monomer can also contain a solvent in which a suitable gas is dissolved under pressure. Such techniques are known from plastics technology. In addition, such microcapsules 6 can also contain a pre-polymer which preferably contains a solvent and a propellant gas dissolved therein under pressure. If such microcapsules 6 are torn by an injury, a puncture or a penetration wound, the contents of a plurality of microcapsules 6 escape at the rim of the hole, forming a foam 7 which now hardens under the influence of the catalysts or the air humidity and permanently closes the hole 4 . In the case of textile-reinforced membranes 1 , adhesion to the walls of the hole 4 also occurs if the plastic contained in the microcapsules 6 does not bind sealingly or only poorly binds to that of the layer 2 or that of the membrane 1 since a plurality of textile fibers are exposed and the plastic emerging from the microcapsules can adhere to their open ends. Otherwise, the plastic of the membrane coating must be matched to that of the layer 2 . Naturally and optimally, said plastics are matched to one another, and the sealing can thus be optimized.
FIG. 6 shows a plan view of a blister film 8 which either contains a monomer or, in a selected distribution, a monomer and a suitable polymerization partner or a moisture-curing pre-polymer with accelerator, in a plurality of blisters 9 . The size of the blisters 9 can be selected and adapted in a broad framework so that, in conjunction with the distances a between the blisters 9 , this ensures that in the event of injuries to the membrane which go beyond the self-healing capability of the layer 7 , a plurality of such blisters 6 are torn. A foam then forms, as described for FIG. 5 , which enters into the injury and polymerizes there. A distance d>a is provided between the rows of blisters 9 at said distances a, which allows the blister film to be fastened to the layer 2 by gluing or welding.
Naturally, the blisters 9 can be produced in any suitable shape and the surface coverage thereby optimized. The size of the blisters 9 can also be varied widely.
FIG. 7 shows a variant of the exemplary embodiment from, also in plan view. Here, elongated blisters 10 are provided, for example, filled with a monomer. In a second position, on the back of the blister film 8 , other blisters 11 are arranged coincidentally (shown with dotted rims). Naturally, the shapes can also be selected differently here and the respective size ratios of the blisters 10 , 122 can be provided differently. It corresponds to the inventive idea to arrange the blisters 10 , 11 such that if a blister 10 is injured, a blister 11 is also injured so that a polymerizing plastic is formed and can penetrate into a hole 4 and seal this. In this exemplary embodiment a strip d>a can also be provided to allow the blister film 8 to be glued or welded to the layer 2 , without injuring the blisters 10 , 11 .
An alternative to the method examples in FIGS. 6 and 7 is shown in FIG. 8 . Before the layer 2 is pressure-polymerised, a blister film 12 is applied thereto which, compared to the blister films 8 already described, additionally has a perforation extending into the surface, consisting of a plurality of small holes 13 which preferably have a diameter of 0.1 to 1.0 mm. The blisters 9 again, for example, contain two components of a suitable plastic.
After applying the blister film 12 , the polymerisation now takes place under pressure, as described for FIG. 1 . The blister film 12 is fixed on the layer 2 by partial penetration of the layer 2 into the perforation.
Although various embodiments of the method and apparatus of the present invention have been illustrated in the accompanying Drawings and described in the foregoing Detailed Description, it will be understood that the invention is not limited to the embodiments disclosed, but is capable of numerous rearrangements, modifications, and substitutions without departing from the spirit and scope of the invention as set forth in the foregoing specification and following claims. | The invention relates to a membrane that heals on its own after being damaged mechanically as well as a method for producing said membrane which is used for pneumatic structures featuring an internal operating pressure of 10 mbar to 500 mbar. The inventive membrane is provided with a plastic layer on the pressure side, said plastic layer being interspersed with blisters that have a diameter ranging from 10μ to 200μ. | 1 |
CROSS-REFERENCE TO RELATED APPLICATION
This application is a divisional of application Ser. No. 09/577,533, filed May 24, 2000, entitled “SYSTEM AND METHOD FOR PRODUCTION AND AUTHENTICATION OF ORIGINAL DOCUMENTS”.
FIELD OF THE INVENTION
The present invention relates to the field of counterfeit resistant documents, and more particularly to systems and methods employing database techniques to verify authenticity.
BACKGROUND OF THE INVENTION
The problem of counterfeiting is long established. Since it was recognized that a document itself could represent value, a motivation has existed for forgery. Two types of methods evolved for preventing counterfeiting: counterfeit resistant features, such as signatures, special printing, special document recording medium recording stock, magnetic and/or electrical features, and the like; and legal sanctions for an otherwise easy copying process. For example, most cultures provide heavy sanctions for counterfeiting of currency, typically much harsher than private document counterfeiting.
The issues of authentication and counterfeit deterrence can be important in many contexts. Bills of currency, stock and bond certificates, credit cards, passports, bills of lading, as well as many other legal documents (e.g., deeds, wills, etc.) All must be reliably authentic to be useful. Authentication and avoidance of counterfeiting can also be important in many less obvious contexts. For example, improved verification/counterfeiting prevention mechanisms would be very useful in, for example, verifying the contents of shipping containers, quickly identifying individuals with particular health or criminal histories, etc. Counterfeit products are, by definition, unauthorized copies of a product, its packaging, labeling, and/or its logo(s). Attractive targets for counterfeiters are items with significant brand equity or symbolic value, where the cost of production is below the market value.
In the commercial manufacturing world, it is not uncommon for counterfeit or otherwise unauthorized goods to be manufactured, distributed, and sold in direct competition with authentic goods. Counterfeiting has reached epidemic proportions worldwide, especially in the area of consumer goods including goods made from fabric, plastic, leather, metal, or combinations thereof such as clothing, handbags and wallets, perfumes, and other consumer goods. Electronics and software products are also particular targets of counterfeiters, who appropriate the value of trademarks or copyrights without license. Since costs savings based on decreased incremental cost of production (exclusive of license fees) is not a necessary element in the counterfeiting scheme, the counterfeit articles may be of apparently high quality and closely resemble authentic articles. Indeed, counterfeit articles can so closely resemble genuine goods that consumers readily confuse the counterfeit articles with the authentic articles. In other circumstances, the manufacturer segments the world market for different sales and distribution practices, so that the “counterfeit” goods may be essentially identical to authorized goods. Further, in many instances, a manufacturer produces goods under license from an intellectual property owner, and thus sales outside the terms of the license agreement are also “counterfeit”.
A wide variety of attempts have been made to limit the likelihood of counterfeiting. For example, some have tried to assure the authenticity of items by putting coded or uncoded markings thereon (e.g., an artist's signature on his or her painting). Unfortunately, as soon as the code is broken—e.g., a counterfeiter learns to duplicate a signature, this method becomes worthless for authentication purposes. In the context of paper products (e.g., currency), counterfeiting-prevention methods have also used two-dimensional authentication mechanisms—e.g., watermarks or special threads incorporated within the paper used to make the currency. These mechanisms are clearly helpful, but they can also be overcome. For example, counterfeiters routinely bleach a one dollar bill (in such a way that the colored threads which mark the special currency paper are not damaged) and then imprint the markings of a one-hundred dollar bill thereon. Thus, the mere release of physical security materials into the market forms one limitation on their unfettered use.
Other authentication methods have utilized mechanisms that provide three dimensions of data. For example, the holograms provided on many credit cards provide more variables (i.e., relative to two-dimensional threads or watermarks) which may be precalibrated, and thereafter, used to verify the authenticity of an item. Nevertheless, since holograms have a pre-set, or deterministic, pattern they may also be duplicated and counterfeit products made. Further, since the holograms are invariant, they are subject to pilferage before application to goods, or translocation from authorized to unauthorized goods in the marketplace. Authentication mechanisms, which utilize deterministic patterns, are inherently vulnerable to counterfeiting since the counterfeiter, in essence, has a “fixed” target to shoot at. High security schemes, such as military codes, have encryption keys that change frequently. This method, however, assists prospectively in securing valuable time-sensitive information, and does not prevent subsequent decryption of a previously transmitted message. At the other end of the spectrum, a random element-based authentication mechanism would provide an incessantly “moving” and nonrepeating target that would be practically impossible to undetectably duplicate, without knowledge of the encoding scheme.
Finally, although existing authentication mechanisms provide adequate protection against counterfeiting in some contexts, increasingly powerful tools are available to decode encrypted messages, making more secure schemes necessary for long-term protection. For example, in conjunction with its monitoring and surveillance activities, governments routinely seek to break or circumvent encryption codes. The technologies employed are then quickly adopted by the private sector, and indeed government regulations seek to maintain weak encryption standards, facilitating code-breaking. In addition to computers, current counterfeiters have access to extremely powerful tools for undermining physical copy-protection schemes—e.g., color photocopying equipment, reverse engineering of semiconductor chips, etc. These factors have combined to continually provoke strong demand for new methods and mechanisms for authenticating items, especially methods and mechanisms that are less vulnerable to counterfeiting and/or employ new copy-protection mechanisms.
More recently, techniques have evolved for authentication of digital information, for example based on cryptological techniques. However, these techniques do not serve to verify the authenticity of a particular copy of the information. In fact, modern digital content protection schemes do seek to prevent digital copying of content; however, these rely on secure hardware for storage of the digital content, and a breach of hardware security measures results in copyable content with no distinction between an original and a copy thereof.
A number of modern systems implement challenge-response authentication, which provide enhanced security for encryption keys and encrypted content. See, for example, U.S. Pat. No. 6,028,937 (Tatebayashi et al.), U.S. Pat. No. 6,026,167 (Aziz), U.S. Pat. No. 6,009,171 (Ciacelli et al.) (Content Scrambling System, or “CSS”), U.S. Pat. No. 5,991,399 (Graunke et al.), U.S. Pat. No. 5,948,136 (Smyers) (IEEE 1394-1995), and U.S. Pat. No. 5,915,018 (Aucsmith), expressly incorporated herein by reference, and Jim Wright and Jeff Robillaid (Philsar Semiconductor), “Adding Security to Portable Designs”, Portable Design, March 2000, pp. 16–20.
The present invention therefore addresses instances where the issue is not merely whether the information is authentic, but rather whether the information is authentic (and unaltered), and the copy itself an original. Obviously, known techniques may be used to authenticate the content of a document, for example, by providing self-authenticating digital signatures, remote database authentication, trusted intermediary techniques, and the like. Likewise, numerous techniques are available for providing self-authenticating features for the physical medium, for example, security threads, inks, papers and watermarks, printing techniques (e.g., intaglio printing, microlithography), fluorescent inks and/or fibers, steganographic patterns, magnetic and/or electrical/electronic patterns, and the like.
In fact, database techniques are known for authenticating objects associated with documents (labels or certificates), in which the document is both self-authenticating and may further reference a remote database with authentication information for the document or associated object. These techniques, however, are not intended to primarily secure the document itself, and thus the techniques fail to particularly address document content security and authentication, as well as models for commercial exploitation thereof.
It is known that the color of an object can be represented by three values, and that the color may be used for identification and authentication. For example, the color of an object can be represented by red, green and blue values, an intensity value and color difference values, by a CIE value, or by what are known as “tristimulus values” or numerous other orthogonal combinations. For most tristimulus systems, the three values are orthogonal; i.e., any combination of two elements in the set cannot be included in the third element. One such method of quantifying the color of an object is to illuminate an object with broad band “white” light and measure the intensity of the reflected light after it has been passed through narrow band filters. Typically three filters (such as red, green and blue) are used to provide tristimulus light values representative of the color of the surface. Yet another method is to illuminate an object with three monochromatic light sources or narrow band light sources (such as red, green and blue) one at a time and then measure the intensity of the reflected light with a single light sensor. The three measurements are then converted to a tristimulus value representative of the color of the surface. Such color measurement techniques can be utilized to produce equivalent tristimulus values representative of the color of the surface. Generally, it does not matter if a “white” light source is used with a plurality of color sensors (or a continuum in the case of a spectrophotometer), or if a plurality of colored light sources are utilized with a single light sensor.
PRIOR ART
Tamper Evident Certificates
U.S. Pat. Nos. 5,913,543 and 5,370,763 (Curiel), expressly incorporated herein by reference, relates to a tamper evident and counterfeit resisting document, for example a temporary vehicle registration which may be made of paper or paperboard. The document has a zone for inserting information and a pattern within said zone for resisting counterfeiting. A transparent tape which preferably has a silicone resin coating which contains a wax is adhesively secured over information contained within the zone. In other embodiments, an alteration resistant article contains variable data and includes an outer film having an upper surface and a lower surface with an adhesive secured to the lower surface. A hologram for receiving at least a portion of the variable data on the upper surface is secured to the outer film lower surface and, in one embodiment, the hologram has portions which have release properties and portions which have greater adhesive bonding properties than the release containing portions. These respective portions may be established by providing a release material on certain portions of the upper surface of the hologram and providing adhesive enhancing materials on other portions of the hologram upper surface. The hologram may be embossed and have a metallized upper surface. A plurality of relatively small hologram particles may be provided in the outer layer and/or the adhesive layer. The hologram is secured to a substrate which, in one embodiment, has an upper surface printed with pattern means which are printed to a lesser depth than the variable data. In another embodiment, the hologram is provided as a unit with the outer film and overlies the variable data. This system therefore provides physical techniques for document authentication and preventing content alteration.
U.S. Pat. No. 5,601,683 (Martin, Feb. 11, 1997), incorporated herein by reference, provides a photocopy resistant document, having a background pattern or logo which is printed with solvent-sensitive, dye based ink. The presence of this photocopy-resistant background pattern or logo limits copying.
U.S. Pat. No. 5,949,042 (Dietz, II, et al., Sep. 7, 1999), expressly incorporated herein by reference, provides a gaming ticket validation system and method.
Artificial Watermarks
U.S. Pat. No. 5,928,471 (Howland, et al. Jul. 27, 1999), expressly incorporated herein by reference, relates to improved security features for paper, and in particular to a method of making paper and transparentising selected areas of paper to provide enhanced security features. The invention thus provides a method of making paper comprising the step of depositing fibers onto a support surface to form a porous absorbent sheet, applying a transparentising resin to at least portion of said porous sheet and subsequently impregnating the porous sheet with a sizing resin.
The following patents, expressly incorporated herein by reference, provide enhanced security features for use with finished paper and for non-currency and non-security papers. EP-A2-0203499 discloses a method of applying a pseudo watermark to paper. This method comprises the preparation of a paper containing thermally sensitive material, the presence of which renders the translucency of the paper variable by temperature change. When heat is subsequently applied to a part of the surface of the paper, a region of the paper becomes semi-translucent. U.S. Pat. No. 2,021,141 (Boyer, November 1935) discloses a method of applying pseudo watermarks to paper, by applying a resinous composition to finished paper which permeates the paper and causes it to become more transparent, or translucent, than the surrounding area. GB-A-1489084 describes a method of producing a simulated watermark in a sheet of paper. The sheet is impregnated in the desired watermark pattern with a transparentising composition which, when submitted to ultra violet radiation, polymerizes to form a simulated watermark. U.S. Pat. No. 5,118,526 (Allen, et al., Jun. 2, 1992) describes a method of producing simulated watermarks by applying heat, in the desired watermark pattern, onto a thin solid matrix of waxy material placed in contact with a sheet of paper. This results in an impression of a durable translucent watermark. U.S. Pat. No. 4,513,056 (Vernois, et al., Apr. 23, 1985) relates to a process for rendering paper either wholly or partially transparent by impregnation in a special bath of a transparentization resin and subsequent heat cross-linking of the resin. EP-A1-0388090 describes a method of combining a see-through or print-through feature with a region of paper which has a substantially uniform transparency which is more transparent than the majority of the remainder of the sheet. JP 61-41397 discloses a method for making paper transparent and a method for its manufacture for see-through window envelopes. The method utilises the effect of causing ink cross-linked by ultra-violet rays to permeate paper thus causing that part of the paper to become transparent.
Copy Resistant Printing Techniques
U.S. Pat. No. 5,946,103 (Curry, Aug. 31, 1999), expressly incorporated herein by reference, relates to halftone patterns for trusted printing. Predetermined machine and/or human readable information is embedded in at least one serpentine pattern that is printed on each original document, so that any given instance of such a document can be later verified or refuted as being the original by determining whether this information can be recovered from the document or not. The method for verifying the originality of printed documents, said comprises providing at least one trusted printer for printing original documents, embedding predetermined information in each of the original documents in at least one halftone pattern that is composed of halftone cells, each of the cells containing a fill pattern which is symmetric about a central axis of the cell, with the information being represented by the angular orientations of the respective axis of symmetry of at least some of the cells; and classifying the documents as original documents only if said predetermined information can be recovered therefrom. Thus, the technique relies on information which can be readily printed but not readily photocopied.
Self-clocking glyph codes have been developed for embedding machine readable digital data in images of various descriptions. See, for example, Bloomberg et al. (U.S. patent application, filed May 10, 1994 under Ser. No. 08/240,798) for Self-Clocking Glyph Codes and U.S. Pat. No. 5,453,605 (Hecht et al., Sep. 26, 1995) for Global Addressability for Self-Clocking Glyph Codes. To integrate these glyph codes into line art images, the data typically are embedded in small, similarly sized, spatially formatted, elliptical or slash-like marks or “glyphs” which are slanted to the left or right in generally orthogonal orientations to encode binary zeros (“0's”) or ones (“1's”), respectively. Customarily, these glyphs are written on a spatially periodic, two-dimensional lattice of centers at a density that enables up to about 500 bytes of data per square inch to be stored on a document. These glyph codes are well suited for incorporating digital data channels into textual and other types of line art images.
U.S. Pat. No. 5,193,853 (Wicker, Mar. 16, 1993), and U.S. Pat. No. 5,018,767 (Wicker, May 28, 1991), incorporated herein by reference, provide anticounterfeiting methods wherein a marked image has a minute dot or line pitch which varies from normal scanning resolution of typical copying devices, making such mechanical copying detectable.
U.S. Pat. No. 5,315,112, (Tow, May 24, 1994) for Methods and Means for Embedding Machine Readable Digital Data in Halftone Images, describes the use of “circularly asymmetric” halftone dots for incorporating self-clocking glyph codes into halftone images, and defines a workable approach if the data is confined to the midtone regions of the image in accordance with a known or identifiable spatial formatting rule. High sensitivity, however, is required to recover the embedded data with acceptable reliability from the darker or lighter regions of the image.
U.S. Pat. No. 5,706,099, (Curry, Jan. 6, 1998) for Method and Apparatus for Generating Serpentine Halftone Images, expressly incorporated herein by reference, provides circular serpentine halftone cell structures, e.g., Truchet tiles, for embedding data in images. These serpentine halftone cells have a high degree of rotational tone invariance. The arcuate fill patterns may be rotated 45 degrees with respect to the halftone cell boundaries to produce another rotationally distinguishable pair of halftone structures. These structures have been called Manhattans and also are sometimes referred to as ortho-serpentines.
As described in more detail in U.S. Pat. No. 5,696,604, (Curry, Dec. 9, 1997) for Analytic Halftone Dot Construction for a Hyperacuity Printer U.S. Pat. No. 5,410,414 (Curry, Apr. 25, 1995) for Halftoning in a Hyperacuity Printer, and U.S. Pat. No. 5,710,636 (Curry, Jan. 20, 1998) for Method and Apparatus for Generating Halftone Images Having Human Readable Patterns Formed Therein, which are hereby incorporated by reference, halftone patterns may be generated somewhat differently from the traditional way that halftones are generated. The goal is to more precisely control the way the edges of the halftone fill pattern or “shape” evolves as it grows from highlight to shadow. More particularly, in traditional digital halftoning, turning on an appropriate number of bits in a threshold array generates the desired tone. The array holds a sequence of threshold values that may spiral outward from a central location as the threshold values ascend. Bits corresponding to those locations in the halftone cell “turn on” if the incoming data intensity is equal to or greater than the threshold value for that bit location. This method generates halftone dots that grow asymmetrically, as one threshold after another is traversed through a range of intensity values from, say, 0 to 255. For serpentine patterns, however, it is desired to grow the halftone fill pattern at all positions on its perimeter simultaneously to maintain better control of the shape. Therefore, a two step process typically is employed for generating the halftone fill patterns. First, an analytical shape function is defined which grows according to a predetermined evolution from the smallest shape for highlight regions, through midtones, and finally to full coverage of the halftone cell. In this step, shape information is maintained with “infinite precision” with analytic functions. Second, as the area of the shape gets larger, the fill pattern or shape is rendered as if it were a segment of text or line art with a corresponding shape. The result is more control over the shape and the tone evolution of the halftone because they are defined with analytic functions. Nevertheless, it is believed that would be possible to use the traditional thresholding array to generate serpentines given a large enough threshold array.
There are two main goals when analytically defining the shape function. The first is to define functions that can evolve through growth from the smallest shape at intensity value of zero to the largest shape at a value of, say, 255 in a continuous manner. Any jumps in tone caused by discontinuities in the functions will be readily visible in the halftone images. The second goal is ensure that the functions can be solved for the position and angle of the nearest edge of the shape from any point within the halftone cell, at all stages of its evolution with analytic accuracy. This allows the shape, which is defined by a hyperbolic shape function, to be precisely rendered. The strategy used to create a family of curves is to fix the focal point to a suitable value, and then select a x, y value along a halftone cell side, for each family member.
One of the qualities that causes the tone of serpentine halftone patterns to be substantially invariant to rotation is that there is very little change at the boundary between neighboring halftone cells upon 90-degree rotation. This is achieved by selecting the points of intersection for the curve pair defining the fill patterns or shape to be equidistant from the midpoint of the halftone cell side. Two hyperbolic curves are used to define the serpentine shape, and the points at which those curves intersect the periphery of the halftone cell are selected so that these intersections are equally displaced in opposite directions from the midpoint of the cell side. In order to make full use of the analytic precision with which the halftone shape is defined, the rendering of the edges of the shape typically is carried out by modulating the laser of a laser printer with a precision that is finer than the size of the scan spot. For instance, in the time it takes the spot to sweep out its own diameter, up to eight bits of digital information can be provided for modulating it. Likewise, inkjet printers may also produce modulated dot patterns.
The serpentines printed in full color, with the correct color balance and halftone shapes are extremely difficult to reproduce reprographically. The narrow, diagonally extending, unfilled areas in halftone cells representing the darker tones are especially difficult to reproduce faithfully because ordinary copying tends to cause near neighboring shapes to blur together, thereby degrading (if not obliterating) the shape information and clues that aid in determining cell direction. Without these distinguishing features, the image takes on the form of a “waffle” pattern, and is easily recognized as a forgery. Although typical color copiers are excellent at reproducing the correct tones for high quality images, they must supply their own halftone algorithms to do this properly. They usually have their own electronic halftoners embedded in the electronics of the machine, and these halftoners typically are optimized for machine dependent tone reproduction curves and implementationally dependent halftone dot shapes. Accordingly, it is extremely unlikely that an existing halftone that is not a serpentine can reproduce a serpentine halftone. Another possible method of reproducing serpentine images is to scan them in, process the image to determine cell orientation, then reproduce the original data file required to print an “original”. This requires access to a printer that can print serpentines, an unlikely prospect for the casual counterfeiter.
Accordingly, serpentines are an excellent candidate for trusted printing applications. For this application, a “trusted printer” (i.e., a printer controlled by a trusted party, such as a service bureau) typically is employed for printing original documents that are designed to include one or more serpentine patterns. Predetermined machine and/or human readable information is embedded in at least one of the serpentine patterns that is printed on each original document, so that any given instance of such a document can be later verified or refuted as being the original instance by attempting to recover this known information from the document in question. This is not an absolute safeguard against counterfeiting, but it is a significant hindrance to those who may attempt to pass off xerographic copies or other conveniently produced copies as original documents.
The feature that gives serpentines a large dynamic range also makes them difficult to copy. As the hyperbolas asymptotically approach the limiting diagonal of the halftone cell, the small region of white is extremely difficult to copy without loss of contrast. The resulting “waffle” appearance of the halftone screen conveniently lacks directionality. This makes serpentines a candidate for image authentication and counterfeit deterrence.
Moiré effects have been used in prior art for the authentication of documents. For example, United Kingdom Pat. No. 1,138,011 (Canadian Bank Note Company) discloses a method which relates to printing on the original document special elements which, when counterfeited by means of halftone reproduction, show a moiré pattern of high contrast. Similar methods are also applied to the prevention of digital photocopying or digital scanning of documents (for example, U.S. Pat. No. 5,018,767 (Wicker), or U.K. Pat. Application No. 2,224,240 A (Kenrick & Jefferson)). In all these cases, the presence of moiré patterns indicates that the document in question is counterfeit. Another known method provides a moiré effect used to make visible an image en coded on the document (as described, for example, in the section “Background” of U.S. Pat. No. 5,396,559 (McGrew, Mar. 7, 1995)), based on the physical presence of that image on the document as a latent image, using the technique known as “phase modulation”. In this technique, a uniform line grating or a uniform random screen of dots is printed on the document, but within the pre-defined borders of the latent image on the document the same line grating (or respectively, the same random dot-screen) is printed in a different phase, or possibly in a different orientation. For a layman, the latent image thus printed on the document is hard to distinguish from its background; but when a reference transparency consisting of an identical, but unmodulated, line grating (respectively, random dot-screen) is superposed on the document, thereby generating a moiré effect, the latent image pre-designed on the document becomes clearly visible, since within its pre-defined borders the moiré effect appears in a different phase than in the background.
U.S. Pat. No. 6,039,357 (Kendrick, Mar. 21, 2000), expressly incorporated herein by reference, relates to security bands to prevent counterfeiting with color copies. A protected/security document is provided that foils counterfeiting even if a laser photocopy machine is utilized. The document has at least three discrete half-tone printed bands disposed on its surface, provided by dots or lines. Each printed band has a different screen density and within each bands the dots or lines comprise a warning word or symbol (e.g. “Void”), or a background. The dots or lines of either the “Void” or background drop out when photocopied, while the dots or lines of the other do not. The dots or lines that do not drop out may be dimensioned so that there are about 24–34 per centimeter, while for those that do drop out there are about 52–64 per centimeter. The bands are typically arranged either linearly or in concentric circles, and interband areas having density gradually transitioning between the densities of adjacent bands are provided. The total density variation between discrete bands is typically about 10–35%, depending upon ink color, typically about 1.0–10% gradation between adjacent bands. Full tone indicia, which does readily reproduce, is also printed on the substrate.
U.S. Pat. No. 5,995,638 (Amidror, et al., Nov. 30, 1999), incorporated herein by reference, relates to methods and apparatus for authentication of documents by using the intensity profile of moiré patterns, occurring between superposed dot-screens. By using a specially designed basic screen and master screen, where at least the basic screen is comprised in the document, a moiré intensity profile of a chosen shape becomes visible in their superposition, thereby allowing the authentication of the document. If a microlens array is used as a master screen, the document comprising the basic screen may be printed on an opaque reflective support, thereby enabling the visualization of the moiré intensity profile by reflection. Automatic document authentication is supported by an apparatus comprising a master screen, an image acquisition means such as a CCD camera and a comparing processor whose task is to compare the acquired moiré intensity profile with a prestored reference image. Depending on the match, the document handling device connected to the comparing processor accepts or rejects the document. An important advantage is that the process can be incorporated into the standard document printing process, so that it offers high security at the same cost as standard state of the art document production. The system is based on the moiré phenomena which are generated between two or more specially designed dot-screens, at least one of which being printed on the document itself. Each dot-screen consists of a lattice of tiny dots, and is characterized by three parameters: its repetition frequency, its orientation, and its dot shapes. Dot-screens with complex dot shapes may be produced by means of the method disclosed in U.S. patent application Ser. No. 08/410,767 filed Mar. 27, 1995 (Ostromoukhov, Hersch).
U.S. Pat. No. 6,014,453 (Sonoda, et al., Jan. 11, 2000), expressly incorporated herein by reference, relates to a counterfeit detecting method and device to generate counterfeit probability data and apparatus employing same. Counterfeit probability data are generated indicating that a non-reproducible document is being processed even when the pattern which identifies such documents has been defaced. One set of rules and membership functions is stored in each of three memory sets, for each of (1) an unaltered pattern identifying a non-reproducible document, (2) an altered version of that pattern, and (3) a pattern identifying an ordinary reproducible document. A fuzzy inference unit uses these rules and membership functions to generate data representing the probability that a counterfeiting attempt is occurring. These probability data are transmitted to the copy machine through a control CPU to prevent unlawful copying.
Chemical Testing
U.S. Pat. No. 6,030,655 (Hansmire, et al., Feb. 29, 2000), expressly incorporated herein by reference, relates to positive identification and protection of documents using inkless fingerprint methodology. A system is provided for coating a portion of the document with a chemical compound, for determining an image thereupon, including the steps of first providing a document; next, applying a clear chemical coating onto at least a portion of the document; applying an non-visible image onto the chemical coated portion of the document; providing an activator solution; applying the activated solution to the chemically coated portion of the document to reveal the image thereupon; identifying the stamped image for assuring that the stamped image is not a counterfeit or the like.
U.S. Pat. No. 5,289,547 (Ligas, et al., Feb. 22, 1994), incorporated herein by reference, discloses a method for authenticating articles including incorporating into a carrier composition a mixture of at least two photochromic compounds that have different absorption maxima in the activated state and other different properties to form the authenticating display data on the article, subjecting the display data to various steps of the authenticating method, activation of all photochromic compounds, preferential bleaching of less than all of the photochromic compounds, and/or bleaching of all the photochromic compounds, and subsequent examination of the display data following the various activation and bleaching steps by verifying means to enable authentication.
U.S. Pat. No. 4,507,349 (Fromson, et al. Mar. 26, 1985), incorporated herein by reference, provides a currency security system employing synthetic layers and sublimatable dye-formed images on the layers.
Physical Characteristics
U.S. Pat. No. 4,767,205 (Schwartz, et al., Aug. 30, 1988), incorporated herein by reference, discloses an identification method and identification kit based upon making up groups of microsized particles normally visible to the naked eye with each particle in each group being of a selected uniform size, shape and color. Coded identification is established by transferring a population of particles from a selected number of the groups to the item to be identified and then confirming such identification by examining the marked item under high magnification with a light microscope.
Physical Security Schemes—Films and Embedded Filaments
U.S. Pat. No. 4,157,784 (Grottrup, et al., Jun. 12, 1979), incorporated herein by reference, discloses a document security system that optically reveals erasures or modifications of printed matter.
U.S. Pat. No. 3,391,479 (Buzzell et al., July, 1968), incorporated herein by reference, discloses a card security system that provides a dichroic film covering information on the card.
U.S. Pat. No. 3,880,706 (Williams, April, 1975), incorporated herein by reference, discloses a document security system provided by a fused polymer net within a paper pulp substrate.
U.S. Pat. No. 4,247,318 (Lee, et al., Jan. 27, 1981), incorporated herein by reference, provides a security paper formed from non-woven polyethylene film-fibril sheets.
U.S. Pat. No. 4,186,943 (Lee, Feb. 5, 1980), incorporated herein by reference, discloses a banknote or document security system that provides an optically distinctive thin film structure in the body of the banknote or document.
U.S. Pat. No. 4,445,039 (Yew, Apr. 24, 1984), incorporated herein by reference, discloses an encoded document security system having a security element with a readable physical characteristic.
U.S. Pat. No. 4,652,015 (Crane, Mar. 24, 1987), incorporated herein by reference, discloses security paper for banknotes and currency having a metallized film having fine imprinting thereon.
U.S. Pat. No. 4,552,617 (Crane, Nov. 12, 1985), incorporated herein by reference, discloses a document security system provides dissolvable strips of microcarrier material having encoding thereon which persists after the carrier dissolves. U.S. Pat. No. 4,437,935 (Crane, Jr., Mar. 20, 1984), incorporated herein by reference, discloses a document security system provides a dissolvable carrier web material having encoding thereon which attaches to the paper fibers and persists after the web dissolves.
U.S. Pat. No. 5,393,099 (D'Amato, Feb. 28, 1995), incorporated herein by reference, provides an anti-counterfeiting method for currency and the like having embedded micro image security features, such as holograms and diffraction gratings.
Physical Security Schemes—Electromagnetic
U.S. Pat. No. 5,602,381 (Hoshino, et al., Feb. 11, 1997), and U.S. Pat. No. 5,601,931 (Hoshino, et al., Feb. 11, 1997), incorporated herein by reference, relate to system and method for authenticating labels based on a random distribution of magnetic particles within the label and an encrypted code representing the distribution printed on the label, and possibly data imprinted on the label.
U.S. Pat. No. 3,701,165 (Huddlester, October, 1972), incorporated herein by reference, discloses a method of marking garments with a substance detectable by magnetic detecting devices. When the magnetized substance on the garment part is detected in a process of making garments, subsequent garment making steps are actuated in response to the detection of the stitching.
U.S. Pat. No. 4,820,912 (Samyn, Apr. 11, 1989), incorporated herein by reference, provides a method and apparatus utilizing microwaves for authenticating documents, having a random distribution of stainless steel fibers embedded and scattered in a card base member. Microwaves are applied to a large number of metallic wires which are embedded and scattered at random in a document or a card, and a proper digital mark responsive to a response microwave signature is recorded in a suitable region of the document or card according to specific rules. To check the authenticity of the document or card, microwaves are applied to the document or card, and a response microwave signature is collated with the digital mark. The document or card is determined as being authentic when the microwave signature and the mark correspond.
Optical Characteristics and Detection
U.S. Pat. No. 5,325,167 (Melen, Jun. 28, 1994) relates to a record document authentication by microscopic grain structure and method. A record document may be authenticated against reference grain data obtained from the document at a prior time. The body of the document is formed by base medium bearing the record entries such as text within record site. The grain seal site is located at a predetermined location within the base medium. The unique grain structure within the seal site are microscopic and function as a seal for authenticating the document. The seal site is initially scanned to provide a stream of reference data generated by the surface reflection of the grain structure. This reference grain data is stored in memory for future authentication use. The seal site is then currently scanned to generate a stream of current grain data for comparison to the reference grain data.
U.S. Pat. No. 3,942,154 (Akami, et al., Mar. 2, 1976), incorporated herein by reference, discloses a method and apparatus for recognizing colored patterns. The method includes encoding the colors of individual picture elements in a fabric pattern by comparing the level of transmittance or reflectance of the picture element at pre-selected wavelengths with stored values representing a reference color to generate a multibit code indicative of the color of the picture element. A comparator used for this purpose incorporates an error either proportional to the wavelength or of constant value so that the output of the comparator will indicate identity with the stored value if the input value for the picture element is within a certain range of the stored value.
U.S. Pat. No. 4,514,085 (Kaye, Apr. 30, 1985), incorporated herein by reference, provides a method for authenticating documents by marking the document with an encapsulated liquid crystal, and then observing the document under conditions which exploit the unique optical characteristics of liquid crystals.
U.S. Pat. No. 5,591,527 (Lu, Jan. 7, 1997), incorporated herein by reference, provides optical security articles and methods for making same, having layers of varying refractive index forming an image, which is viewable only across a narrow range of viewing angles and is viewable in ambient (diffuse) light, thus affording a readily apparent verification of the authenticity of the substrate.
U.S. Pat. No. 5,580,950 (Harris, et al., Dec. 3, 1996), incorporated herein by reference, provides negative birefringent rigid rod polymer films, formed of a class of soluble polymers having a rigid rod backbone, which when used to cast films, undergo a self-orientation process aligning the polymer backbone parallel to the film surface, resulting in a film that displays negative birefringence.
U.S. Pat. No. 5,549,953 (Li, Aug. 27, 1996), incorporated herein by reference, provides optical recording media having optically variable security properties. Thin film structures, which have an inherent color shift with viewing angle, provide both optically variable security properties and optical data decodable by optical means. The multilayer interference coating has a dielectric material, which is transparent, and a recording layer made of a light absorbing material, a crystalline-structural changing material, or a magneto-optic material. Data is encoded optically or photolithographically as bar codes or digital data.
The use of optically variable pigments has been described in the art for a variety of applications, such as inks for counterfeit-proof applications such as currency, and generically for coating compositions. They are described, for example, in U.S. Pat. No. 4,434,010 (Ash, Feb. 28, 1984), U.S. Pat. No. 4,704,356 (Ash, Feb. 28, 1984), U.S. Pat. No. 4,779,898 (Berning, et al., Oct. 25, 1988), U.S. Pat. No. 4,838,648 (Phillips, et al., Jun. 13, 1989), U.S. Pat. No. 4,930,866 (Berning, et al., Jun. 5, 1990), U.S. Pat. No. 5,059,245 (Phillips, et al., Oct. 22, 1991), U.S. Pat. No. 5,135,812 (Phillips, et al., Aug. 4, 1992), U.S. Pat. No. 5,171,363 (Phillips, et al., Dec. 15, 1992), and U.S. Pat. No. 5,214,530 (Coombs, et al., May 25, 1993), incorporated herein by reference. Pigments of these types are prepared by depositing inorganic transparent dielectric layers, semi-transparent metal layers, and metal reflecting layers onto a flexible web, and separating the layers from the web in such a manner as to fragment the deposited thin film layer structure into pigment particles. These particles are in the form of irregularly shaped flat pigment flakes. These pigments are capable of producing dramatic visual effects, including dichroic effects not observed in other types of pigments. A multilayer thin film interference structure is formed having at least one metal reflecting layer, at least one transparent dielectric layer, and at least one semi-transparent metal layer. Various combinations of these layers can be utilized to achieve the desired optically variable effect. Layer thickness can be varied according to the particular desired characteristics of the pigment. For example, U.S. Pat. No. 5,135,812, incorporated herein by reference, describes useful thickness being on the order of 80 nm for the metal reflecting layer, 5 nm for the semi-opaque metal layers, and thickness of a plurality of halfwaves of the particular design wavelength for the transparent dielectric layers.
U.S. Pat. No. 6,038,016 (Jung, et al., Mar. 14, 2000) and U.S. Pat. No. 5,966,205 (Jung, et al., Oct. 12, 1999), expressly incorporated herein by reference, relate to a method and apparatus for optically detecting and preventing counterfeiting. Perimeter receiver fiber optics are spaced apart from a source fiber optic and receive light from the surface of the object being measured. Light from the perimeter fiber optics pass to a variety of filters. The system utilizes the perimeter receiver fiber optics to determine information regarding the height and angle of the probe with respect to the object being measured. Under processor control, the optical characteristics measurement may be made at a predetermined height and angle. Translucency, fluorescence, gloss and/or surface texture data also may be obtained. Measured data also may be stored and/or organized as part of a data base. Such methods and implements are desirably utilized for purposes of detecting and preventing counterfeiting or the like.
Fluorescent Fibers and Patterns
U.S. Pat. No. 1,938,543 (Sanburn, December, 1933) teaches that detectable fibers which have been specially treated with a chemically sensitive substance can be incorporated into paper and, upon contacting such paper with a second chemical agent, the detectable fibers change color and become distinguishable. As illustrated in U.S. Pat. No. 2,208,653 (Whitehead, July, 1940), authenticatable paper can also be made by including fibers of an organic ester of cellulose that have been treated with a tertiary amine. The treated fibers are invisible in the paper and become fluorescent under ultraviolet light. U.S. Pat. No. 2,379,443 (Kantrowitz et al., July, 1945) discloses authenticatable paper made by the addition of a small percentage of cellulosic fibers that have been treated with hydrated ferric chloride which has been hydrolyzed to iron hydroxide. The treated fibers are capable of acquiring a deep blue color upon application to the paper of a potassium ferrocyanide solution, followed by an orthophosphoric acid solution.
U.S. Pat. No. 3,839,637 (Willis, Oct. 1, 1974), incorporated herein by reference, discloses the impregnation of spaced courses of yarn in a fabric with a material which is not visible under daylight, but which is visible only when subjected to ultra-violet light, so as to provide guide lines for cutting, or measuring indicia to enable visual counting of the number of yards of cloth in a roll from the end thereof without the necessity of unrolling the bolt.
U.S. Pat. No. 4,623,579 (Quon, Nov. 18, 1986), incorporated herein by reference, discloses a decorative composite article, which may be longitudinally slit to form a yarn product, which has a combined phosphorescent and fluorescent decorative appearance. The composite article includes paired outer layers of a thermoplastic resin between which is disposed a decorative layer comprising a composition including a colorant component having a phosphorescent colorant and a fluorescent colorant, and a resin binder material. The fluorescent colorant is present in an amount by weight that is up to an amount equal to that of the phosphorescent colorant. The present binder material may be selected from polyester, polyurethane and acrylic polymers and copolymers, with a mixture of butadiene-acrylonitrile rubber and polyurethane composition being preferred. The composite article is prepared by coating two resin films with the composition, followed by contacting the films with each other on their coated surfaces and applying heat and pressure to bond them together to form the decorative composite article.
U.S. Pat. No. 4,756,557 (Kaule, et al., Jul. 12, 1988), expressly incorporated herein by reference, relates to a security document having a security thread embedded therein and methods for producing and testing the authenticity of the security document. In order to increase the protection of security documents such as ban notes, etc., against forgery, security threads are embedded in the document that have at least two areas extending in the longitudinal direction of the thread and differing in their physical properties. The thread is preferably a coextruded multicomponent synthetic thread whose individual components contain additives such as dyes or fluorescent substances and/or particles having electrical or magnetic properties. The testing of the authenticity of the security thread is directed toward the presence of these additives and their mutual geometrical distribution in certain areas of the security thread.
U.S. Pat. No. 6,019,872 (Kurrle, Feb. 1, 2000), expressly incorporated by reference, relates to authenticatable bleached chemical paper products, prepared from a bleached chemical papermaking furnish containing a minor but detectable amount of lignin containing fibers selected from the group consisting of mechanical, thermomechanical, chemi-thermomechanical and bleached-chemi-thermomechanical, in an amount sufficient to be detectable with the use of a phloroglucinol staining technique.
U.S. Pat. No. 6,054,021 (Kurrle, et al., Apr. 25, 2000), expressly incorporated herein by reference, relates to a process of manufacturing authenticatable paper products, in which the paper made from the papermaking furnish includes fluorescent cellulosic fibers.
U.S. Pat. No. 6,045,656 (Foster, et al., Apr. 4, 2000) relates to a process for making and detecting anti-counterfeit paper. In this process, a certain percentage of wood fiber lumens which have been loaded with one or more fluorescent agents are added to the papermaking pulp. These wood fiber lumens would look normal under regular light, but will glow when exposed to various manners of radiation.
U.S. Pat. No. 6,035,914 (Ramsey, et al., Mar. 14, 2000), expressly incorporated herein by reference, for counterfeit-resistant materials and a method and apparatus for authenticating materials, relates to the use of fluorescent dichroic fibers randomly incorporated within a media to provide an improved method for authentication and counterfeiting protection. The dichroism is provided by an alignment of fluorescent molecules along the length of the fibers. The fluorescent fibers provide an authentication mechanism of varying levels of capability. The authentication signature depends on four parameters; the x, y position, the dichroism and the local environment. The availability of so many non-deterministic variables makes counterfeiting difficult. Essentially, fibers having a readily detectable, non-RGB colorspace characteristic, e.g., fluorescent dichroism, are embedded randomly within a fibrous substrate. Fibers near the surface are readily identified due to their fluorescence. The fibers are then analyzed for dichroism, i.e., having a polarization axis. The positions of these dichroic fibers are useful for authenticating the substrate.
The fibers are distributed throughout the media in a random fashion during the production process. Thus the fiber related signature is a random variable rather than a deterministic one. In fact, it is not believed that any methods presently exist for copying fiber placement within a substrate. The signature of every item will be different making it more difficult to reverse engineer. For example, two-dimensional images (e.g. in the x-y plane) of papers incorporating the inventive fluorescent dichroic fibers provide increased security over the prior art “blue” threads used in currency. A comparison of a white light image and a fluorescence image showing the two-dimensional distribution of florescent dichroic fibers provides unique information. Fibers lying at or near the surface of the paper are easily observed by the white light image but are quickly masked below the surface. In a fluorescence image, fibers that lie below the surface are also readily observable. A comparison of the two images provides a signature. Furthermore, processing of the paper (calendaring) further alters this image comparison. The pressing process reduces the fluorescence from the surface fibers while not perturbing the subsurface fibers thus depth information is available by comparing the two images.
The fluorescent fibers' emission characteristics will also vary depending upon the angular orientation of the fibers within the media relative to a polarized excitation source. For example, at a given wavelength, the intensity of electro-magnetic energy emitted by the fibers may vary considerably depending upon whether the fibers within the media are vertically or horizontally oriented relative to the direction of a linearly polarized excitation source and a parallel polarization analyzer. Hence, the dichroic nature of the fibers provides a fourth variable for each point along the fiber (i.e., x, y, z and dichroism/emission behavior).
The emission spectrum of each fluorescent dichroic fiber, can provide data on the fiber's local environment. For example, consider the use of the present invention in paper media or in an aerosol application. The local environment of the fluorescent, dichroic fibers cause photon scattering (e.g., the orientation and number density of the paper fibers) and absorption (e.g., varying thickness of the dried carrier vehicle in an aerosol application). This local environment is indirectly observed through the measurement of the fluorescent dichroic fiber's apparent fluorescent anisotropy. This apparent fluorescent anisotropy assumes random values because the process of incorporating the fibers into the media is a random process.
It is not necessary to analyze each variable for authentication; varying levels of security may be obtained by selecting one or more feature for analysis. For example, at the first level (i.e., the lowest authentication/lowest cost), an item having fluorescent dichroic fibers incorporated therewith may merely be checked to see that the fluorescent fibers are present in the item. The particular fluorescent agent used may be kept secret and dyes which fluoresce in non-visible regions of the electromagnetic spectrum may be employed, so copying this feature may be difficult. At the second level of authentication accuracy, an item having fluorescent, dichroic fibers may be checked to see that the florescent fibers present in the media have the correct fluorescence anisotropy. This level of authentication exceeds that of the first level because the fluorescence anisotropy is dependent upon the molecular structure of the fluorescent molecule and the specific processing conditions used to prepare the fibers containing the fluorescent molecules. The third level of authentication accuracy involves generating a prerecorded x-y pattern of the fluorescent fibers in the item (e.g., by logging the particular random pattern of fibers present in a particular credit card when the card is manufactured). When the item is presented for authentication the observed pattern is compared with the prerecorded pattern. Since each item would have a unique pattern, detection of a counterfeit would simply involve detection of a duplicate or unmatchable pattern. At the highest level of authentication accuracy, the x-y-apparent fluorescent anisotropy pattern of the fluorescent dichroic fibers in the item would be prerecorded. As in the above case, when the item is presented for authentication the observed pattern is compared with the prerecorded pattern. Since the values for the variables in the x-y-apparent fluorescent anisotropy pattern are random, this level of authentication yields an item that is virtually impossible to duplicate. Calculations, using the number density of “blue” and “red” fibers incorporated into currency paper as a base case, indicate that the probability of a random repeat of the x-y-apparent fluorescent anisotropy pattern is about 1 part in 10 1000 , an extremely unlikely event.
Cryptographic Techniques
The original forms of cryptography involved the use of a single secret key that was used to both encrypt and decrypt the message (known as symmetric cryptography). One challenge to this technique is the logistics of communicating the secret key to the intended recipient without other parties gaining knowledge of the key. In 1976, Whitfield Diffie and Martin Hellman introduced the concept of Public Key cryptography (asymmetric cryptography). In their system, each person is the owner of a mathematically related pair of keys: a Public Key, intended to be available to anyone who wants it; and a Private Key, which is kept secret and only known by the owner. Because messages are encrypted with a Public Key and can only be decrypted by the related Private Key, the need for the sender and receiver to communicate secret information (as is the case in symmetric cryptography) is eliminated.
Public Key encryption is based on two mathematically related keys that are generated together. Each key in the pair performs the inverse function of the other so what one key encrypts, the other key decrypts, and vice versa. Because each key only encrypts or decrypts in a single direction, Public Key encryption is also known as asymmetric encryption. Encryption and authentication take place without any sharing of Private Keys: each person uses only another's Public Key or their own Private Key. Anyone can send an encrypted message or verify a signed message, but only someone in possession of the correct Private Key can decrypt or sign a message.
The two primary uses of Public Key cryptography, encryption and digital signatures. Encryption messages are encrypted by using the Public Key of the intended recipient. Therefore, in order to encrypt a message, the sender must either have or obtain the Public Key from the intended recipient. The recipient of the message decrypts the message by using their Private Key. Because only the recipient has access to the Private Key (through password protection or physical security), only the recipient can read the message. In order to create a digital signature, the sender's computer performs a calculation that involves both the sender's Private Key and the message. The result of the calculation is a digital signature, which is then included as an attachment to the original message. The recipient of the message performs a similar calculation that includes the message, the digital signature of the sender, and the sender's Public Key. Based on the result of the recipient's calculation, known as a hash, it can be determined whether the signature is authentic (or is fraudulent) and whether the message had been intercepted and/or altered at any point between the sender and the recipient.
In most cryptosystems, with some exceptions, such as elliptic key encryption, the larger the key size, the stronger the encryption. While some people could argue that you can never have too strong a level of encryption, in the world of cryptography the word ‘overkill’ can certainly be applicable. With stronger encryption comes greater system complexity and longer processing durations to both encrypt and decrypt.
Presently, there are four different ‘grades,’ that refer to the strength of the protection: Export grade gives minimal real protection (40-bit for symmetric encryption or 512 for asymmetric). Personal grade (56- or 64-bits symmetric, 768 asymmetric) is recommended for keys that are not very important, such as those that protect one person's personal e-mail or those that serve as ‘session keys’ for low-importance transactions. Commercial grade (128-bit symmetric or 1024 asymmetric) is recommended for information that is valuable and fairly sensitive, such as financial transactions. Military grade (160-bit symmetric or 2048-bit asymmetric) is recommended for information that is truly sensitive and must be kept secret at any cost.
U.S. Pat. No. 5,984,366 (Priddy, Nov. 16, 1999), expressly incorporated herein by reference, relates to unalterable self-verifying articles. Self-verifying article creation includes receiving recipient-specific data, encoding a first selected subset of the recipient-specific data and fixing the encoded subset along with other human-recognizable data on a surface of an article. Self-verifying article authentication includes scanning a surface to locate an encoded first data set, decoding the first data set and comparing the decoded first data set with a control data set, which may also be fixed upon the surface, to determine the authenticity of the received self-verifying article. According to one disclosed embodiment, enhanced data security can be obtained and maintained by verifying a machine-readable data set on an object for acceptability against predetermined criteria which may include searching a data base (e.g., an organized, comprehensive collection of data stored for use by processing system(s)) of previously issued articles to determine uniqueness. The transmission may be by wired or non-wired communication. In order to verify authenticity, an encoded data set (divided in two) on an article to be authenticated is read and processed, locally or remotely, to first check consistency between the divided parts, and to provide biometric authentication information about a presenter or bearer of the object.
U.S. Pat. No. 5,932,119 (Kaplan, et al. Aug. 3, 1999), and WO 97/25177, Shachrai et al., expressly incorporated herein by reference, relate to a laser marking system, with associated techniques for authenticating a marked workpiece. Images of marked objects are stored, and may be authenticated through a database, and/or through a secure certificate of authenticity, including an image of the marked object. According to Kaplan et al., difficult to reproduce characteristics of an object are used as an integrity check for an encoded message associated with the object. These characteristics may be measured or recorded, and stored, for example within a marking on the object, or in a database. Advantageously, these measurements and characteristics may be derived from an image of the object captured in conjunction with the marking process. In fact, by storing such images and providing a pointer to the image, e.g., a serial number, the measurements or characteristics to be compared need not be determined in advance. Therefore, according to such a scheme, the object to be authenticated need only include a pointer to a record of a database containing the data relating to the object to be authenticated. This allows information relating to characteristics of the object, which may be difficult to repeatably determine or somewhat subjective, to be preserved in conjunction with the object. An image of the object on a certificate of authenticity may be used to verify that the object is authentic, while providing a tangible record of the identification of the object. Known secure documents and methods for making secure documents and/or markings are disclosed in U.S. Pat. No. 5,393,099 (D'Amato, Feb. 28, 1995); U.S. Pat. No. 5,380,047 (Molee, et al., Jan. 10, 1995); U.S. Pat. No. 5,370,763 (Curiel, Dec. 6, 1994); U.S. Pat. No. 5,243,641 (U.S. Pat. No. 4,247,318 (Lee, et al., Jan. 27, 1981); U.S. Pat. No. 4,199,615 (Wacks, et al., Apr. 22, 1980); U.S. Pat. No. 4,059,471 (Haigh, Nov. 22, 1977); U.S. Pat. No. 4,178,404 (Allen, et al., Dec. 11, 1979); and U.S. Pat. No. 4,121,003 (Williams, Oct. 17, 1978), expressly incorporated herein by reference. U.S. Pat. No. 5,464,690 (Boswell, Nov. 7, 1995) and U.S. Pat. No. 4,913,858 (Miekka, et al., Apr. 3, 1990), expressly incorporated herein by reference, relate to certificate having holographic security devices.
It is known to provide a number of different types messages for cryptographic authentication. A so-called public key/private key encryption protocol, such as available from RSA, Redwood Calif., may be used to label the workpiece with a “digital signature”. See, “A Method for Obtaining Digital Signatures and Public Key Cryptosystems” by R. L. Rivest, A. Shamir and L. Adelmann, Communications of ACM 21(2):120–126 (February 1978), expressly incorporated herein by reference. In this case, an encoding party codes the data using an appropriate algorithm, with a so-called private key. To decode the message, one must be in possession of a second code, called a public key because it may be distributed to the public and is associated with the encoding party. Upon use of this public key, the encrypted message is deciphered, and the identity of the encoding party verified. In this scheme, the encoding party need not be informed of the verification procedure. Known variations on this scheme allow private communications between parties or escrowed keys to ensure security of the data except under exceptional authentication procedures. See also, W. Diffie and M. E. Hellman, “New directions in cryptography”, IEEE Trans. Information Theory, Vol. IT-22, pp. 644–654, November 1976; R. C. Merkle and M. E. Hellman, “Hiding information and signatures in trapdoor knapsacks”, IEEE Trans. Information Theory, Vol. IT-24, pp. 525–530, September 1978; Fiat and Shamir, “How to prove yourself: practical solutions to identification and signature problems”, Proc. Crypto 86, pp. 186–194 (August 1986); “DSS: specifications of a digital signature algorithm”, National Institute of Standards and Technology, Draft, August 1991; and H. Fell and W. Diffie, “Analysis of a public key approach based on polynomial substitution”, Proc. Crypto. (1985), pp. 340–349, expressly incorporated herein by reference. Another encoding scheme uses a DES-type encryption system, which does not allow decoding of the message by the public, but only by authorized persons in possession of the codes. This therefore requires involvement of the encoding party, who decodes the message and assists in authentication.
U.S. Pat. No. 6,028,936 (Hillis, Feb. 22, 2000), U.S. Pat. No. 6,021,202 (Anderson, et al., Feb. 1, 2000), U.S. Pat. No. 6,009,174 (Tatebayashi, et al. Dec. 28, 1999), U.S. Pat. No. 5,375,170 (Shamir, Dec. 20, 1994), U.S. Pat. No. 5,263,085 (Shamir, Nov. 16, 1993), and U.S. Pat. No. 4,405,829 (Rivest, et al., Sep. 20, 1983), incorporated herein by reference, provide encryption and digital signature or document content distribution schemes. U.S. Pat. No. 5,600,725 (Rueppel, et al., Feb. 4, 1997), and U.S. Pat. No. 5,604,804 (Micali, Feb. 18, 1997), incorporated herein by reference, provide public key-private key encryption systems. U.S. Pat. No. 5,166,978 (Quisquater, Nov. 24, 1992), incorporated herein by reference, provides a microcontroller for implementing so-called RSA schemes. U.S. Pat. No. 6,002,772 (Saito, Dec. 14, 1999), expressly incorporated herein by reference, provides An embedded digital watermark scheme.
U.S. Pat. No. 6,065,119 (Sandford, II, et al., May 16, 2000), expressly incorporated herein by reference, provides a method of authenticating digital data such as measurements made for medical, environmental purposes, or forensic purpose, and destined for archival storage or transmission through communications channels in which corruption or modification in part is possible. Authenticated digital data contain data-metric quantities that can be constructed from the digital data by authorized persons having a digital key. To verify retrieved or received digital data, the data-metrics constructed from the retrieved or received data are compared with similar data-metrics calculated for the retrieved or received digital data. The comparison determines the location and measures the amount of modification or corruption in the retrieved or received digital data.
Methods that hide validation information within the data being authenticated offer an alternative means to validate digital data. Digital watermarks can be added to data by methods falling generally into the field of steganography. Steganographic methods are reviewed by W. Bender, D. Gruhl, and N. Morimoto in “Techniques for Data Hiding,” Proc. SPIE, Storage and Retrieval for Image and Video Databases III, 9–10 Feb., 1995, San Jose, Calif. This reference also is incorporated herein by reference.
One method of impressing a digital watermark is given by G. Caronni, in “Assuring Ownership Rights for Digital Images,” Proc. Reliable IT Systems, VIS '95, 1995, edited by H. H. Bruggemann and W. Gerhardt-Hackl (Vieweg Publ. Co.: Germany). Another method is given by I. J. Cox, J. Kilian, T. Leighton, and T. Shamoon in “Secure Spread Spectrum Watermarking for Multimedia,” NEC Research Inst. Tech. Report 95-10, 1995. These references also are incorporated herein by reference.
Unlike the checksum or digital signature that calculate a measure of the original data, digital watermarking techniques modify the data in order to encode a known signature that can be recovered. The presence of the hidden signature in received data verifies that the data are unchanged, or its absence reveals that the data were modified from the watermarked form. The method of Cox et al (1995) supra is designed specifically for digital images, and it is sufficiently robust to survive even transformations of the digital data to analog form. However, all the above methods proposed for digital watermarking generally detect modifications by means of an external signature, i.e., no metric that measures the fidelity of the original digital data is used. Consequently, there exists no ability to measure in any detail the extent of the changes made or to estimate the precision of the received data. The steganographic watermarking methods differ from the digital signature and checksum methods primarily by being invisible, and by using the digital data to convey the watermark, thus eliminating the need for an appended value.
U.S. Pat. No. 5,592,549 (Nagel, et al., Jan. 7, 1997), expressly incorporated herein by reference, relates to a method and apparatus for retrieving selected information from a secure information source. A device is disclosed for retrieving information from a secure electronic information source, wherein at least some of the information is in encrypted form and may be decrypted for use. The device comprises: (a) a computer, having an input device and a display device, for selecting information to be retrieved from the information source; (b) an information retrieval device, coupled to the computer, for retrieving the selected information from the information source; (c) a decryption device, coupled to the computer, for decrypting at least portions of the selected information retrieved from the information source; and (d) a data logging device, coupled to the computer, for maintaining a data log of the selected information as it is retrieved from said information source and decrypted. According to the invention, a unique brand code is automatically, electronically added to at least some of the selected and decrypted information, and to the data log.
U.S. Pat. No. 5,394,469 of Robert Nagel and Thomas H. Lipscomb discloses a personal computer or “host computer” a CD-ROM reader and a “decryption controller”. The decryption controller is addressable by the host computer as if it were the CD-ROM reader. Upon receipt of an information request, the decryption controller initiates a request to the CD-ROM reader for the desired information, retrieves this information, decrypts it (if it is encrypted) and then passes it to the host computer. The decryption controller is thus “transparent” to the host computer.
U.S. Pat. No. 6,044,463 (Kanda, et al., Mar. 28, 2000) expressly incorporated herein by reference, relates to a method and system for message delivery utilizing zero knowledge interactive proof protocol. The message delivery system guarantees the authenticity of a user, the reliability of a message delivery, and the authenticity of the message delivery, while preventing an illegal act, and which can prove them at a later time. The system has an information provider terminal including a user authentication unit for carrying out a user authentication of the user according to a zero knowledge interactive proof protocol using check bits E generated according to a work key W, and a transmission unit for transmitting to the user a cipher-text C in which a message M to be delivered to the user is enciphered according to a secret key cryptosystem by using the work key W, and the check bits E. The system also has a user terminal including a message reception unit for taking out the work key W by using at least the check bits E, and obtaining the message M by deciphering the ciphertext C according to the secret key cryptosystem by using the work key W.
U.S. Pat. No. 5,926,551 (Dwork, et al., Jul. 20, 1999) expressly incorporated herein by reference, elates to a system and method for certifying content of hard-copy documents. The system and method facilitate proof that a specific item, such as a document, has been sent via a communication medium, such as the mail service of the United States Postal Service, at a specific time. A bit map image is produced, such as by scanning a hard copy document. Preferably the bit map is compressed into a data string and hashed. The hash file is signed by a certifying authority, such as the USPS, using an existentially unforgeable signature scheme. The original document, a code representation of the string, and a code representation of the signature are sent via the communication medium. As a result, the combination of materials sent provides proof of the authenticity of the content of the document.
U.S. Pat. No. 5,745,574 (Muftic, Apr. 28, 1998), expressly incorporated herein by reference, relates to a security infrastructure for electronic transactions. A plurality of certification authorities connected by an open network are interrelated through an authentication and certification system for providing and managing public key certificates. The certification system with its multiple certification and its policies constitute a public key infrastructure facilitating secure and authentic transactions over an unsecure network. Security services for applications and users in the network are facilitated by a set of common certification functions accessible by well-defined application programming interface which allows applications to be developed independently of the type of underlying hardware platforms used, communication networks and protocols and security technologies.
A digital signature standard (DSS) has been developed that supplies a shorter digital signature than the RSA standard, and that includes the digital signature algorithm (DSA) of U.S. Pat. No. 5,231,668 (Kravitz, Jul. 27, 1993). This development ensued proceeding from the identification and signature of the U.S. Pat. No. 4,995,081 (Leighton, et al., Feb. 19, 1991) and proceeding from the key exchange according to U.S. Pat. No. 4,200,770 (Hellman, et al., Apr. 29, 1980) or from the El Gamal method (El Gamal, Taher, “A Public Key Cryptosystem and a Singular Scheme Based on Discrete Logarithms”, 1 III Transactions and Information Theory, vol. IT-31, No. 4, July 1985), all of which are expressly incorporated herein by reference.
U.S. Pat. No. 6,041,704 (Pauschinger, Mar. 28, 2000), expressly incorporated herein by reference, relates to a public key infrastructure-based digitally printed postage system. See also, U.S. Pat. No. 6,041,317 (Brookner, Mar. 21, 2000), U.S. Pat. No. 6,058,384 (Pierce, et al., May 2, 2000) and European Patent Application 660 270, expressly incorporated herein by reference, which apply encrypted postage markings to mail. U.S. Pat. No. 5,953,426 (Windel, et al. Sep. 14, 1999), expressly incorporated herein by reference, discloses a private key method for authenticating postage markings. A data authentication code (DAC) is formed from the imprinted postage message, this corresponding to a digital signature. The data encryption standard (DES) algorithm disclosed in U.S. Pat. No. 3,962,539 (Ehrsam et al., June. 1976) is thereby applied, this being described in FIPS PUB 113 (Federal Information Processing Standards Publication).
The data in the deciphered message includes a set of unique or quasi unique characteristics for authentication. In this scheme, the encoding party need not be informed of the verification procedure.
Typical encryption and document encoding schemes that may be incorporated, in whole or in part, in the system and method according to the invention, to produce secure certificates and/or markings, are disclosed in U.S. Pat. No. 5,422,954 (Berson, Jun. 6, 1995); U.S. Pat. No. 5,337,362 (Gormish, et al. Aug. 9, 1994); U.S. Pat. No. 5,166,978 (Quisquater, Nov. 24, 1992); U.S. Pat. No. 5,113,445 (Wang, May 12, 1992); U.S. Pat. No. 4,893,338 (Pastor, Jan. 9, 1990); U.S. Pat. No. 4,879,747 (Leighton, et al., Nov. 7, 1989); U.S. Pat. No. 4,868,877 (Fischer, Sep. 19, 1989); U.S. Pat. No. 4,853,961 (Pastor, Aug. 1, 1989); and U.S. Pat. No. 4,812,965 (Taylor, Mar. 14, 1989), expressly incorporated herein by reference. See also, W. Diffie and M. E. Hellman, “New directions in cryptography”, IEEE Trans. Information Theory, Vol. IT-22, pp. 644–654, November 1976; R. C. Merkle and M. E. Hellman, “Hiding information and signatures in trapdoor knapsacks”, IEEE Trans. Information Theory, Vol. IT-24, pp. 525–530, September 1978, Fiat and Shamir, “How to prove yourself: practical solutions to identification and signature problems”, Proc. Crypto 86, pp. 186–194 (August 1986); “DSS: specifications of a digital signature algorithm”, National Institute of Standards and Technology, Draft, August 1991; and H. Fell and W. Diffie, “Analysis of a public key approach based on polynomial substitution”, Proc. Crypto. (1985), pp. 340–349, expressly incorporated herein by reference.
In order to provide enduring authentication, it may be desired that multiple codes, containing different information in different schemes, be encoded on the object, so that if the security of one code is breached or threatened to be breached, another, generally more complex code, is available for use in authentication. For example, a primary code may be provided as an alphanumeric string of 14 digits. In addition, a linear bar code may be inscribed with 128–512 symbols. A further 2-D array of points may be inscribed, e.g., as a pattern superimposed on the alphanumeric string by slight modifications of the placement of ablation centers, double ablations, laser power modulation, and other subtle schemes which have potential to encode up to about 1 k–4 k symbols, or higher, using multi-valued modulation. Each of these increasingly complex codes is, in turn, more difficult to read and decipher.
As is known from U.S. Pat. No. 5,932,119 (Kaplan, et al., Aug. 3, 1999), intrinsic imperfections or perturbations in the marking process may be exploited for authentication. Thus, a pattern may be provided which can be analyzed, but for which techniques for copying are generally unavailable. Thus, a marking pattern, even applied using standard means, may provide an opportunity for counterfeit resistant feature identification.
In like manner, intentional or “pseudorandom” irregularities (seemingly random, but carrying information in a data pattern) may be imposed on the marking, in order to encode additional information on top of a normally defined marking pattern. Such irregularities in the marking process may include intensity modulation, fine changes in marking position, and varying degrees of overlap of marked locations. Without knowledge of the encoding pattern, the positional irregularities will appear as random jitter and the intensity irregularities will appear random. Because a pseudorandom pattern is superimposed on a random noise pattern, it may be desirable to differentially encode the pseudorandom noise with respect to an actual encoding position or intensity of previously formed markings, with forward and/or backward error correcting codes. Thus, by using feedback of the actual marking pattern rather than the theoretical pattern, the amplitude of the pseudorandom signal may be reduced closer to the actual noise amplitude while allowing reliable information retrieval. By reducing the pseudorandom signal levels and modulating the pseudorandom signal on the actual noise, it becomes more difficult to duplicate the markings, and more difficult to detect the code without a priori knowledge of the encoding scheme.
A number of authentication schemes may be simultaneously available. Preferably, different information is encoded by each method, with the more rudimentary information encoded in the less complex encoding schemes. Complex information may include spectrophotometric data, and image information. Thus, based on the presumption that deciphering of more complex codes will generally be required at later time periods, equipment for verifying the information may be made available only as necessary.
Known techniques for using ID numbers and/or encryption techniques to preventing counterfeiting of secure certificates or markings are disclosed in U.S. Pat. No. 5,367,148 (Storch, et al., Nov. 22, 1994); U.S. Pat. No. 5,283,422 (Storch, et al. Feb. 1, 1994); and U.S. Pat. No. 4,814,589 (Storch, et al., Mar. 21, 1989), expressly incorporated herein by reference.
In addition to being analyzed for information content, i.e., the markings, the object image may also be compared with an image stored in a database. Therefore, based on a presumptive identification of an object, an image record in a database is retrieved. The image of the presumptive object is then compared with the stored image, and any differences then analyzed for significance. These differences may be analyzed manually or automatically. Where a serial number or other code appears, this is used to retrieve a database record corresponding to the object that was properly inscribed with the serial number or code. Where the code corresponds to characteristics of the object and markings, more than one record may be retrieved for possible matching with the unauthenticated object. In this case, the information in the database records should unambiguously authenticate or fail to authenticate the object.
U.S. Pat. No. 5,974,150 (Kaish, et al., Oct. 26, 1999), expressly incorporated herein by reference, relates to a system and method for authentication of goods. An authentication system is provided based on use of a medium having a plurality of elements, the elements being distinctive, detectable and disposed in an irregular pattern or having an intrinsic irregularity. Each element is characterized by a determinable attribute distinct from a two-dimensional coordinate representation of simple optical absorption or simple optical reflection intensity. An attribute and position of the plurality of elements, with respect to a positional reference is detected. A processor generates an encrypted message including at least a portion of the attribute and position of the plurality of elements. The encrypted message is recorded in physical association with the medium. The elements are preferably dichroic fibers, and the attribute is preferably a polarization or dichroic axis, which may vary over the length of a fiber. An authentication of the medium based on the encrypted message may be authenticated with a statistical tolerance, based on a vector mapping of the elements of the medium, without requiring a complete image of the medium and elements to be recorded.
U.S. Pat. No. 5,592,561 (Moore, Jan. 7, 1997), incorporated herein by reference, suggests a system that provides an authenticating, tracking/anti-diversion, and anti-counterfeiting system that can track various goods. The system includes a control computer, a host computer, a marking system, and a field reader system, which are all compatible and can be physically linked via data transmission links. An identifiable and unique mark is placed on each good, or on materials out of which the goods are to be made, which enables subsequent inspection. The marks or patterns include areas where a marking agent is applied in an encrypted pattern and areas where it is not applied. The pattern can be scanned or captured by a reader and deciphered into encoded data. The entry can then either be compared directly to a set of authentic entries on a database or decoded and compared to a set of data on the centrally located host database. The marking system provides control over imprinting, allowing a limited number of authorized codes to be printed before reauthorization is required. In order to provide marking validation, a camera captures images of imprints. After imprinting of the encoded marking, an image of the marking is obtained and centrally authenticated as a valid code, which may be stored in a database along with stored pertinent information pertaining to this specific product. Monitoring of the marked goods is facilitated by including a unique encrypted pattern having, for example, a unique owner identifier, a unique manufacturer identifier, a unique plant identifier, a unique destination identifier, and time and date information.
U.S. Pat. No. 5,367,319 (Graham, Nov. 22, 1994), incorporated herein by reference, provides a system wherein an object, such as currency, is randomly marked, such as with an ink jet printer. Counterfeiting of the object by copying is detected by sensing duplication of the random pattern.
U.S. Pat. No. 5,499,924 (Berson, et al., May 30, 1995), incorporated herein by reference, relates to a digital camera with an apparatus for authentication of images produced from an image file. U.S. Pat. No. 5,351,302 (Leighton, et al., Sep. 27, 1994), incorporated herein by reference, relates to a method for authenticating objects based on a public key cryptography method encoding an ascertainable characteristic of the object, such as a serial number.
U.S. Pat. No. 5,574,790 (Liang, et al., Nov. 12, 1996), incorporated herein by reference, provides a multiple-reader system for authentication of articles based on multiple sensed fluorescent discriminating variables, such as wavelengths, amplitudes, and time delays relative to a modulated illuminating light. The fluorescent indicia incorporates spatial distributions such as bar codes as discriminating features, to define a user-determined and programmable encryption of the articles' authentic identity.
U.S. Pat. No. 5,426,700 (Berson, Jun. 20, 1995), incorporated herein by reference, provides a public key/private key system for verification of classes of documents, to verify the information content thereof. U.S. Pat. No. 5,420,924 (Berson, et al. May 30, 1995), and U.S. Pat. No. 5,384,846 (Berson, et al., Jan. 24, 1995), incorporated herein by reference, provide secure identification cards bearing an image of the object to be authenticated. U.S. Pat. No. 5,388,158, incorporated herein by reference, provides a method for making a document secure against tampering or alteration.
U.S. Pat. Nos. 5,191,613, 5,163,091 (Graziano, et al., Nov. 10, 1992), U.S. Pat. No. 5,606,609 (Houser, et al., Feb. 25, 1997), and U.S. Pat. No. 4,981,370 (Dziewit, et al., Jan. 1, 1991), incorporated herein by reference, provide document authentication systems using electronic notary techniques. U.S. Pat. No. 6,049,787 (Takahashi, et al., Apr. 11, 2000), U.S. Pat. No. 5,142,577 (Pastor, Aug. 25, 1992), U.S. Pat. No. 5,073,935 (Pastor, Dec. 17, 1991), and U.S. Pat. No. 4,853,961 (Pastor, Aug. 1, 1989), incorporated herein by reference, provide digital notary schemes for authenticating electronic documents.
U.S. Pat. No. 4,816,655 (Musyck, et al., Mar. 28, 1989), incorporated herein by reference, provides a document authentication scheme which employs a public key-private key scheme and which further employs unscrambled information from the document.
U.S. Pat. No. 4,637,051 (Clark, Jan. 13, 1987), incorporated herein by reference, provides a system for printing encrypted messages which are difficult to forge or alter.
U.S. Pat. No. 4,630,201 (White, Dec. 16, 1986), incorporated herein by reference, provides an electronic transaction verification system that employs random number values to encode transaction data.
U.S. Pat. No. 4,463,250 (McNeight, et al., Jul. 31, 1984), incorporated herein by reference, provides a method for detecting counterfeit codes based on a low density coding scheme and an authentication algorithm.
See also, U.S. Pat. No. 4,150,781 (Silverman, et al., Apr. 24, 1979); U.S. Pat. No. 4,637,051 (Clark, Jan. 13, 1987); U.S. Pat. No. 4,864,618 (Wright, et al., Sep. 5, 1989); U.S. Pat. No. 4,972,475 (Sant' Anselmo, Nov. 20, 1990); U.S. Pat. No. 4,982,437 (Loriot, Jan. 1, 1991); U.S. Pat. No. 5,075,862 (Doeberl, et al., Dec. 24, 1991); U.S. Pat. No. 5,227,617 (Christopher, et al., Jul. 13, 1993); U.S. Pat. No. 5,285,382 (Muehlberger, et al., Feb. 8, 1994); U.S. Pat. No. 5,337,361 (Wang, et al., Aug. 9, 1994); U.S. Pat. No. 5,370,763 (Curiel, Dec. 6, 1994); U.S. Pat. No. 4,199,615 (Wacks, et al., Apr. 22, 1980); U.S. Pat. No. 4,178,404 (Allen, et al., Dec. 11, 1979); U.S. Pat. No. 4,121,003 (Williams, Oct. 17, 1978), U.S. Pat. No. 5,422,954 (Berson, Jun. 6, 1995); U.S. Pat. No. 5,113,445 (Wang, May 12, 1992); U.S. Pat. No. 4,507,744 (McFiggans, et al., Mar. 26, 1985); and EP 0,328,320, incorporated herein by reference.
Thus, there remains a need for a system and method for efficiently authenticating documents as being unaltered originals, while providing high throughput document production. In addition, there remains a need for a method and system for marking documents such that the markings are not readily reproducible with commonly available technologies and so that the markings contain sufficient information for document authentication, identification, and verification. Heretofore, such systems have had various shortcomings.
SUMMARY AND OBJECTS OF THE INVENTION
The present invention therefore relates to a system which provides authentication of originality of a document, by authenticating that the recording medium is authentic, that the document content is unaltered, and that the document content is imprinted on the appropriate unique recording medium.
As noted above, there are numerous known methods for authenticating a unique recording medium. There are also numerous known methods for authenticating a document defined by a digital data set. However, the art has failed to fully address the need for authentication of both the originality of the document content and the recording medium therefore, in a manner suitable for decentralized production of original documents.
According to the present invention, both the production of authenticatable original documents and the authentication thereof may be performed “off-line”, meaning that, during the process, no communications tasks need be conducted in real time. Of course, real time communications may be employed.
Initially, it is noted that it is preferred that a first line of authentication derives from visible and readily analyzed features of the recording media, which make forgery thereof difficult. For example, microprinting, Moiré patterns and other printed indicia which are difficult to photocopy without appearing copied, are preferred. Intaglio printing also imposes a difficult hurdle for a forger.
In addition, one or more inks or printing features which provide a “chemical” level of security, may be employed, requiring a forger to obtain proprietary or difficult to obtain components, such as thermal color change inks, iridescent or dichroic particle inks, specific dyes or fluorescent properties, fluorescent and/or dichroic fibers, or the like.
One known method for authentication of the recording medium comprises use of randomly distributed optically detectable fibers included in the papermaking pulp. These fibers may be colored or fluorescent. Typically, it is preferred that a small area of the recording medium having number of fibers be scanned for authentication, rather than the entirety of the stock. However, during production, the entire stock may be scanned, with normal authentication based on a subset of the scanned data.
In this case, the authentication requires two inquiries: do the fibers have locations that correspond to those of the authentic stock? And, are the fibers real or imprinted. The former inquiry can be addressed by a two-dimensional imaging process, while the later must analyze fiber depth within the stock. This depth is, for example, determined by parallax, focal plane, identification of overlying fibers, or special properties. Since the fiber characteristic is non-deterministic (or seemingly so), fiber properties provide a characteristic that existing duplication systems cannot control, the certificate with encoding is very difficult to undetectably duplicate.
One way to optically distinguish printed features from fibers is to employ dichroic fibers, which have an anisotropic interaction with light, producing a measurable light polarization. By detecting this anisotropy, fibers may be distinguished from printed markings.
The document may thereafter be authenticated using an on-line technique, wherein the identifier of the document is employed to retrieve a remotely stored representation of the document, including fiber pattern, for authentication. The returned information may be an image or express description of the pattern of the document captured during the production process, a digital signature (hash) of the pattern, or a description of an authentication method, which may vary randomly, according to a cost schedule, or other pattern. It is noted that the stored image pattern is preferably not transmitted for authentication, both due to its size, and because this provides a forger with the full constellation of characteristics which must be copied to falsely authenticate the document. Rather, a variable subset of the information is preferred, with an irreversible hash to prevent reconstruction of the source data file. This data, in turn, is preferably transmitted using a secure scheme, although typically the content of the transmission will be available at the authentication station. Hardware security may be provided to limit access to this information, but this level of security may not be warranted in most cases.
The document content, or a digital signature thereof, may be stored remotely, and retrieved based on a unique identification of the document. The required communications may, for example, occur through use of the Internet. See, U.S. Pat. No. 6,052,780 (Glover, Apr. 18, 2000), U.S. Pat. No. 6,011,905 (Huttenlocher, et al. Jan. 4, 2000) and U.S. Pat. No. 5,933,829 (Durst, et al., Aug. 3, 1999), expressly incorporated herein by reference.
The document content may also be authenticate using an on-line digital signature, or may be authenticated using a digital signature or other self-authenticating cryptographic technique, which also confirms the document identity.
In an off-line authentication technique, the authentication information is recorded on the document, and must thus securely identify some irreproducible and essentially unique characteristic aspect of the recording medium, which may be ascertained at the time of authentication. As stated, this characteristic may be a fiber pattern of the paper recording medium, a printed identifier on a document having antiforgery features, or the like.
Typically, in order to provide counterparty identification, the private key of the sender is maintained and employed to sign communications. In fact, such authentication of the authentication authority is typically unnecessary or obtained through other means. For example, the entity seeking authentication proactively contacts the authentication authority, thus making impersonation difficult. Therefore, instead of employing the same private key for each communication, thus risking a security breach in the event of disclosure of the key, the present invention provides a method and system wherein a unique or quasi-unique private key is employed for each authentication message, wherein the encrypted message and public key are either imprinted on the document or transmitted to the authentication site. The public key therefore is used to both decrypt and authenticate the message which, in turn, provides data for authenticating the document.
In an off-line authentication method, preferably the authentication site is provided with a certificate issued by the content owner, which thus provides a cryptographic verification of the authority responsible for the document content.
The recording media itself may thus include features which are difficult to reproduce, such as watermarks, embedded fibers, security threads, holograms, or the like.
Therefore, it is seen that, as a first level of authentication, the authenticity of the recording medium may be examined, generally without any required assistance to the human senses.
While this level of security is often very powerful, it does not address the use of authentic media for forged documents. This concern arises because the recording media according to the present invention may be widely distributed, and further the production facilities cannot generally be made totally secure. Thus, it is desired to have a further level of security to authenticate the medium itself.
A preferred authentication method for the medium provides a cryptographic level of security. In this case, an overt (readily visible) marking is placed on the recording medium, which includes a message. This message may be, for example, a cryptographic message that defines an irreproducible characteristic of the recording medium, such as a microscopic fiber pattern. This message is provided with a digital signature, making alteration thereof difficult. Thus, a relatively simple algorithm is employed to verify that the message imprinted on the recording medium is authentic, and that the message described the actual recording medium. The cryptographic technique is preferably a public key algorithm, wherein the respective public key is known or even imprinted on the document. The public key is then employed to authenticate the message, which in turn is used to authenticate the recording medium. The private key from the originator is maintained as a secret, and since the public key and private key for a pair, the ability of the public key to decrypt the message authenticates the message as deriving from the originator. If the key imprinted on the document is relied upon, then it is preferred that a certification authority be available to verify that the key is authorized, although this may be used statistically rather than for every transaction.
Thus, it is seen that the recording medium may be authenticated with a very high degree of security. This is an important aspect of many embodiments of the invention, as this will assure that the document is an original and not a copy. In cases where copying of the content is of lesser concern, aspects of the security and authentication of the recording medium may be relaxed.
The recording medium, which is preferably a standard size paper, such as 8½×11 inches, is preprinted early in the production process with a unique identifier, which may be a serial number, but is preferably a random identifier. This randomness may be, for example, a combination of a serial number and randomly selected word, facilitating human reading of the identifier. The random component is called a “one time pad”. The identifier for this purpose may be the same (or overlapping) with the authentication marking of the recording medium.
In order to provide further security at this stage, the unique identification message may also be included within the authentication scheme for the recording medium.
With the authentication information for the recording medium and unique identifier present, the recording medium may then be publicly distributed. Thus, it is a particular aspect according to an embodiment of the present invention that the authenticatable recording medium need not be held under tight security from the time it is produced until the time it is imprinted with the desired content. In fact, according to this embodiment of the invention, a business model is provided for the distribution and sale of authenticatable medium, for various uses, which can be customized with particular content on a standard-type printer. Thus, original certificates such as birth certificates, wills, licenses, copyright works, and the like may be printed at distributed locations under direct authority of the appropriate authority, with accounting and accountability provided.
In some cases, the rights holder will directly print the documents, in which case the trusted authority may be dispensed with as a party to the printing transaction
In order to add the content to the document, the identifier for each piece of recording medium (or the beginning identifier in a sequence) is transmitted to a trusted authority, along with an identifier for the document content to be printed. The trusted authority then either negotiates with the rights holder, or internally accounts for the use, and returns information necessary for printing the document.
The return information is, for example, the document content itself, preferably in graphic form. The content is also digitally signed, with the recording medium identifier, and therefore is self-authenticating.
Thus, the recording medium is authenticated, the content is authenticated, and the content is specific for the recording medium identifier.
Alternately, an on-line technique may be used for authentication of the recording medium, content, and/or the merger of the two. Thus, an identifier (preferably not in the form of a sequential serial number) for the recording medium is used to reference a remotely stored file containing the authentication information. On-line authentication potentially increases security, but reduces anonymity of the entity seeking to authenticate the document, often increases transaction cost and may be an inconvenience. Preferably, however, an on-line authentication scheme is available in addition to a self-authentication scheme, possibly defining different authentication information. Further, even when self-authentication is employed, at least a random statistical sampling of the documents being authenticated are authenticated using higher scrutiny, thereby increasing the probability of detection of counterfeiting and the risks thereof. Further, since authentication using cryptographic techniques requires a computing device, it is preferred that authentication information from off-line transactions are later uploaded and analyzed. Even after the fact, the detection of forgery may allow action to be taken to apprehend the forger and/or reduce future risks.
According to the present invention, one embodiment provides a new type of cryptographic technique. For each recording medium, a public key-private key pair is selected. These may be unique for each document. A document serial number and randomly selected passcode (e.g., a randomly selected word or pair of dictionary words) is selected, and imprinted on the document. In conjunction therewith, the public key is printed. Thereafter, during printing of the content, a cipher-text message including the serial number and passcode are downloaded from a central authority, and printed on the document. Thus, the public key printed on the document may then be used to authenticate the cipher-text message. In this case, the private key may be discarded immediately after use for self-authentication schemes, or retained for public key infrastructure communications and authentication of the originator of the message.
Likewise, other techniques may be employed to match the content destined for a particular recording medium with that medium. For example, a graphic pattern may be preprinted on the recording medium during initial production. Thereafter, during printing of the content, a second graphic image may be printed in conjunction, in a form which facilitates unaided human examination. As noted above, copying is limited by a visible set of copy-protection features of the document, as well as the possibility of encoding a unique characteristic of the recording medium. Since cryptographic authentication techniques or digital signatures are employed, it is not possible to substitute recording media without having digital data, which would be revealed during authentication.
Accordingly, both on-line and off-line techniques are employed, with the content printing process particularly being preferably on-line. It is noted that, in some instances, a content printer may “check out” certain recording media, and thus perform the actual printing off-line. This occurs, for example, when the printer is the content owner, and thus the risk of misuse is low. However, it is preferred that all such printing be an interactive on-line process.
Preferably, the technique employs a relatively simple recording medium stock, which may be printed on a relatively standard printer. Security is obtained, therefore, by ascertaining a feature of the stock which is difficult to copy or alter in a desired manner, yet may be readily examined in use. Thus, the problem is asymmetric, with a forger having a significant hurdle, including both physical and algorithmic steps.
Because of the preferred business model for use of the recording medium, in contrast to many prior authenticatable document production systems, neither the customized printing which defines the document content, nor the security of the printer and stock, can be or is mainly relied upon to prevent counterfeiting. Thus, proprietary printers are not required, and the stock may be widely distributed without fear of undermining system security. This therefore allows, for example, standardization and ubiquity of the technology.
Due to an intended low cost, items such as theatre and stadium tickets, coupons, and the like may be readily produced according to this scheme. Because of the high level of security afforded, gift certificates, vouchers, script, currency, valuable documents, securities, negotiable instruments, stock certificates, legal documents, wills, private and business communications and the like, may also be securely printed. In the case of personal identification documents, advantageously, a biometric characteristic of the individual may be printed on the document as document content in plain text or cipher text, or merely logically associated with the document.
Since security is preferably not provided by limiting access level to the uncustomized recording medium, it must be provided at a different level, and indeed, this level is the printing process which uniquely associates the original document content with the recording medium. Therefore, the authentication relies, at least in part, on the security of the central authority which performs (or authorizes and controls) the preprinting process, the code imprinted with the content, and the authorization process, if on-line. In fact, the present techniques allow relatively high security, limited more by internal controls by the central authority than the ability of the third party to crack the cryptographic scheme.
In essence, prior to customized printing, stock is provided having an identifier. During the manufacture of the stock, individual pieces are marked with a unique identifier and a particular characteristic (intrinsic or imparted) of the stock is recorded. For example, a fiber pattern (basic, colored, fluorescent, etc.), which is essentially random, may be recorded. Alternately, a bleed pattern of an ink droplet on a porous surface of the stock, or other intrinsic or applied feature may be used. It is important that the feature not be deterministic; i.e., the process defined for forming the feature is not useful for replicating the feature, and that no known technology could nevertheless be reasonably used to replicate the feature.
Alternately, stock with sufficiently secure anticounterfeit features is preprinted with a digital; signature and an identifier. The preprinted stock is distributed. When a party desires to print an authentic document, he identifies the stock and the document to be printed to a central authority, who then receives an authorization (or accounts for a preauthorization) from the rights holder of the document itself. The central authority then transmits a document definition for the printed page, including a public key-private key encrypted message which a verification of the document identification, a digital signature of the content, and other identification/authentication information. This message is transmitted, for example, through the Internet to an Internet Protocol (IP) address of a printer or print server. The digitally signed document content is then printed on the stock. To authenticate such a document, the stock itself is examined for authenticity. The cryptographic information is then examined, to determine whether the content has been altered, and the identification matches the imprinted identification on the document. Thus, the originality of the document is verified.
Since the content printing is preferably an on-line process, no duplicate prints would be allowed. Saving a document image for duplication, or photocopying would be of no avail, since the cryptographic code includes the unique identifier of the stock. If a forger was to try to preempt the true recording medium by printing a forgery first, then as soon as the true medium appears, a forgery will be identified. In fact, in this case, the “forgery” is in fact an original, and only one original will be allowed. The forgery, in this case, will be accounted as an original. A forgery after the fact (e.g., based on a copying process) would have to overcome the security features of the recording medium to produce an identical medium.
A centralized database therefore holds a descriptor of each piece of stock, associated with its unique identifier. The blank stock is then widely distributed, for use in accordance with the invention. A preferred economic model prices the blank stock as a commodity, although the database remains proprietary and centralized. The stock may also have authentication instructions imprinted thereon. Use of the database may therefore entail a cost, for example to print content or authenticate a document. Since the content printing is preferably an on-line process, while the authentication may be on-line or off-line, preferably the content printing process includes a higher margin than authentication. On the other hand, a differential pricing scheme may be provided for authentic and counterfeit documents. In fact, counterfeits may be charged either more or less than authentic documents. A customer may reasonably pay more for detection of a counterfeit. On the other hand, the central authority may pay a bounty for apprehension of counterfeiters, seeking to assure the integrity of the system.
In use, a user of the system seeking to print a document, defines the desired content, which may involve a monetary accounting to a rights holder, either directly or through an agent. For example, the central authority may serve as agent, collecting funds and authorizing printing of content. Alternately, a rights holder may seek to produce documents on its own account.
Thus, for example, a page description language (PDL) or bitmap image of each page is defined and associated with the stock identifier, including a self-authentication message which includes an identification of the stock. The defined content is then imprinted on the stock preprinted with the identifying information. In the case of multipage documents or multiple originals, a grouping of sheets of stock may be made, for data processing efficiency. Thus, the document content signature may be present, for example, only on the first page.
Where an intrinsic irreproducible feature of the stock is encoded, and the stock is preferably authenticated using the irreproducible feature and identifier, copying of a properly printed document is impossible. Further, possession of stock and an otherwise valid printer is insufficient to undermine the security of the process.
Where the difficulty in reproducing the recording medium is the substantial barrier to copying, care must be taken to assure that the document unique identifier cannot be obliterated or altered, for example using standard techniques. Further, blank document security (prior to preprinting) must be maintained.
In the case of a self-authenticating document, the content in this case is encrypted using a public key-private key technology, or defined with a digital signature, and encoded on the document in conjunction with the irreproducible characteristic of the stock. Authentication is then performed by means of analyzing the code for authenticity, e.g., to verify the originator of the document and the content thereof. In this case, security of the private key is necessary to ensure authenticity, in the manner of a digital signature, for example, using a modification of the method disclosed in U.S. Pat. No. 5,912,974 (Holloway, et al., Jun. 15, 1999), expressly incorporated herein by reference. However, in contrast to the prior art teaching, by encoding the characteristic of the stock, verification of originality is also achieved.
The present technology differs from that described in U.S. Pat. No. 5,932,119 (Kaplan, et al. Aug. 3, 1999), WO 97/25177, Shachrai et al., and U.S. Pat. No. 5,974,150 (Kaish, et al., Oct. 26, 1999) in that authentication of document content is employed. A principal motivation for an embodiment of the present invention is, rather than to authenticate a secondary article, or for the marking to authenticate the substrate itself, to use a marking on the substrate to authenticate a document content imprinted on the substrate as an original.
According to another embodiment of the invention, the document content is imprinted on, or in association with, a piece of secure serialized (or uniquely identified) currency, such as U.S. or foreign nation currency. Therefore, in this case, not only are the intrinsic protections provided therein applicable, but also the legal anti-counterfeiting scheme itself for sanctioning counterfeiters. The serial number of the currency is then used to access a database for authenticating the document content. The currency may be physically associated with the document, for example stapled or placed ion an associated envelope, or the document imprinted on the currency itself (where legally permissible). In the former case, it is possible that a document which is a photocopy of the original is associated with the currency; however, in many instances, such substitution is not objectionable, since only one “original” defined by the serial number of the currency is permissible. It is noted that in the instance of counterfeit currency with duplicated serial numbers, the technique would generally fail, and care should be exercised to avoid non-uniquely identified currency. It is noted that U.S. currency (and other currencies) includes randomly distributed colored fibers, which may themselves be subject to authentication.
In order to detect dichroism, for example of dichroic fibers embedded in a medium, one embodiment of the invention provides for the use of at least two light sources or a time varying light source system, or at least two detectors or a time varying detector system, to illuminate the dichroic fibers, selectively measuring the pattern of the characteristic, which in this case is optical anisotropism.
In some cases, absolute authentication is not required; rather, a significant risk of a counterfeiter being caught is sufficient. Therefore, the technique need not provide 100% detection of all counterfeiting, but rather a significant probability of detection. Thus, for example, pieces of stock may be classified into one of 256 classes by a reliable but secret method. Therefore, less than 0.5% of counterfeits (on otherwise authentic stock) will be able to pass as authentic. To make the problem more difficult, for example, the fibers of an entire document, e.g., 8.5×11 inches, are analyzed and encoded into a class, by each 0.5×0.5 inch portion. During authentication, one or more of the portions are randomly selected for authentication. Thus, while the probability of accidentally authenticating is less than 0.5%, the task of the counterfeiter is to copy the entire pattern, since the relevant region is unknown. This makes the authentication and counterfeiting highly asymmetric.
Advantageously, the serial number and/or other encoding on the stock is imprinted in machine readable form, for example OCR adapted typefaces, magnetic ink coded recording (MICR) toner, bar codes, 2D bar codes, or other known forms. Advantageously, the same sensor for detecting the characteristic of the substrate is used for reading information from the document. For example, a random pattern of magnetic toner particles may define the random characteristic, which may be read with the same sensor as an MICR character reader.
In fact, one aspect of the invention provides a code imprinted on the document using a plurality of coding levels. For example, a serial number is printed on the face of the document, using two to four distinctive fonts. Therefore, each character represents about 5 to 8 bits of data. Preferably, the font coding defines a separate message than the digit coding. Two-dimensional bar codes and glyph codes may also be employed to imprint machine readable authentication information.
The present invention also encompasses an authentication device which may be used to authenticate a document by relatively untrained users, to provide a validation of the document, while maintaining the security of the scheme. Thus, for example, security features may be provided to prevent use of the authentication device to “break” the encoding scheme, which, for example, includes an identification of the features being authenticated.
Therefore, a number of characteristics may be desirable for the authentication device: (1) small size, for example less than 0.05 cubic meter, preferably less than 0.003 cubic meter; (2) low power consumption, for example less than about 10 Watts average, more preferably less than about 0.2 Watt quiescent, 5 Watts peak power draw from a power supply; (3) physical security against disassembly and reverse engineering; (4) electronic security against reverse engineering or code readout; (5) operational security against repeated attempts to verify counterfeit certificates; (6) time-out authorization, requiring periodic reauthorization to remain operational; (7) audit trail capability, to track users and particular usage; (8) adaptive capabilities to compensate for changes over time, such as dirt, defective pixels, wear, etc.; (9) non-predictable authentication schemes, for example selectively analyzing different sub-portions of the certificate in great detail for normal analyses; (10) high security encryption algorithms and optionally support for multiple redundant and independent encryption schemes.
The principal purpose of the authentication device is for cryptographic processing, whereas recording medium authentication may be performed primarily by eye. However, automated recording medium authentication may also be included in this device, especially if it has an optical (or other appropriate) scanner for reading encoded digital information.
The document may be provided with codes having a multiplicity of complexity levels. Thus, even if a first level code is broken, one or more higher complexity codes may then be employed. The advantage of this system over a single level complex code is that the complexity of the detection devices used in the first level may be reduced, and the nature and even existence of the higher level codes need not be revealed until necessary. Further, it is noted that different applications require different security, and therefore it is advantageous to provide a single stock of authenticatable blank medium, which upon use, may be provided with a defined level of security. This, in turn, allows the market to be segmented into classes of users, who may have differing cost sensitivities require different levels of service. Thus, some users may suffice with a 1–10 character password for a self-authenticating encoded document, while others may require maximum security, for example, 2048 bit encryption with remote authentication, and, for example, biometric authentication (e.g., fingerprint) of the bearer of the document.
Preferably, the encoding and authentication processes employ a system that prevents tampering, reverse engineering or massive interrogation, which might lead to a determination of the underlying algorithm and/or the generation of valid codes for counterfeit goods. Alternately, the authenticator may contain no secret information at all, or operate on-line with, for example, a wireless communication link to a central server. Thus, for example, a secure central server may provide authentication services, over secure communications channels. For example, a wireless application protocol (WAP) compliant device may be employed.
When the central server is queried to authenticate a forgery, an entry is made in a log, and further if multiple queries occur in a cluster, the server operates to generate an exception report. The server may also cease responding, alert an operator, or throttle the throughput to prevent rapid brute force attacks. Thus, by providing on-line authentication, enhanced security is provided through monitoring and responding to event context.
Self-authentication may be based on a secure public key algorithm. A security risk exists in that if a common private (secret) encryption key is discovered or released, the usefulness of the encoding on a bulk of document is diminished, and a counterfeiter can generate self-authenticating documents without the knowledge or consent of the normal provider. Until the pool of authentic goods bearing the broken encoding is depleted, or the authentic goods deemed withdrawn, counterfeiters may continue generally undetected. Self-authentication schemes are subject to brute force cracking attempts, since the hacker's activities are not published. Once an authentication code (private key) is discovered, it may be used repeatedly. The present invention therefore provides, even for self-authenticating documents, an optional on-line authentication process using a different code or complexity, which is employed at least randomly to assure a risk of counterfeit detection at a point of presentment.
It is noted that the imprinted code on the certificate need not be visible and/or comprehensible, but rather may itself be a security feature. Thus, special inks, printing technologies, or information storage schemes may be employed. Advantageously, the serial number (or unique identifier) of each document may be provided with security features, and indeed the intrinsic irregularities (e.g., bleed of ink or laser print toner patch edge roughness) on the edges of the serial number imprint themselves providing the non-deterministic characteristic. In this case, like in Kaplan et al., supra, an optical scanner for reading the serial number may simultaneously capture the document irregularity. In a self-authenticating scheme, a code is provided on the document, including a description of the irregularity and a description of the document content, to ensure there has been no alteration. In cases where alteration is not an issue, the document content can be presented as “null”, and only the irregularity subject to authentication. This will be the case where the document stock is customized for a purpose, for example certain theatre or stadium tickets, and therefore the mere possession of an authentic document is sufficient.
Alternately, the irregularity scanner may be distinct from the code reader. For example, an imprint may be formed on the document with an ink having reflective or dichroic flecks. The reader, in this case, may be a simple diode laser, with a uniform beam pattern, illuminating the imprint, and capturing the reflection/diffraction pattern thereof. Thus, while alphanumeric codes and other readily visible codes may be read by eye, subtle encoding methods may require specialized equipment for reading. Therefore, another aspect of the invention provides an automated system for reading codes inscribed on a document. The image analysis capability will generally be tuned or adapted for the types of coding employed, reducing the analysis to relevant details of the marking. Where a pseudorandom code appears in the marking pattern, the individual mark locations and their interrelations are analyzed.
According to another embodiment of the invention, a document stock is provided with a substantially irregular color pattern on a microscopic scale, but having a uniform average background reflection. Therefore, attempts to copy the document will require that the background be subtracted, and the forgery placed on a clean piece of similar stock. This provides the opportunity to steganographically hide pseudorandom image information in the image microstructure of the document, using techniques which are essentially invisible. For example, if the stock includes a relatively high density of light colored cellulose fibers, a sparse pattern of dots could be printed on the stock using the same dye. Therefore, it would be difficult or impossible to analyze every color portion of the document to distinguish fibers from printed dots; however, the document could be authenticated by knowing the imposed locations of the dots. Simple photocopying of the document with the fiber and dot pattern would be ineffective since visually, the gross appearance would be different from an authentic document. This has the advantages that the stock need not be scanned during manufacture to determine the pattern, that a simple mask or set of masks (e.g., dots and voids) could be used for authentication, and that the stock precustomization may be distributed and decentralized. Advantageously, an optical mask is formed using a transmissive liquid crystal light shutter overlayed on the document. In this manner, a first mask defines dot locations, a second mask defines locations which should have no dots (but may have fibers), a third mask defines a printed document content, and a fourth mask defines locations which should have no content, all of which may be visually confirmed. Thus, for authentication, the document code is used to call up an associated database record, or the selfauthentication codes read. This defines the four masks, which are applied sequentially to the light shutter.
According to a preferred embodiment, the pattern on the document is represented as an image projected on a surface, with the surface not necessary being constrained to be planar. Therefore, relative deformations of the authentication pattern may be resolved through mathematical analysis using known transform and image normalization techniques, such as Fourier, wavelet, etc. transforms. The relative deformations, as well as any other deviations from the encoded patterns, which may, for example, represent lost or obscured markings or fibers, noise, environmental contamination with interfering substances, errors or interference in the original encoding process, etc., are then used to determine a likelihood that the document itself corresponds to the originally encoded certificate. Thus, the determined authenticity is preferably associated with a reliability thereof, based on stochastic variations in the properties of the document and stochastic variations in the generation of the associated secure code. A threshold may then be applied to define an acceptable error rate (false positive and false negative) in the authentication process. In general, for valuable paper documents, a threshold may be set relatively high, while for low value documents the authentication threshold may be significantly lower.
According to one embodiment of the invention, the stock precustomization system therefore includes a reader, for reading the unique characteristics of the stock, such as a polarization sensitive imaging device for reading a distribution of dichroic fibers embedded in paper, and a stock imprinter, e.g., for imprinting a substantially unique identifier and optionally a message, on the stock. A description or signature of the read information is stored in a database in association with the identification applied to the stock. During customization, which is typically an on-line process, the content is defined. The content, a description or signature thereof, may be stored in conjunction with the identifier, in the central database.
In some instances, it may be desired to maintain the document content secret from a remote authentication source (central database). In this case, the document content may be encrypted, or only a document digital signature with substantial information loss, but still a high probability of detection of tampering, provided. Further, a three-party transaction, involving the content owner, database registrar, and content user, may occur, in which the database registrar does receive the content nor maintain the authentication data for the document.
During customization, the identification of the stock and the identification of document content (or the content itself) is transmitted to the central server hosting the database, and the document content stored in association with the identification. For self-authentication, this information is then encrypted using an algorithm, to produce an encrypted message, which is then printed in the document stock, using a standard type printer, possibly along with authentication instructions. The encryption may be a multitier system, for example including a 56-bit algorithm, a 128 bit elliptic algorithm, and a 1024 bit algorithm. Each message level is preferably printed separately on the stock, for example, the 56 bit encrypted message as a binary or bar code, and the 128 bit elliptic and 1024 bit encrypted message as a set of two-dimensional matrix codes. Alternately, the higher level messages may be encrypted by the lower level algorithms, providing a consolidated multiple encryption system. Preferably, each encrypted message corresponds to successively more detailed information about the label and/or the object, optionally with redundant encoding or potentially without any overlap of encoded information. This system allows readers to be placed in the field to be successively replaced or upgraded over time with readers that decode the more complex codes. By limiting use of the more complex codes, and release of corresponding code readers, until needed, the risk of premature breaking these codes is reduced. In addition, the use of codes of varying complexity allows international use even where export or use restrictions are in place of the reader devices.
According to a preferred embodiment, a customized print driver or printer firmware is provided to automate the communication, which is preferably through a TCP/IP stack, through the Internet using secure socket layer communications (SSL), through a VPN, or through a private network (intranet).
A modified paper tray (or paper tray accessory) in a printer may be used to automatically read the stock serial number, which in this case is advantageously a bar code disposed perpendicular to a paper path of the stock. Alternately, a stated identification of a set (e.g., ream) or sequential stock may be identified, with automated incrementing of the sequence. Thus, with few modifications, standard printers and computer software may be employed. Possibly more importantly, standard applications and generally standard operating systems may be employed. The process may therefore be embedded, in whole or in part, in the printer hardware. If the process is embedded in the hardware, the content identification must be transmitted to the printer from an application or interface, so that the printer may communicate with the central server to retrieve the authentication information and provide accounting information.
If the self-authentication reader includes secret information, it preferably has a secure memory for storing specifics of the algorithm(s), which is lost in event of physical tampering with the devices. Further, the devices preferably have a failsafe mode that erases the algorithm(s) in case of significant unrecoverable errors. Finally, the systems preferably include safeguards against trivial marking or continuous interrogation, while allowing high throughput or checking of documents. Since the algorithm memory within the reader may be fragile, a central database or server may be provided to reprogram the unit in case of data loss, after the cause of loss is investigated. Any such transmission is preferably over secure channels, for example 128-bit encryption or so-called secure socket layer (SSL) through a TCP/IP communication protocol. Each reader system preferably has a unique identification number and set of encryption keys for any communication with the central system.
The present invention provides a particular economic opportunity for an administrator of an authentication database. The administrator serves as a trusted third party, allowing production of original and authenticatable documents while accounting to the originator thereof, and authentication of documents without direct communications between the originator of the document and the recipient. The administrator, in turn, has the ministerial functions of maintaining security of the database and integrity of the system, and responding promptly to document creation and on-line authentication requests. For these services, the administrator may charge for the document stock, e.g., per document or page print, based on a value represented by the document, for authentication services, selectively and differentially based on an authentication outcome, a flat rate over time for maintenance of authentication files, or according to other economic recovery theories.
In general, the payments will often be considered micropayments, e.g., those in which the transactional expense is low and of a similar magnitude to the value of the services, e.g., less than about $1.00. When aggregated, traditional payment schemes may be appropriate; however, when individually accounted, micropayment technology is preferably employed. Micropayment technology may also provide a degree of anonymity, whereas traditional electronic funds transfer generally requires tracability of funds and identification of accounts.
It is noted that the methods according to the present invention may also be employed as a digital content management system, in which case compensation may be provided to the originator of the document content for usage thereof, with a central consolidated accounting scheme. See, for example, U.S. Pat. No. 5,991,414 (Garay, et al., Nov. 23, 1999), U.S. Pat. No. 5,949,876 (Ginter, et al., Sep. 7, 1999), U.S. Pat. No. 5,982,891 (Ginter, et al., Nov. 9, 1999), U.S. Pat. No. 5,943,422 (Van Wie, et al., Aug. 24, 1999), U.S. Pat. No. 5,933,498 (Schneck, et al., Aug. 3, 1999), U.S. Pat. No. 5,629,980 (Stefik, et al., May 13, 1997) and U.S. Pat. No. 5,634,012 (Stefik, et al., May 27, 1997), expressly incorporated herein by reference.
Micropayments are often preferred where the amount of the transaction does not justify the costs of complete financial security, and some degree of anonymity is desired. The transaction produces a result which eventually results in an economic transfer, but which may remain outstanding subsequent to transfer of the underlying goods or services. The theory underlying this micropayment scheme is that the monetary units are small enough such that risks of failure in transaction closure is relatively insignificant for both parties, but that a user gets few chances to default before credit is withdrawn. On the other hand, the transaction costs of a non-real time transactions of small monetary units are substantially less than those of secure, unlimited or potentially high value, real time verified transactions.
Thus, a rights management system embodiment according to the present invention may employ an applet, local to the client system, which communicates with other applets and/or the server and/or a vendor/rights-holder to validate a transaction, at low transactional costs.
It is noted that the security for the economic payment for a document need not of the same level as the security for authentication of the resulting document.
The following U.S. patents, expressly incorporated herein by reference, define aspects of micropayment, digital certificate, and on-line payment systems: U.S. Pat. No. 5,930,777 (Barber); U.S. Pat. No. 5,857,023 (Demers et al.); U.S. Pat. No. 5,815,657 (Williams); U.S. Pat. No. 5,793,868 (Micali); U.S. Pat. No. 5,717,757 (Micali); U.S. Pat. No. 5,666,416 (Micali); U.S. Pat. No. 5,677,955 (Doggett et al.); U.S. Pat. No. 5,839,119 (Krsul; et al.); U.S. Pat. No. 5,915,093 (Berlin et al.); U.S. Pat. No. 5,937,394 (Wong, et al.); U.S. Pat. No. 5,933,498 (Schneck et al.); U.S. Pat. No. 5,903,880 (Biffar); U.S. Pat. No. 5,903,651 (Kocher); U.S. Pat. No. 5,884,277 (Khosla); U.S. Pat. No. 5,960,083 (Micali); U.S. Pat. No. 5,963,924 (Williams et al.); U.S. Pat. No. 5,996,076 (Rowney et al.); U.S. Pat. No. 6,016,484 (Williams et al.); U.S. Pat. No. 6,018,724 (Arent); U.S. Pat. No. 6,021,202 (Anderson et al.); U.S. Pat. No. 6,035,402 (Vaeth et al.); U.S. Pat. No. 6,049,786 (Smorodinsky); U.S. Pat. No. 6,049,787 (Takahashi, et al.); U.S. Pat. No. 6,058,381 (Nelson); U.S. Pat. No. 6,061,448 (Smith, et al.); U.S. Pat. No. 5,987,132 (Rowney); and U.S. Pat. No. 6,061,665 (Bahreman). See also, Rivest and Shamir, “PayWord and MicroMint: Two Simple Micropayment Schemes” (May 7, 1996), expressly incorporated herein by reference; Micro PAYMENT transfer Protocol (MPTP) Version 0.1 (22 Nov. 1995) et seq, http://www.w3.org/pub/WWW/TR/WD-mptp; Common Markup for web Micropayment Systems, http://www.w3.org/TR/WD-Micropayment-Markup (9 Jun. 1999); “Distributing Intellectual Property: a Model of Microtransaction Based Upon Metadata and Digital Signatures”, Olivia, Maurizio, http://olivia.modlang.denison.edu/˜olivia/RFC/09/.
It is therefore an object of the invention to provide a system and method for authentication of a counterfeit-resistant document, comprising means for automatically describing an apparently non-deterministic characteristic of a recording medium of the document, means for receiving a document content of the counterfeit resistant document, means for storing the description of the apparently non-deterministic characteristic and document content in association with each other, and means for comparing the stored description of the apparently non-deterministic characteristic and document content with an observed apparently non-deterministic characteristic and document characteristic.
It is a further object of the invention to provide an authentication system comprising a plurality of media, each having a plurality of counterfeit-resistant non-deterministic elements, a detector, detecting the elements, a storage system for storing a description of the detected elements, a recording system for recording a content on the medium, means for storing the content, and means for comparing a set of detected elements and stored content with a set of observed elements of the media and content to authenticate the media and content. The elements may comprise, for example, a non-deterministic directional vector of a characteristic of a respective element. The elements may also be disposed in a non-deterministic spatial arrangement in the medium.
It is a further object of the invention to provide a system and method, for providing a counterfeit resistant document recording medium, having thereon a predefined unique document identifier and at least one security feature, defining a variable document content for imprinting on an identified recording medium, storing the variable document content in a database indexed by associated document identifier, and authenticating the counterfeit resistant document by authenticating the security feature and comparing the stored document content with a perceived document content. The step of authenticating the security feature preferably comprises execution of a cryptographic process. Further, the process includes accounting for storing and/or authenticating, for example, charging a financial account, or otherwise allocating cost and profit. The authenticating may, for example, be a self-authentication process performed without outside data access, or, for example, a local process for authenticating the security feature and a remote process for authenticating the document content. The remote process may be asynchronous with and delayed from the local process.
According to another embodiment of the invention, it is an object of the invention to provide a process for authenticating a document comprising (1) providing a document to be authenticated, having predefined document content, (2) providing a serialized piece of paper currency, (3) physically associating the document and the paper currency, and (4) storing document content in association with the serial number of the paper currency. Thus, the presumed authenticity of the currency (and intrinsic security features which underlie that presumption) is bootstrapped to authenticate the associated document. For example, the document is authenticated by recalling a database record including a serial number of a piece of physically associated paper currency and a document content, analyzing the paper currency for identity of serialization and authenticity, and comparing the recalled document content with a document content of the document to be authenticated.
Another object of the invention is to provide an authentication system comprising an authentication certificate having a counterfeit resistant element and a document content, a secure code associated with the authentication certificate defining an apparently non-deterministic characteristic of the counterfeit resistant element and a digital signature of the document content, an system for reading the apparently non-deterministic characteristic, and a processor for comparing the read apparently non-deterministic characteristic of the authentication certificate and content thereof with the associated secure code to determine an authenticity of the authentication certificate, the authenticity being associated with a reliability thereof, based on stochastic variations in the apparently non-deterministic characteristic, and stochastic variations in the received input used for generation of the associated secure code. The secure code is, for example, a public-key/private-key authentication code. The apparently non-deterministic characteristic may, for example, comprises one or more characteristics selected from the group consisting of: a pseudorandom imprint pattern, a non-deterministic pattern of elements comprising the media, an interaction of an aliquot of liquid dye with non-deterministic pattern of elements comprising the media, and a non-deterministic pattern of an imprint on the medium.
The apparently non-deterministic characteristic comprises, for example, a feature that is incompletely represented in a tri color representation, e.g., RGB, MCY, YUV, CIE 1931, etc. Thus, the feature may include, for example, non-optically detectable features, such as a magnetic or thermal signature, an optical characteristic which involves a narrowband spectral analysis or more than three color bands, or an optical characteristic relating to optical polarization.
The apparently non-deterministic characteristic may, for example, also comprise a deterministic characteristic which is hidden, i.e., a steganographic code. In this case, a sparse pattern generated by a pseudorandom code may be provided. This code may be imprinted separately from or together with the document content. In order to make the steganographic characteristic counterfeit resistant, it is preferably hidden in a feature of the medium. Thus, if a counterfeiter seeks to copy the counterfeit resistant document in sufficient detail to include the steganographic code, the copy will also include features intrinsic to the medium, resulting in a requirement for use of a corresponding medium which is, itself, absent any conflicting features, a requirement which may be made very difficult by selection of the stock. If the counterfeiter seeks to copy only the apparent document features, the steganographic code will be filtered, and thus absent from the copy. Thus, the apparently non-deterministic characteristic may be imprinted on the document in deterministic fashion. Alternately, the apparently non-deterministic characteristic may be truly non-deterministic, i.e., the result of random and irreproducible processes and effects, and for example, may be intrinsic to the medium substrate. Accordingly, a unique identifier of the document may comprise a serial number, and the apparently non-deterministic characteristic comprises a pseudorandom copy-resistant printed marking, wherein a secret algorithm or cryptographic technique defines a mapping between the serial number and a pattern of the pseudorandom copy-resistant printed marking. The authentication system may further comprise means for executing the secret algorithm and maintaining a security of the secret algorithm or cryptographic technique, and means for comparing an observed characteristic of a document to be authenticated to an output of the executing means.
According to one embodiment of the invention, a description of the apparently non-deterministic characteristic is imprinted as encrypted data on the document, allowing the medium to be self-authenticating. Therefore, it is possible to determine whether the medium is the same medium for which the encrypted data was originally defined. Further, a digital signature of the document content, which may be code ranging from a checksum of the digital data representing the document content to a complete representation of the document content may be provided on the document. Thus, a digital signature or digital notarization, in known manner, may be employed to authenticate the visible content of the document. Advantageously, the description of the apparently noon-deterministic characteristic of the media and the digital signature representing the document content are combined and encrypted together, so that neither is separable prior to decryption. The encryption preferably comprises a public key-private key algorithm.
Alternately or in addition to self-authentication features, the authentication may comprise a remote database access. In this case, the medium or document is uniquely identified, such as by a serial number. The document identification is then conveyed to the remote database, where the authentication data, including the description of the medium and description of document content is retrieved. According to one embodiment, the document content in the remote database is distinct from information imprinted on the document; since the remote server is presumed to be a trusted source, a direct communication between remote server and requested is considered reliable. In other cases, the remote database includes identical information or document content description information and supplemental information. For authentication, the document identifier may be manually entered by a person or automatically acquired, for example by an optical scanner, MICR reader, or the like.
It is another object of the invention to provide an infrastructure for generating authenticatable original documents, using relatively standard office equipment. In this case, preprocessed media are distributed through standard distribution channels for office supplies. This media is serialized and a description of apparently non-deterministic characteristics is recorded. The medium, which in this case is paper, for example 16–32 lb. stock, has a low contrast, apparently non-deterministic pattern resulting from manufacturing processes, with the recorded description being either a description of a non-deterministic pattern, or a steganographic code hidden in the non-deterministic pattern of the media. The paper is loaded into a printer, with the serial numbers recorded and entered into a software application executing on a print server device, for example a print driver or print spooler associated with the printer. In the case of self-authenticating documents, for each document printed, the software application prints on the document an encrypted code describing the apparently non-deterministic features of the medium as well as a digital signature of the document content. Since this may occur at an operating system level, application programs need not be modified. The encrypted code may be generated in a number of ways. First, the document content and medium identifier may be transmitted to a remote server, for processing into a digital signature, hashed (irreversible process) with the description of the apparently non-deterministic features of the medium, and encrypted, using a public key-private key algorithm. Preferably, the data is compressed. In this case, the information may also be stored at the remote server for remote verification. Second, a description of the apparently non-deterministic features of the medium may be downloaded from a remote server or a local storage medium, such as a CD-ROM, and processed locally to generate the self-authentication signature. In order to provide system security, in this case, the description of the apparently non-deterministic features of the medium are preferably output from a secure encryption processor, for example having a decryption algorithm stored in volatile memory with memory purging in the event of tampering, which receives a document content and medium identifier, and outputs an encrypted hashed digital signature of the document content and description of the apparently non-deterministic features of the medium. This processor may be a server connecting to a computer network, a “dongle” device, or the like.
If the description of the apparently non-deterministic features of the medium is intrinsic to the identification of the medium, such as part of or resulting from the serialization, then it is possible to authenticate the medium and document content separately. Thus, a self-authenticating code may be preprinted on the medium. The document digital signature is processed to include the identification of the medium, for example the serial number. However, this has the potential flaw that if a counterfeiter comes into possession of blank media which he serializes with the desired number, and then applies an apparently authentic self-authentication algorithm, a casual authentication would not reveal the deception. Therefore, the self-authentication algorithm for the medium must be highly secure, i.e., very difficult to forge a self-authentication signature.
Thus, it is an object of the invention to provide print driver software, transmitting an identification of the recording medium and a description of the document content to a remote server upon printing of the document content on the medium.
It is also an object of the invention to provide print driver software, for transmitting an identifier of the recording medium to a remote server, receiving a description of the apparently non-deterministic characteristic from the remote server, and imprinting an encrypted message on the medium comprising a description of the apparently non-deterministic characteristic and the document content or a digital signature thereof.
It is a further object of the invention to provide, for authentication of document, an authentication device having an optical imaging system for automated description of the document, either the document content, the apparently non-deterministic features of the medium, or both. The automation provides two potential advantages; first, human effort is not necessary for describing the features, and second, a definition or identification of the particular features employed in authentication need not be published in human comprehensible form. Optical systems are advantageous because they are well developed, provide high precision, accuracy, and speed, and may be readily shielded from external influences. Of course, other types of authentication devices may be provided, for example magnetic, thermal, electronic or the like. Advantageously, the authentication features require between 600–2800 dpi resolution optical scanning with 10–16 bit dynamic range in one or more broadband or narrowband ranges. Preferably, a standard-type 600 dpi 36 bit color optical scanner is employed for authentication. Of course, as the minimum authentication feature size increases, the ability to foil counterfeiters also typically diminishes. A single optical scanner may be use for both reading the document content and observing the apparently non-deterministic features of the medium presented. Alternately, security dyes having predetermined spectrographic characteristics are employed, which are detected using a spectrographic (narrowband) optical scanner to match a predetermined spectral characteristic with an observed spectral characteristic for authentication. Thus, a single scanner or multiple scanner may be provided.
In a self-authentication embodiment, an authentication device is preferably self-contained, including one or more readers for the document digital signature, document content (if the digital signature is truncated), and medium authentication feature(s), decryption processor, and user interface. Preferably, the authentication device includes an internal accounting system and is tamper proof, to monitor usage of the device and prevent unauthorized analysis of embedded algorithms and security (cryptographic) codes.
Advantageously, the document content is provided in a word-processing file or page description language format, rather than as a bitmap, although either form may be acceptable.
It is also an object of the present invention to provide financial models and accounting systems for self authenticating documents which reflect alternate schemes for recouping investment and compensating a service provider. These include a charge per sheet of authentication medium, a charge per document creation, a charge for database lookup or retrieval, a flat fee for a type of usage, a variable charge depending on an encryption algorithm complexity, a charge for authentication services, a selective charge for authentication failures, e.g., instances of possible counterfeiting, a recurring fee for on-line data storage, and/or a combination or subcombination thereof.
The present invention also means for comparing at least two descriptions of apparently non-deterministic characteristics of the same medium having differing degrees of complexity. Thus, “simple” and “complex” authentication modes are supported. Each of these modes may be separately accounted; thus, the cost for obtaining a decryption key for the simple authentication may be less than the complex decryption.
According to one embodiment of the invention, the apparently non-deterministic characteristic comprises at least one region having a magnetic property. For example, if magnetic toner particles, e.g., ferrite-containing, are included at low density randomly distributed through a laser printer toner cartridge, the resulting print will have a non-deterministic pattern of magnetic particles. It would be quite difficult to selectively place magnetic particles in the exact locations necessary to forge authenticity.
In authenticating a document, it is preferred that the decision of authenticity be made in a probabilistic manner, rather than a concrete manner. Authentication may therefore be provided with a decision, as well as an associated statistical reliability. Further, one embodiment provides an adaptive threshold, based, for example, on the circumstances of presentment, value of the document, noise or interfering factors, required throughput, correlations of sets of authentication features, and/or other factors. Fuzzy logic or neural networks may be employed for authentication.
According to one embodiment of the invention, a transform is applied to a scanned image of the document and a comparison of the stored data and observed characteristics of the document performed in a transformed domain or in a normalized space. The transform is, for example, a rotationally invariant two dimensional transform. The transform may thus normalize for a characteristic selected from the group consisting of rotation, skew, stretch, and fade.
It is a further object of the invention to provide a plaintext decryption key imprinted on a secure document, the document content being stored remotely, further comprising means for transmitting in encrypted form the description of the apparently non-deterministic characteristic and document content, for decryption by the decryption key.
It is another object of the invention to provide a method of authenticating a document, comprising providing a document stock having anti-counterfeit features; preprinting the document with an essentially unique identifier; defining a content for the document having an associated digital signature for verification of the document content and essentially unique identifier; and printing the content and digital signature on the document stock. The method preferably further comprises the step of authenticating the document by verifying that the digital signature corresponds to the document content and essentially unique identifier.
The anticounterfeit features preferably comprise a set of visually distinct fibers in said document stock and/or a lithographed pattern printed on said document stock. The essentially unique identifier preferably comprises a composite of a random portion and a serialized portion.
The method also preferably comprises the step of accounting to a content proprietor for a printing of the document. The accounting step preferably comprises issuing a request for the content and electronic payment information; and receiving content and associated digital signature.
The printing may be through a secure or unsecure communications channel. This security relates to whether the page image or other information received by the printer is transmitted in the clear, or is subjected to cryptographic techniques such that no easily interceptable electronic signal (e.g., through an external cable) defining the printed page exists.
According to another embodiment of the invention, a stochastic characteristic integral with the recording media is analyzed to provide an encryption key necessary for an authentication process. Thus, the non-deterministic characteristic is itself employed to encrypt a message, which is then decrypted using the same key, which is intrinsic to the media, and difficult to copy. This may be a symmetric algorithm or public key-private key algorithm. In this embodiment, the authentication may be self-authentication or involve a trusted party. In the later case, a unique identifier of the document is transmitted to a remote processor, a representation of the document content encrypted using a public key-private key algorithm and information defining an appropriate public key is transmitted to a local cryptographic processor, wherein the local cryptographic processor decrypts the document based on the encrypted document content, public key and private key.
The medium may be subdivided into a plurality of regions, each having its own authentication code. Thus, during initial medium preprocessing and identification, it may be completely analyzed for all regions. However, during authentication, a random subset of the regions may be selected for analysis. Thus, while the authentication process may be substantially simplified, a counterfeiter would be required to reproduce the entire medium, not knowing which region will be randomly selected, in order to avoid substantial risk of detection. The characteristics of each region may be thus defined and encrypted separately.
These and other objects will become apparent. For a fuller understanding of the present invention, reference should now be made to the following detailed description of the preferred embodiments of the invention as illustrated in the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described with respect to the drawings of the Figures, in which like numbers designate like parts, and in which:
FIG. 1 is a top view of a self-authenticating document according to the present invention;
FIG. 2 is a top view of an authenticatable document according to the present invention;
FIG. 3 is a schematic view of a document preprocessing system according to the present invention;
FIG. 4 is a schematic view of a document content printing system according to the present invention;
FIG. 5 is a schematic view of a document authentication system according to the present invention;
FIGS. 6A and 6B are flow diagrams, respectively, of a method of generating and authenticating a document, respectively.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The detailed preferred embodiments of the invention will now be described with respect to the drawings. Like features of the drawings are indicated with the same reference numerals.
EXAMPLE 1
In order to form counterfeit-resistant document stock, fluorescent dichroic fibers may be incorporated into papermaking processes, as fibers within the pulp matrix of a papermaking process. The fiber position and orientation will, in this case, be strictly non-deterministic, and further, copying fiber locations and orientations will be essentially impossible. The degrees of freedom for these fibers include the fiber position, orientation, depth of fiber within fiber matrix, dichroic ratio, color and/or spectrometric characteristics, fiber microenvironment, etc.
The fluorescent dichroic fibers can be used to provide several levels of increasing authentication/counterfeiting-detection. The presence of fibers and their dichroism, the position and orientation of fibers, the depth and environment of fibers, the spectral characteristics of individual fibers, spatial variation of characteristics within a single fiber, etc.
As shown in FIG. 1 , a self-authenticating document is provided having a stock 1 , printed document content 2 , authentication region 3 , and encrypted encoding region 4 .
FIG. 2 differs from FIG. 1 in that the encrypted encoding region 4 of FIG. 1 is replaced or supplemented with a document identifier 5 , which may be a serial number or the like.
FIG. 3 shows a schematic diagram of a document preprocessing system, and FIG. 6A the corresponding method. Raw stock 1 is scanned 101 by scanner 10 to determine a non-deterministic pattern of fibers 6 within the authentication region 3 . This data is then stored 102 , for example in temporary memory 11 under control of a host computer 15 , or in association with an identifier of the stock 1 .
In the case of a self-authenticating document, as shown in FIG. 1 , the data is then hashed with a digital signature of the document content 103 , defined by a page description language file 12 , encrypted, and printed 104 on the face (or obverse) of the document in the encrypted coding region 4 .
Alternately, the scanning operation may be performed prior to stock distribution, with each piece of stock having an imprinted document identifier 5 . The database of document identifiers 5 and scanned images may then be maintained locally to a printer 13 or remotely. If stored remotely, a print driver application may access the file in real time through an Internet 18 or other network access connection. Instead of the scanner 16 , a simple reader 17 may be provided for reading the document identifier 5 , which may be a bar code, MICR imprint, or the like.
FIG. 4 shows a schematic drawings of a document printer according to the present invention. Advantageously, the scanner 16 is provided as a part of a paper tray for a printer 13 , with a universal serial bus (USB) connection 14 to a host computer 15 , or communicating through a printer interface or print server interface. Immediately prior to printing, the fibers within the authentication region 3 are scanned with scanner 16 , and the data transmitted to the host computer 15 . A print driver application executing on the host computer 15 processes the scanned image, with a page description language (PDL) file 12 received for printing on the printer 13 . The print driver application hashes and encrypts the scanned image (or descriptors thereof) with the PDL file 12 or a digital signature thereof, to generate a two-dimensional bar code or glyph for printing within the encrypted encoding region 4 , which is used to generate a modified PDL file. In this case, an authentication code identifying the authorized producer of the document and tracking information, is preferably encoded as well.
In order to authenticate a document, an apparatus as shown in FIG. 5 is provided. This device includes a fiber scanner 20 , having a polarization-sensitive beamsplitter 21 (such as a calcite crystal), illumination source 22 (such as a krypton incandescent lamp), transmit filter 23 (e.g., Ratten high pass for excitation of fluorescence), receive filter 24 (narrowband for passing fluorescence), and a pair of optical imagers 25 , 25 ′ (for respective polarization axes) (1.0″ 1024 pixel CCD line scanner). The device also includes document scanner 26 having a 200–400 dpi monochrome line scanner 27 , much as is found in a standard facsimile machine.
During use, as shown in FIG. 6B , a document to be authenticated is scanned by all three scanners, in a single pass 110 . The fiber scanner 20 acquires an image of the fiber pattern 111 , as well as the 2D bar code or glyphs 112 . The document scanner 26 acquires an image of the document content 113 . A processor 30 then applies a decryption algorithm 115 to the acquired code, and compares the extracted fiber pattern to the observed fiber pattern 116 , and the digital signature of the document content to the observed document content 117 . The comparison is then subjected to a statistical analysis 118 to determine authenticity. Finally, an authentication is output 119 .
The processor 30 may be local to the scanner and self contained, as in a self-authentication embodiment, or distributed or remote in a remote authentication embodiment. The encryption algorithm in a self-authentication embodiment is, for example, a public key-private key algorithm.
EXAMPLE 2
According to a second embodiment, a recording medium stock is provided having at least one anticounterfeit feature, similar to the new U.S. currency ($20, $50, And $100 Federal Reserve Notes). In a later stage of production, a readily ascertainable essentially unique identifier is imprinted on the document. In contrast to currency, this identifier is preferably not a serial number, but rather a composite of a serialized portion and a random portion. By providing a composite, two ends are achieved; the random portion makes determining any valid identifier difficult, while the serial portion ensures that each composite is a unique identification. Together, the identifier has greater length, often an advantage when the identifier is a part of a message encrypted with a long encryption key.
The recording medium may also have imprinted thereon a set of colored dots in unpredictable locations, with the number and location of the dots recorded.
Associated with the imprinting of the identifier, a self-authenticating message is defined, including the identifier, using a public key-private key encryption method. The key pair may be selected on a per document or random basis, per ream (range of recording medium), per pre-identified client (i.e., content owner), or in other manner, and is used to generate a cipher-text message, which is stored in association with the identifier of the recording medium. A message is then recorded on the recorded medium including the document identifier (serial number and randomly-generated password), and optionally, the public key.
The private key is maintained in secrecy at the point of origin, and indeed need not be communicated in any way.
At a later time, a user defines the desired document content and communicates this to the service provider, for example a gift certificate or theatre ticket, as well as the unique identifier of a piece of recording medium which was obtained through, for example, a retail channel. An accounting transaction takes place to account for the value of the content. This accounting is, for example, a three party transaction, with the user paying the service provider, and the service provider accepting a commission and compensating the content owner.
The content is then authorized for imprinting, and a message transmitted to the user from the service provider including an image of the document content, optionally including a copy of the unique identifier, optionally a dot pattern corresponding to the color dots on the recording medium, optionally the public key previously defined for the recording medium, optionally a digital signature for the document content and the unique identifier, and optionally a second randomly generated password. This digital signature and an explicit or implicit identification of the associated public key are required for self-authentication. The optional second password provides high security for on-line authentication.
Thus, a first level of authentication provides that the recording medium appears to be authentic, the preprinted identifier matches the identifier printer with the content, and the color dots are covered. A second level of authentication provides that the cipher-text message, decrypted with the public key, matches the document identifier and the document content corresponds to the digital signature.
A machine-readable glyph pattern or 2-D bar code may be defined as part of the document content image. A document scanner at the point of authentication, for example a 200 dpi scanner (similar to the ITU telefacsimile standard) may be used, and indeed the authentication may be embedded in a facsimile machine. In case the document is consumed at the point of authentication, the original may be truncated, for example by shredding or marking with a “VOID” indication. A record of each authentication is preferably maintained for deferred transmission to the central server, and possible accounting.
There has thus been shown and described novel anticounterfeit documents, and associated apparatus and methods, which fulfill all the objects and advantages sought therefore. Many changes, modifications, variations, combinations, subcombinations and other uses and applications of the subject invention will, however, become apparent to those skilled in the art after considering this specification and the accompanying drawings which disclose the preferred embodiments thereof. All such changes, modifications, variations and other uses and applications which do not depart from the spirit and scope of the invention are deemed to be covered by the invention, which is to be limited only by the claims which follow. | A system and method for authenticating documents and content thereof. A counterfeit resistant document recording medium is provided, having thereon a predefined unique document identifier and at least one security feature. The recording medium is thereafter imprinted with document content, which typically varies between documents. The document content is stored in a database, indexed by an associated document identifier. The document may then be authenticated by checking the security feature and comparing the stored document content with a perceived document content. The system provides a number of opportunities for commercial exploitation, including sales of identified recording media, recording of information in a database, on-line authentication transactions, differential accounting for document validations and counterfeit identifications, imprinting devices, authentication devices, and the like. The system prevents counterfeiting of valuable documents through casual means by providing both physical and logical security. | 6 |
This application is a continuation of application Ser. No. 317,006, filed Feb. 28, 1989, now abandoned.
BACKGROUND OF THE INVENTION
The present invention relates to methods of producing shaped articles formed of composites or laminates. More particularly, the present invention allows the formation of complex or difficult shapes out of fiber/thermoplastic resin composites while controlling the final fiber positioning.
Because of their strength, composites or laminates of fibers and thermoplastic resins are useful in the production of a number of shaped parts. These composites are primarily made of continuous or discontinuous fibers of fiberglass, graphite, carbon, polyaramides such as KEVLAR, polyethylene, or other strengthening fibers bound in a thermoplastic resin. Continuous fiber composites are frequently manufactured in the form of sheets or panels.
Unfortunately, the reinforcing fibers which strengthen the resin and give the composite additional support and structural integrity can cause problems during processing and forming operations, particularly in the manufacturing of parts having complex shapes such as rectangular boxes or spherical surfaces. When such complex shapes are formed using standard molding techniques, e.g., by heating the composite and molding it to the desired shape under pressure, the reinforcing fibers move and slide, causing some portions of the molded piece to have few or no fibers while other sections have too many fibers. This movement of fibers leads to a difference in mechanical properties at various locations in the final product. This variation in quality can lead to rejection of the part, or if the problem is less severe, overdesign of the part.
In order to prevent these problems, some complex shapes have been formed by creating the composite in situ, e.g., laying the fibers into a mold in the final shape and adding heat and pressure to soften and consolidate the thermoplastic components. This procedure is more expensive than conventional procedures and still may not solve the problem of fiber movement and the resulting property differential. Therefore, the search for better ways of forming complex molded products of composites has been continuing.
Accordingly, an object of the invention is to provide a method forming composites or laminates into desired shapes while controlling fiber movement.
A further object of the invention is to provide a method of forming a complex shape from a composite while organizing the fibers of the composite in a predetermined pattern.
Another object of the invention is to provide a method for further strengthening complex shaped articles formed from composites.
These and other objects and features of the invention will be apparent from the following description and the drawing.
SUMMARY OF THE INVENTION
The present invention features a method of making a composite or laminate into a desired, shape, or a variety of predetermined complex shapes, while controlling the placement of the fibers in the laminate during processing. The objects of the invention are achieved by using a special piercing die which allows control of the fibers in the composite during the molding process.
As a two stage process, two molds or dies are provided in the method of the invention: a first shaping die for forming the composite into an approximation of the final desired shape with desired fiber placement, and a second shaping die in the form of the final shape which is used to complete the molding process. The first shaping die has piercing studs or pins at preselected locations and is thus called a piercing die. These studs or pins may be somewhat flexible, or have a complex shape in order to better penetrate the composite. The composite sheet, which is formed of a thermoplastic resin with fibers therethrough, is normally heated to a temperature above the melting point of the thermoplastic resin and the composite is formed into an approximation of the final shape in the first shaping die. The composite may be heated outside the die or the die itself may be heated to a sufficiently high temperature that during processing, the composite reaches the desired temperature. In this first or rough forming step, the piercing studs in the first shaping die are allowed to at least partially pierce the laminate at predetermined locations so that they push the fibers aside rather than breaking them. These studs lock the fibers at particular locations, thereby controlling fiber movement, and keeping the fibers from moving from areas of high tension to low tension. The resultant fiber control, which ensures that the composite retains the predetermined pattern of the fibers, is accomplished by the positioning, and size of, the studs. The studs may or may not be coated with a release or other agent before the molding process.
After the composite is made into an approximation of the final shape in the first shaping die, it is then ready for further processing. In one embodiment, the workpiece is allowed to partially cool in the first shaping die until it attains sufficient structural integrity then it is removed and placed on a second shaping die. The work piece is then heated and molded on the second shaping die into the final shape. The second shaping die, which forms the composite into the shape of the final workpiece, is normally a second die; however, in one of the preferred embodiments of the invention, the second shaping die may be the same as the first shaping die. This is accomplished by having retractable piercing studs in one portion of the die. As the rough forming step forms the approximate shape, the studs retract, forming a smooth die to complete final processing, and allowing the holes formed in the rough forming step to be healed.
In another embodiment of the invention, through the thickness or transverse reinforcing materials, e.g., fibers can be inserted into the composite after the rough forming step for additional strengthening. To accomplish this, the holes formed by the piercing studs in the composite can be filled with fibers or other reinforcing materials, which may or may not be the same material as the fibers in the laminate, in a direction roughly perpendicular to the laminate surface. In some cases, the studs themselves could release from the die and become the reinforcing medium or inserts. These inserts strengthen the laminate by acting as a third dimensional barrier to failure. If transverse reinforcing fibers or inserts are not used, the holes formed by the piercing studs in the rough forming step are then filled in by resin and fibers during the final forming step.
The edges of the composite may or may not be clamped during either step but clamping during the first, rough forming step can provide sufficient tension on the composite during the piercing and rough forming to prevent fiber wrinkling and buckling. This is particularly useful for composites which have discontinuous fibers; however, clamping which allows some slipping may still be helpful even if continuous fibers are used.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded perspective illustration of a first shaping die useful in the invention showing the piecing studs and an unshaped composite sheet;
FIG. 2 is a perspective illustration of a composite workpiece in place on the studded portion of the first shaping die of FIG. 1, with the piecing studs and the fibers visible; and
FIG. 3 is an exploded perspective illustration of a second shaping die and a finished composite article.
DETAILED DESCRIPTION OF THE INVENTION
The method of the present invention allows the formation of complex shapes from laminates or composites with controlled fiber placement. This process can easily produce shapes which were previously exceptionally difficult to manufacture, e.g., hemispheres or box shapes. By controlling the fiber location in the processing, the final product is stronger and more durable than those previously known.
FIG. 1 illustrates a first shaping or piercing die 10 useful in the invention. The piercing or male portion 12 of the die 10 has a series of piercing studs 20 located in a predetermined pattern. These studs, which may have any length but preferably are longer than the thickness of the composite or laminate sheet 30, are forced onto laminated sheet 30, piercing laminate 30 and forcing reinforcing fibers 35 apart. Fibers 35 are controlled in their movement by the location of piercing studs 20 so that by selection of the proper pattern of piercing studs 20, the pattern of fibers 35 in the finished product can be predetermined.
In operation, the clamped or unclamped composite or laminated sheet 30 may be clamped on female portion 14 of piercing die 10 and male portion 12, carrying piercing studs 20, is forced onto laminate 30 and female portion 14. The positions of the parts of piercing die 10 can be reversed. Laminate 30 may be preheated up to or above the melting temperature of the thermoplastic resin therein, or piercing die 10 may be heated to a sufficiently high temperature that laminate 30 softens in the die.
As the die is closed, piercing studs 20 penetrate laminate 30, pushing aside rather than breaking fibers 35. The location of piercing studs 20 are set to control the movement of fibers 35. Once die 10 is closed, laminate 30 has achieved the approximate shape of the final workpiece. Die 10 and workpiece 30 may be allowed to cool somewhat in the closed position until laminate 3 has sufficient structural integrity for removal.
After laminate 30 has cooled, die 10 is opened. FIG. 2 shows laminate 30 on piercing portion 12 after opening. Piecing studs 20 are visible through laminate 30 and fibers 35 are shown as being pushed aside. The fibers 35 may be discontinuous or continuous fibers. Normally, laminate 30 is removed from die 10 and placed in a second die, a matched metal consolidation die, such as is shown in FIG. 3 as part 100. This die has the shape of the final part and is used for molding the composite into the final shape. As is evident, this shape is similar, but not necessarily identical, to the shape of piercing die 10. In fact, in a preferred embodiment of the invention, the female portion 114 of consolidation die 100 is the same as female portion 14 of piercing die 10. This allows the initial molding to be carried out on piercing die 10, followed by the retraction of piercing portion 12 with the retention of laminate 30 on female portion 14. Processing is continuous with male portion 112 mating with female portion 14. Using this procedure, laminate 30 need not be removed from the supporting die during processing.
The final shape of laminate 30 is made by heating and molding laminate 30 in consolidation die 100. As described previously, consolidation die 100 could be heated, transferring the heat to laminate 30. In most embodiments, the heating and molding under pressure of laminate 30 in consolidation die 100 not only retains the pattern of fibers 35 since there is low stress and tension on the workpiece since major shaping is carried out in the first step, but the thermoplastic resin and fibers are then allowed to flow sufficiently to fill in, or "heal" the holes formed by piercing studs 20.
Two other embodiments of the invention, which constitute minor modifications of the procedure just described, are also important. The first of these modifications is the use of the same piercing die 10 to perform both the rough forming step and the final forming. This can be accomplished by having the piercing studs 20 on male portion 12 be retractable. In operation, the piercing, rough forming step takes place using the same procedure as previously described. After the rough forming step, piercing studs 20 are retracted into male portion 12, yielding a smooth surface. Composite 30 would be continuously pressed by die 10, forming the final shape. In this process, an intermediate cooling step is not required. Since piercing studs 20 are retracted, the holes formed by piercing studs 20 will fill-in and the final form of composite 30 is achieved.
The second variation of the invention is to fill the holes formed by piecing studs 20 with transverse fibers or other reinforcing materials before final processing. These transverse inserts strengthen composite 30. One preferred method is to use piecing studs 20 not just as piercing studs but also as fiber pulling or material injecting components or as the reinforcements themselves. In another embodiment, piercing studs 20 are released from male portion 12 and become inserts in the final composite product. As final processing takes place, the flow of the thermoplastic resin locks the inserts in place, forming a much stronger shaped composite.
The method of the invention may be used with any composite or laminate, woven or unwoven. Although substantially any thermoplastic resin can be used in the invention, resins such as polyacrylates, polyesterimides, polyether ether ketone, polyethylene sulfide, nylon, polycarbonate, polyethylene, polypropylene, acrylonitrile butadiene styrene copolymer, polymethyl methacrylate, and polyamideimide are preferred. In like manner, almost any type of structural supporting fiber which keeps its own structure at temperature above the melting point of the thermoplastic resin can be used. The fibrous material useful in the invention includes fiber glass, carbon, graphite, boron and KEVLAR.
Those skilled in the art may determine variations on the materials and methods described herein. Such other variations are included within the following claims. | A new method of forming composites or laminates into complex shapes has been developed. A process using a die with piercing studs allows control of fibers motion during processing, leading to better composite parts. | 1 |
This application is a continuation of U.S. patent application Ser. No. 08/997,176 filed Dec. 23, 1997 U.S. Pat. No. 6,144,695.
I. BACKGROUND OF THE INVENTION
1. Technical Field
This invention relates to the field of providing high speed digital data services to a digital service subscriber and, more particularly, to so-called asymmetric digital subscriber line (ADSL) services and to a method of reducing near-end crosstalk in discrete multi-tone (DMT) modems located at a central office and at the subscriber's premises for providing ADSL services.
2. Description of the Related Arts
In the field of cable television, cable modem technology is emerging which provides increased bandwidth services to the home. Cable television equipment manufacturers are promoting the upgrading of cable television distribution plant to comprise so-called hybrid optical fiber and coaxial cable (hybrid fiber/coax) facilities. It is anticipated in the cable field that bandwidths to and from the subscriber can be increased so that bidirectional voice and data services may be provided in addition to traditional cable television programming. In the related field of telecommunications, there exists a considerable amount of embedded distribution plant comprising high capacity twisted wire pair cable. Historically, each cable pair was specially loaded with inductance coils at periodic intervals along the path from a serving central office to the subscriber's premises to improve voice telephony performance. The inductance loading countered the effects of the high capacity cable and provided a flat bandwidth on each twisted cable pair at voice frequencies. On the other hand, frequencies higher than voice bandwidth were intentionally attenuated to such a degree that the twisted wire cable pair was unusable for other than a voice channel. When the loading is removed, the twisted cable pair bandwidth improves and becomes more comparable to that of coaxial cable.
An emerging technology in the telecommunications arts that competes with cable modem technology is so-called asymmetric digital subscriber line (ADSL) technology. Referring to FIG. 1 taken from American National Standards Institute standards document T1.413-1995, there is shown a public switched telecommunication network (PSTN) 105 and a digital network (for example, a frame relay, asynchronous transfer mode (ATM), Internet or other digital network) 110 at the left. At the right is the subscriber's premises. The digital network 110 is coupled via a logical interface V to an ADSL transceiver unit (ATU) at the serving central office (C). Also at a serving central office are located a splitter 120 for splitting the telecommunications services from the digital services, typically based on frequency. For example, a voice channel may still be preserved at from 0-4000 Hz. The splitter function may be integrated into ATU-C 115 (and at the remote subscriber site, into ATU-R 135 ). Interface U-C represents the subscriber loop (twisted pair) interface at the central office C and interface U-R represents the subscriber loop interface at the remote subscriber terminal end of the twisted wire cable pair or other facility 125 . Facility 125 may comprise, for example, a twisted wire pair or a hybrid optical fiber/twisted wire pair facility or other wired or wireless facility having comparable or greater bandwidth. Service module (SM) 150 or 155 at the remote location may comprise an intelligent telecommunications terminal, a personal computer, a television terminal, an energy management system, a security system or other service module known in the art. Plain old telephone service is (POTS) module 145 represents a traditional telecommunications terminal such as a facsimile terminal, voice bandwidth modem or standard telephone. Facility Cl distribution 140 within the subscriber premises may comprise, for example, a bus such as a home bus or a star network or other configuration. By bus as used herein is intended a communications link that may be wired or wireless connecting a plurality of devices together. The bus may be arranged so that there is contention for access to the bus according to priorities or be provided sufficient capacity to alleviate the likelihood of contention. Interface T represents the interface between a service module (SM) and/or a bus/star 140 to other service modules (SM's).
Referring to FIGS. 2A and 2B, there are shown respectively an ATU-C transmitter whose reference diagram is taken from A.N.S.I. T1.413-1995 and an ATU-C receiver whose reference diagram is derived therefrom. In FIG. 2A, there is shown an expanded functional block diagram of the transmitter portion of ATU-C 115 of FIG. 1. A multiplexer/sync control unit 200 provides the interface to the digital network 110 . Various high speed data rate links AS 0 , AS 1 , AS 2 and AS 3 at multiples of 1.536 Mbits/sec are provided toward digital network 110 . In particular, each AS link represents an independent downstream simplex (unidirectional downstream) bearer of data traffic. Lower speed data services are also shown and represented by LSO (16 or 64 kbits/sec), LS 1 (160 kbits/sec) and LS 2 (384 or 576 kbits/sec). Each LS link may represent a duplex bearer (bidirectional) carrying both downstream and upstream traffic or, in the alternative, a unidirectional simplex bearer.
CRC 205 and CRC 210 represent cyclic redundancy check in each direction of transmission. Scrambler and forward error correction 215 , 220 represent scrambling and forward error correction, for example, using Reed-Solomon error correction coding, in each direction of transmission. Interleaver 225 provides a data interleaving function as is further described in A.N.S.I. T1.413-1995, incorporated by reference as necessary. Tone ordering function 230 provides tone selection and control functions as are also described by A.N.S.I. T1.413-1995. Constellation encoder (if used) and gain scaling functions are represented by block 235 . The inverse discrete Fourier transform function applied for data modulation is represented by block 240 . Two data directions are shown coupling IDFT 240 and output parallel to serial buffer 245 where a cyclic prefix is added to each data frame. Finally, a digital to analog converter and analog signal processing function are represented by block 250 which interfaces the subscriber facility 125 .
Referring to FIG. 2B, the ADSL receiver at the central office is shown. The horizontal arrows are reversed in direction from FIG. 2 A. Data demultiplexer 255 interfaces the digital network 110 . Descrambler 265 , 258 , deinterleaver 270 , decoder 280 , DFT 285 , input serial to parallel buffer 290 and analog to digital converter 295 represent the significant changes in function between ATU-C transmitter and receiver.
Referring to FIG. 3, at a subscriber terminal, the transmitter (ATU-R) is similarly configured as ATU-C but it is assumed that channels operate at LS 0 , LS 1 or LS 2 toward the subscriber's equipment. Cyclic redundancy checks 305 / 310 are provided for each direction of transmission to/from subscriber equipment 375 . Scrambler and forward error correction circuits 315 and 320 , for example, using Reed-Solomon error correction coding, are provided for especially secure data transmission. An interleaver 325 is provided in one transmit path. Tone ordering circuitry 330 is necessary for generating and ordering the discrete multi tones of the discret multi-tone (DMT) modem. The constellation encoder and gain scaler 335 may or may not provide a form of trellis data encoding and gain scaling for controlling the tone ordering. IDFT block 340 performs an inverse discrete Fourier transform for modulating the digital data. The output parallel to serial buffer 345 is provided for providing parallel to serial conversion to a digital to analog converter and analog signal processing interface 250 which interfaces the subscriber loop 125 .
The analog signal framing (FIG. 4) used in ADSL technology is obtained by passing quadrature amplitude modulation (QAM) samples through a D/A converter 250 or 350 . These samples are arranged in a superframe of 69 frames (frames 0-68) totaling approximately 17 milliseconds. Altogether 512 samples (256 real and 256 imaginary, 0-511) are taken of the data. An additional 32 samples contain a cyclic prefix, making a total of 544 samples in each frame. The cyclic prefix CP 401 is added, for example, to signal 402 of frame 0 (FIG. 4) at the output parallel/serial buffer 245 and 345 shown in FIGS. 2A and 3 respectively.
Every 69th frame contains a pseudo-random number (PRN) sequence with a nominal length of 544 samples. This PRN sequence (the so-called synch symbol) permits recovery of the frame boundary after interruptions.
The sub-carrier tones are spaced at 4.3125 kHz according to the ANSI Standard T1.413-1995 and at carrier 64 where the frequency is 276 kHz, a pilot carrier is inserted. The data modulated on that pilot is a constant bit value (for example, 0,0). Other details of frame construction, data modulation, tone ordering and the like may be found in the Standard and are not believed to be particularly relevant to the principles of the present invention.
Near-end crosstalk, hereinafter referred to as NEXT, is a potentially severe problem for operating multiple Digital Subscriber Line (DSL) modems over twisted-pair wires between a Central Office (CO) and a subscriber's location. NEXT occurs when the transmissions from one or more modems, particularly those at the central office, capacitively couple into each other's twisted-wire pairs and impair the ability of those modems to receive transmissions from the other end of the tvisted-wire pairs. Moreover, with severe NEXT, a subscriber modem cannot receive transmissions from its transmitting central office modem. This problem is most severe when a modem operates in full-duplex mode in which transmission is simultaneously bi-directional at all frequencies.
Cables that serve subscribers and terminate at a central office can comprise thousands of twisted wire pairs that are bundled together in a limited cross-sectional (typically circular) area. Electrical signals traveling on the twisted pairs can easily electrically couple into physically proximate twisted pairs, consequently, near end crosstalk has a detrimental effect on bit error rate. Since the concept behind ADSL technology is to optimize bandwidth use, the phenomenon of near end cross-talk limits any one of three factors: the distance a subscriber can be from the central office, the digital data rate of service and the bit error rate of any digital data service. As the number of subscribers increase to ADSL technology, the likelihood will increase that an ADSL subscriber will be served by a twisted wire cable pair proximate to that of another subscriber and that frequencies from one twisted wire cable pair will adversely impact the signal to noise ratio of digital signals on an adjacent or proximate cable pair. Consequently, there is a need in the art to alleviate the effects of NEXT.
One way to reduce NEXT might be to assign cable pairs to subscribers in such a way that subscribers to ADSL services are not in the same bundles as other subscribers. Of course, at some point in time, as subscribers to ADSL increase, so does the likelihood that cable pair assignment in such a manner cannot be accomplished. Thus, there is a need in the art for reducing NEXT in ADSL services.
SUMMARY OF THE INVENTION
The present invention offers the possibility of substantially improving one or more of the following parameters: distance of the subscriber from the central office, data rate, and error rate. For example, the distance of the subscriber from the central office may be increased while the data rate and error rate are held constant. According to the principles of the present invention, the framing suggested by ANSI T1.413-1995 is modified and frame alignment is recommended for all frames transmitted by the central office. Also, all frames transmitted by subscriber modems should be aligned to coincide with received frames. An echo canceler may be applied to cancel near end echo as will be further discussed herein. Interspersing transmit frequencies (individual frequencies or bands) between central office and subscriber modems may further reduce the effects of near end crosstalk.
In particular, in accordance with the present invention, the length of the cyclic prefix prepended to each frame of a DMT frame should be increased to a value that is at least the length of the sum of 1) the maximum round trip delay from a central office to a subscriber and 2) the delay required to prevent intersymbol interference or ISI (according to the ANSI standard, 32 samples or 14.5 microseconds to prevent ISI). For example, if the sampling rate is maintained at approximately 2.2 megaHertz and if the maximum round-trip delay is approximately 80 microseconds for an 18,000 foot twisted-wire pair loop, one might increase the cyclic prefix to about 184 samples from the recommended 32 samples or the equivalent of 81.3 microseconds of signal duration or even higher depending on concerns about ISI.
Also, it is advantageous to increase the length of the frame proportionately to the increase in the cyclic prefix. For example, if the cyclic prefix is lengthened from 14.5 microseconds to 81.3 microseconds, then the frame should be lengthened from 250 microseconds to approximately 1 millisecond. If the same sampling rate is maintained (at around 2.2 megaHertz), then other parameters will change accordingly. If the frame length is increased to 1 millisecond, the number of sample points of the IDFT should increase from 512 to, for example, 2048, the carrier spacing should decrease, for example, from 4.1325 kHz to 1.089998 kHz and the DMT's sampling rate should increase slightly from 2208 kHz to 2263 kHz. These numbers are representative only, and other practitioners of the art may deviate depending on the application.
It is a further principle of the present invention to align frames transmitted from the central office toward the subscriber. All frames transmitted by all central office modems are aligned and synchronized to begin at the same time as they are transmitted toward subscribers. That is, all frames transmitted by all central office modems to all subscribers (especially served on the same cable of twisted wire pairs) start and end at the same times. One way to accomplish the alignment is to provide a common shared timing signal to all CO modems from a common source. For example, the signal may comprise a train of narrow, for example, 1 microsecond pulses spaced by the period of a frame (for example, one millisecond). Each central office modem then would align its frames that are transmitted toward respective subscribers over different twisted wire cable pairs with this pulse train.
The pulse train from the common source may be accompanied by a higher frequency signal (for example, a sinusoid or a pulse train at the frequency specified in Section 6.9 of ANSI T1.413-1995) to which each modem could be synchronized. Alternatively, the pilot tone of 276 kHz specified at Section 6.9.1.2 might be applied as the shared resource. Either alternative will save the costs of providing an oscillator within each central office modem.
Now, it is a further principle of the present invention that all frames transmitted by the subscriber's modem toward the central office modem be aligned with the frames that it receives from the central office. Its transmitted frames should coincide with frames it receives from the central office as may be seen from the FIGS. 6 a and 6 c.
With the frames aligned as described and per FIG. 6 and with the lengthened cyclic prefix (for example, 184 samples long), each central office modem samples its received frame wholly within the frame 1) received from its subscriber's modem and 2) transmitted by all other subscriber's modems as in FIG. 5 which shows that each central office modem samples its received frame wholly within the frames transmitted by all other subscribers' modems.
Referring again to FIG. 5, there is shown the frames that a central office modem would receive if the principles of the present invention were followed for two extremes of round-trip delay. When the subscriber is almost adjacent to the central office, the leading edge of the subscriber frame is received 184 samples before the leading edge of the central office sampling. The leading edge of the distant subscriber's frame coincides with the leading edge of the CO's sampling. For these and any delays between these extremes, the CO modem receiver takes its samples entirely within both the frame received from all subscribers' modems and the frames transmitted by all modems at the central office. Thus, a frame transmitted at one carrier frequency is guaranteed to not interfere with a frame received at another carrier frequency. Taking samples from inside the frame preserves the orthogonality of the sinusoids in the discrete Fourier transform (DFT), since the modem's DFT modulator operates on an integral number of periods of each carrier frequency. NEXT is reduced if not eliminated via this orthogonality requirement.
Finally, it is a further principle of the present invention that the central office and subscriber modems' transmit frequencies may be interspersed. For example, one or more bands of frequencies toward the subscriber from the central office may be interspersed with a band of frequencies in the return direction from the subscriber modem to the central office. At the extreme, all odd multipled carriers may be used in the downstream path from the central office and even multipled carriers be used in the upstream path (or vice versa). That is, for example, odd multiples of 1.089998 kHz may be used in the downstream and even multiples in the upstream path exclusive of any band reserved for POTS telephony. This even-odd distribution of upstream and downstream frequencies offers the advantage of degrading nearly symmetrically as distance from the central office and/or NEXT interference increase.
Referring again to FIG. 6, it may be seen that similar benefits are obtained at a subscriber modem. A subscriber's modem will sample only inside the frames transmitted by itself and by other subscriber modems of the same type. Again, sampling inside the frames preserves the orthogonality of sinusoids at adjacent frequencies.
Further advantages and features of the present invention will be understood from studying the accompanying drawings and from reading the following detailed description thereof
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a system reference model showing the primary components of an asymmetric digital subscriber line metallic interface between a subscriber and a central office and between the central office and a digital or public switched telecommunications network.
FIG. 2A is a functional block diagram of an ADSL transmitter unit located at a central office and FIG. 2B is a functional block diagram of an ADSL receiver unit located at a central office.
FIG. 3 is functional block diagram of an ADSL transmitter unit located at a remote subscriber premises location.
FIG. 4 is a diagram of a proposed frame/superframe structure for an ADSL modem and the components thereof such as frame length, cyclic prefix and synch symbol that may be modified according to the present invention to prevent near end crosstalk.
FIG. 5 is shows the result of frame lengthening and alignment principles of the present invention as applied at a central office modem.
FIG. 6 shows the result of the frame lengthening and alignment principles of the present invention as applied at a subscriber modem.
FIG. 7 shows an example of a frequency interspersing step of the present invention as applied to splitting the frequency bands of upstream and downstream transmission.
FIG. 8 shows an example of the frequency interspersing step of the present invention as applied to utilizing every other carrier frequency for upstream or downstream transmission.
DETAILED DESCRIPTION OF THE INVENTION
The basis for central office or subscriber modem design according to the present invention is the Discrete Multitone (D)MT) modem standardized in ANSI Standard T1.413-1995 for an Asymmetric Digital Subscriber Line (ADSL). The terms used herein conform to their usage in the T1.413-1995 standard document. Frame and superframe are defined by Sect. 6.2.1.1; pilot frequency is defined in Sect. 6.9.1.2; the inverse discrete Fourier Transform (IDFT) is defined by Sect. 6.9.2; the synch symbol is shown in FIG. 3 and is defined by Sect. 6.9.3; and cyclic prefix is defined by Sect. 6.10. This invention makes the following changes to the Standard:
Aligning the Frames Transmitted by the Central Office (CO) Modems
The frames transmitted by all central office (CO) modems (for example, that portion of ATU-C 115 of FIG. 1 and FIG. 2 facing the subscriber loop 125 ) according to the present invention are aligned at the central Office; that is, the frames transmitted by all CO modems start and end at the same times. To achieve this alignment, the CO modems may share a common timing signal. This signal may consist of a train of narrow (for example, 1 μsec.) pulses spaced by the period of the frame. Each CO modem would align its frames with this pulse train. This pulse train could be accompanied by a higher-frequency signal (for example, a sinusoid or a pulse train) to which each modem may be synchronized. For example, a pulse train at the sampling frequency specified in Section 6.9.3 for the synch symbol of the ANSI standard might be shared among the CO modems covered by this invention. Alternatively, a sinusoid at the pilot frequency specified in Section 6.9.1.2 of the ANSI standard might be shared. Either alternative would save costs by removing the need for each CO modem to contain its own oscillator or other means for producing a synchronization signal.
Aligning the Transmitted and Received Frames at the Subscribers' Modems
The subscribers' modem (for example, ATU-R 135 of FIG. 1) disclosed in the present invention is designed to align the frames that it transmits (per ATU-R transmitter of FIG. 3) with the frames that it receives, so that its transmitted frame coincides with its received frame. This is illustrated by the 2 nd arrow from the bottom c) in FIG. 6 . The reason for this alignment will be explained subsequently herein.
Lengthening the Cyclic Prefix and the Frame
To implement the changes in alignment at the central office and at the subscriber, the lengths of both the DMT frame and the cyclic prefix contained within the frame are increased from the values specified in the ANSI standard according to the principles of the present invention. The cyclic prefix should be made at least as long as the sum of 1) the maximum round-trip delay from the central office to a subscriber that is the farthest away from the central office (e.g., approximately 80 μsec. for an 18,000 foot twisted-wire cable pair) and 2) the delay required to prevent intersymbol interference (ISI). This delay, for example, is approximately 14.5 microseconds assuming a 32 sample cyclic prefix. Since the ISI prevention delay is much smaller than the maximum round trip delay, the ISI prevention delay may be considered to be immaterial; nevertheless ISI is of concern and should be considered. Although the cyclic prefix could be increased without lengthening the frame, it is advantageous to increase the frame length proportionately to maintain the fraction of time during which data is sent. Other modifications become proportionately useful, for example, decreasing the spacing between carrier frequencies of either the central office or subscriber DMT modem. The modified cyclic prefix is preferably inserted via the output parallel to serial buffers 245 and 345 of the CO and subscriber modems.
Interspersing the CO and Subscribers' Modems' Transmit Frequencies
Optionally, the frequencies used by the central office and subscriber modems can be interspersed—either individually or in groups—to virtually eliminate near end crosstalk (NEXT), provided that the frames are aligned as described above. Referring to FIG. 7, a band of frequencies may be reserved for downstream transmission and a complimentary band of all remaining frequencies may be used for upstream transmission. Referring to FIG. 8, alternatively, all of the central office modems might transmit on the even values of the frequency index, while all of the subscribers' modems might transmit on the odd frequency-indices (or vice versa) where the central office transmit on even is shown in FIG. 8 ( b ) and the subscriber trasnmit on odd is shown in FIG. 8 ( a ). If the carrier frequency separation is 1.0898 kilohertz then odd multiples plus a reserved band x may be used, for example, for upstream transmission and even multiples for downstream, where f is the frequency separation and x the reserved band. Although either of these interspersing approaches would halve the number of carrier frequencies available to each direction of transmission, it would virtually prevent NEXT between all modems utilizing this invention without requiring the use of band-separating filters or echo cancellers. Besides saving costs, interspersing could utilize bandwidth symmetrically and consistently. For example, each direction of transmission could use a constant fraction (such as 50%) of the available bandwidth.
Example of Selecting the Parameters of a Modem According to the Present Invention
If the sampling rate (2.2 megaHertz) is maintained approximately the same as in the ANSI standard, the ANSI standard s parameters may be modified as follows: 1)Increase the DMT frame length from 250 sec. to 1 msec.; 2)Increase the number of points in the DMT's Discrete Fourier Transform (DFT) from 512 to 2048; 3)Increase the number of samples in the DMT's cyclic prefix from 32 to 184; 4)Decrease the DMT's carrier-frequency separation from 4.13125 kHz. to 1.0898 kHz.; and 5) Increase the DMT's sampling rate from 2208 kHz. to 2263 kHz. For simplicity, the example shown in FIGS. 5 and 6 do not show the additional 32 samples for preventing ISI in cyclic prefix (or an increase to 216 samples). Also with the increase in sampling rate, instead of the 69th frame being dedicated to a synch symbol, the 73rd frame may contain frame synchronization information.
With a sampling rate of 2263 KHz., a cyclic prefix of 184 samples is equivalent to a delay of 81.3 μsec., which exceeds the longest anticipated round-trip delay (80 μsec) over the twisted-wire pair. It does not account for intersymbol interference (ISI) prevention delay and, to do so, the cyclic prefix should be 216 samples. Also, the above-suggested 1 msec. frame-length (2 msec. for the transmitter/receiver pair) is not likely to be harmful for telephony applications because it is much less than the 10 msec. delay at which quality impairment becomes noticeable in a telephone call. An additional small delay may be introduced by the convolutional codec and/or interleaver shown in FIGS. 2A and 3.
Benefit of Making the Cyclic Prefix Longer than the Maximum Round-trip Delay
In the above example, the DMT receiver in the central office (CO) takes a number of samples (e.g., 2048) inside each received frame, which in this example contains 2232 (=2048+184 samples), as illustrated in FIG. 5 .
FIG. 5 shows the frames that a central office modem receives from two subscribers at two extremes of round-trip delay. At one extreme the subscriber is almost adjacent to the central office, so that the leading edge of the subscriber's frame is received 184 samples before the leading edge of the CO modem's sampling, and the subscriber is far distant (for example, 18,000 feet) from the central office, so that the leading edge of the subscriber's frame coincides with the leading edge of the CO modem's sampling. These frames are drawn under the assumption that the leading edges of the subscribers' modems' transmitted frames are aligned with the leading edges of the subscribers' modems' received frames, as described previously.
For all delays between these extremes, FIG. 5 shows that the receiver (FIG. 2B) in the CO's modem takes its samples entirely within both the frame received from its subscriber's modem and the frames transmitted by all modems at the central office.
Making the receiver in the modem at the central office to sample entirely within the frame received from the subscribers' modem guarantees that a frame transmitted at one carrier frequency will not interfere with a frame received at another carrier frequency. This prevention of cross-frequency interference occurs because taking samples from inside the frame preserves the orthogonality of the sinusoids in the DFT, since the modem's DFT operates on an integral number of periods of each carrier frequency. This assumes that distortion and frequency misalignment are small and there is minimal intermodulation, harmonic distortion or sidelobe leakage. This orthogonality is a consequence of the DFT, which can be written as ∑ k = 0 N - 1 exp ( - 2 π jk m - n N ) ,
wherein m, n, and N are integers, and where a carrier frequency denoted by m is a potential source of NEXT at a carrier frequency denoted by n, where j={square root over (1)}. The DFT sums to N when m=n , and it sums to 0 when m≠n , showing that two sinusoids at different carrier frequencies are orthogonal to each other. Sidelobes may occur if m is not an integer or when the mth carrier frequency is mistuned but is prevented by synchronizing all central office modem oscillators to a common sinusoid.
Benefit When an Echo-Canceler Is Used
The reduction in NEXT which this orthogonality produces is important for a DSL modem which includes an echo canceler that permits all frequencies to be used simultaneously in both directions of transmission. Although this invention does not prevent NEXT between modems when the transmit and receive carrier frequencies are identical, it does prevent NEXT between the much more numerous N(N−1)/2 pairs of N different carrier frequencies. Broadcasting on an adjacent frequency is not heard on the receive freqency at the central office.
Although no reduction in the total amount of NEXT power occurs if all of the modem's carrier frequencies are transmitted at the same power level, it does prevent a strong signal at any given carrier frequency from contributing an excessive amount of NEXT power to a nearby carrier frequency.
Benefit if the Central Office and Subscriber Modems' Transmit Frequencies are Interleaved
NEXT is prevented almost entirely if the central office and subscriber modems operate with interspersed transmit frequencies, as described above. The orthogonality described above prevents the signal transmitted by a CO modem from interfering with the signal which that modem receives from the subscriber's modem. Consequently, NEXT is virtually eliminated between modems utilizing this invention.
Similar Benefits for Subscribers' Modems
The above benefits for CO modems also apply to the subscribers' modems. This can be seen from FIG. 6, which demonstrates that a subscriber's modem will sample only inside the frames transmitted by itself and by other subscribers' modems of the same type. As was true for the CO modems, sampling inside the frames preserves the orthogonality of sinusoids at adjacent frequencies. As before, this orthogonality reduces NEXT by preventing a frame transmitted by a subscriber modem at one carrier frequency from interfering with a frame received by another subscriber modem at a different carrier frequency.
Reduction of Leakage-Excited Crosstalk (LEXU) in both the CO's and the Subscribers' Modems
To the extent that an echo canceler fails to prevent a fraction of the modem's transmissions from appearing at the input to its analog-to-digital (A/D) converter, interference occurs that we term Leakage-Excited Cross-Talk (LEXT). This invention reduces LEXT for the same reasons that it reduces NEXT, i.e. because the modem samples the received signal during the interval in which that modem is transmitting a frame (as illustrated in FIGS. 5 and 6 ), thereby producing orthogonality. The orthogonality prevents transmissions at any given frequency from interfering with reception at any other frequency.
Thus, there has been shown and described a method and apparatus for reducing near end crosstalk and leakage-excited crosstalk caused by one central office discrete multi-tone modem's interfering with the transmission of a signal by another modem, for example, using proximate twisted wire cable pairs in the same cable. The ANSI T1.413-1995 standard referenced herein should be incorporated by reference as to any subject matter deemed material to an understanding of the present invention whose scope should only be deemed to be limited by the claims which follow. | Near-end crosstalk between identical discrete multi-tone modems is reduced by aligning the frames of all modems at a central office to each other, aligning the frames transmitted by subscribers' modems with the frames received by those modems, and including a cyclic prefix between the central office and the most distant subscriber to be served. By making adjacent DMT carrier frequencies be orthogonal to each other, the aforementioned modifications will reduce both Near End Cross-Talk and Leakage-Excited Cross-Talk. These benefits apply to modems at both the central office and subscriber ends of the communication path. | 7 |
TECHNICAL FIELD
[0001] The present invention relates, in general, to examining body parts and, in particular, to an apparatus and method by which the mechanical stiffness of body tissue being investigated is determined from ultrasonic transmissions to and reflections from the body tissue.
BACKGROUND OF THE INVENTION
[0002] At the present time, ultrasonic imaging is the second largest medical imaging modality after X-ray imaging. In ultrasonic imaging, images are formed by transmitting high frequency acoustic waves into the body and then appropriately mapping the response of returning echoes as the original acoustic signal propagates into the body. An acoustic echo is generated at each interface within the body, which is characterized by an impedance discontinuity. Typically, an image is obtained by mapping the intensity of the returning echo signals as a function of range and direction of propagation. Movement of the ultrasonic waves within a plane allows one to analyze sequentially tissue responses from a large number of directions. Images developed in this manner are known as B-mode images (i.e., “body” mode images).
[0003] Other ultrasonic imaging techniques are in practice at the present time. Color Doppler mode is one such other technique. Color Doppler mode is a methodology in which the mean Doppler frequency shift imposed upon the returning acoustic echoes by moving target structures, such as the blood, is measured and mapped. The mean Doppler shift is determined by measuring the mean phase rotation or time delay between successive acoustic pulses in a series of pulses known as a packet. Likewise, Power Doppler is a mode in which the intensity of the Doppler signal, rather than the mean frequency shift, is mapped to form an image.
[0004] Recently, an imaging mode, known as harmonic imaging, has been introduced. In this method, an ultrasonic pulse is transmitted into the body as with conventional B-mode imaging. Instead of sensing the return of acoustic echoes at the same frequency as the original pulses, filtering techniques are used to sense signals at harmonic frequencies. The intensity of these sensed signals is then mapped in a conventional manner. Because these signals are generated as a function of the non-linear propagation characteristics of the tissue, different anatomical features can be observed; perhaps with better contrast
[0005] In a recently published paper entitled “Investigation of Real-time Remote Palpation Imaging” by Nightingale, Soo, Nightingale, Palmeri and Trahey, Proceedings SPIE Medical Imaging 2001, there is described an experiment in which tissue was first insonified with a conventional ultrasonic pulse and the radio frequency signal associated with the returning acoustic echo then was recorded. Next, the tissue was insonified with a continuous (i.e., relatively long) acoustic wave (120-300 W/cm 2 ) that generated a force within the tissue. Then, the displacement of the tissue resulting from this force was measured using a radio frequency cross-correlation technique between the initial ultrasonic pulse and a second ultrasonic pulse. A displacement, from the resultant force, of as much as 30 microns could be observed. Maximum displacements were generally obtained within 5 ms. The tissue displacements correlated well with B-mode image anatomical structures. The amount of displacement and the recovery time can be associated with the stiffness properties of the propagation media.
[0006] This displacement phenomenon can be explained in terms of the physics of wave propagation. When a wave travels in a medium, be it an acoustic wave or an electromagnetic wave, it carries with it not only energy (E) but also momentum (P). As the acoustic wave propagates into tissue, however, energy is absorbed due to inelastic transport processes. Associated with this energy loss is a commensurate change in momentum. Momentum changes also can occur when energy is reflected from acoustic interfaces. This may be an elastic process.
[0007] From Newton's Laws, this momentum change imposes a force on the differential tissue volume in the path of propagation (dP/dt=F). This force, in turn, causes the infinitesimal tissue volume to move, F=mass×acceleration. The extent of the movement is a function of the stiffness of the material as well as the local absorption.
SUMMARY OF THE INVENTION
[0008] In its simplest form, the present invention may employ algorithms and hardware similar to those that have been used previously in Doppler imaging to display images of the movement of body parts. In the present invention, the ultrasonic signals that are transmitted to the target not only are reflected for developing images of the target from the reflections, but, by appropriate selection of the intensity of the transmitted signals, the body tissue being investigated is deformed or moved when the transmitted signals impinge on the target to measure the displacement due to ultrasonic wave propagation. The deformation or movement of the body tissue being investigated is imaged and is representative of the mechanical stiffness of this body tissue.
[0009] Apparatus for indicating mechanical stiffness properties of body tissue, constructed in accordance with the present invention, includes transmitter means for transmitting to a target in a body (a) a first ultrasonic pulse having a first acoustic intensity sufficient to deform the target, and (b) subsequently a second ultrasonic pulse having a second acoustic intensity, different from the acoustic the intensity of the first ultrasonic pulse, sufficient to deform the target. This apparatus also includes receiver means for receiving (a) a reflection from the target of the first ultrasonic pulse and developing a first signal representative of the position after deformation of the target caused by the first ultrasonic pulse, and (b) subsequently a reflection from the target of the second ultrasonic pulse and developing a second signal representative of the position after deformation of the target caused by the second ultrasonic pulse. This apparatus further includes indicating means responsive to the first signal and the second signal for indicating the change of deformation of the target caused by the second ultrasonic pulse relative to the deformation of the target caused by the first ultrasonic pulse.
[0010] A method for indicating mechanical stiffness properties of body tissue according to the present invention includes the steps of transmitting to a target in a body a first ultrasonic pulse having a first acoustic intensity sufficient to deform the target, receiving a first reflection from the target of the first ultrasonic pulse, transmitting a second ultrasonic pulse having a second acoustic intensity, different from the acoustic the intensity of the first ultrasonic pulse, sufficient to deform the target, and receiving a second reflection from the target of the second ultrasonic pulse. This method also includes the steps of developing from the first reflection a first indication of deformation of the target caused by the first ultrasonic pulse, developing from the second reflection a second indication of deformation of the target caused by the second ultrasonic pulse, and developing from the first deformation indication and the second deformation indication an indication of the deformation of the target caused by the second ultrasonic pulse relative to the deformation of the target caused by the first ultrasonic pulse.
[0011] It is to be understood that the foregoing general description of the present invention and the following detailed description of the present invention are exemplary, but are not restrictive of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The present invention is best understood from the following detailed description when read in connection with the accompanying drawings.
[0013] [0013]FIG. 1 is a block diagram of a first embodiment of apparatus for indicating mechanical stiffness properties of body tissue constructed in accordance with the present invention.
[0014] [0014]FIG. 2 is a block diagram of a second embodiment of apparatus for indicating mechanical stiffness properties of body tissue constructed in accordance with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0015] Referring to FIG. 1, a first embodiment of apparatus for indicating mechanical stiffness properties of body tissue, constructed in accordance with the present invention, includes transmitter means for transmitting to a target in a body a first ultrasonic pulse having a first acoustic intensity sufficient to deform the target and subsequently a second ultrasonic pulse having a second acoustic intensity, different from the acoustic intensity of the first ultrasonic pulse, sufficient to deform the target. For the FIG. 1 embodiment of the present invention, such transmitting means include a pulser 10 and a transducer 12 . Pulser 10 serves as the source of energy for the ultrasonic pulses that are conducted to transducer 12 and, in turn, are transmitted to a target in a body as represented by the acoustic waveform 14 .
[0016] It will be understood that the present invention may involve transmitting more than two ultrasonic pulses. Rather, a series of ultrasonic pulses may be transmitted and any two of the series are considered a transmitted first ultrasonic pulse and a transmitted second ultrasonic pulse.
[0017] In accordance with the present invention, as will be understood from the explanation provided below, to determine the relative deformations of the target caused by deformation of the target by the transmitted first ultrasonic pulse and the deformation of the target by the transmitted second ultrasonic pulse (i.e., two consecutive transmitted ultrasonic pulses), the acoustic intensities of the consecutive transmitted ultrasonic pulses are different. This can be accomplished by setting the acoustic intensity of the transmitted second ultrasonic pulse either greater or less than the acoustic intensity of the transmitted first ultrasonic pulse with only two different levels of acoustic intensity or with three or more levels of acoustic intensity.
[0018] The FIG. 1 apparatus for indicating mechanical stiffness properties of body tissue, constructed in accordance with the present invention, also includes receiver means for receiving a reflection from the target of the first ultrasonic pulse and developing a first signal representative of the position after deformation of the target caused by the first ultrasonic pulse and subsequently a reflection from the target of the second ultrasonic pulse and developing a second signal representative of the position after deformation of the target caused by the second ultrasonic pulse. Waveform 14 also represents reflections of the ultrasonic signals from the target. For the FIG. 1 embodiment of the present invention, such receiving means include transducer 12 . The reflections from the target of the transmitted first and second ultrasonic pulses, respectively, are converted to electrical signals by transducer 12 .
[0019] The electrical signals developed by transducer 12 from the reflections from the target of the transmitted first and second ultrasonic pulses are low level and are amplified, as shown by the FIG. 1 embodiment of the present invention, by a time gain compensation amplifier 16 . Because energy is absorbed as the ultrasonic pulses propagate through tissue, the gain of time gain compensation amplifier 16 is increased with time corresponding to the increased depth within the body from which the reflections return. This equalizes the returning electrical signal amplitude to make the signals relatively independent of the depth within the body from which the reflections return.
[0020] As shown by FIG. 1, the amplified signal for each reflection then is filtered by a bandpass filter 18 to remove unwanted electrical signals outside the frequency range of the returning reflections. This improves the signal to noise ratio.
[0021] In the FIG. 1 embodiment of the present invention, the signals representative of the received reflections of the first and second ultrasonic pulses, respectively, that are transmitted by transducer 12 then pass to a sample and hold circuit that retains the signal voltage at a given instant in time. This voltage is converted from an analog signal to a digital signal by an analog-to-digital converter 22 . Sequences of digital signals, developed by analog-to-digital converter 22 , are representative of the received reflections of the first and second ultrasonic pulses, respectively, that are transmitted by transducer 12 . The sampling by sample and hold circuit 20 is performed sufficiently rapidly in time (at or exceeding the Nyquist rate) to record, in digital form, the information contained in the original analog signals developed from the reflections of the transmitted first and second ultrasonic pulses. It should be noted that modern analog to digital converters might not require the inclusion of a sample and hold circuit.
[0022] The FIG. 1 apparatus for indicating mechanical stiffness properties of body tissue, constructed in accordance with the present invention, further includes indicating means responsive to the first signal representative of the position of the target after deformation of the target caused by the transmitted first ultrasonic pulse and the second signal representative of the position of the target after deformation of the target caused by the transmitted second ultrasonic pulse for indicating the change of deformation of the target caused by the transmitted second ultrasonic pulse relative to the deformation of the target caused by the transmitted first ultrasonic pulse. For the FIG. 1 embodiment of the present invention, such indicating means include means for shifting a selected segment of the waveform of one of the two signals representative of the positions of the target after deformation of the target caused by the transmitted first ultrasonic pulse or the transmitted second ultrasonic pulse till maximum coincidence is achieved between the selected segment with the corresponding segment of the waveform of the other signal.
[0023] In particular, for the FIG. 1 embodiment of the present invention, an estimator 24 includes circuitry which first stores the digital signal representative of the reflection of the first ultrasonic pulse transmitted by transducer 12 and the digital signal representative of the reflection of the second ultrasonic pulse transmitted by transducer 12 (i.e., digital signals representative of reflections of consecutive transmitted ultrasonic pulses). The circuitry of estimator 24 then chooses a short segment of the waveform of the reflection of the transmitted first ultrasonic pulse, perhaps 8 to 32 samples long, starting at the beginning of the waveform, and compares this to the corresponding segment of the waveform of the reflection of the transmitted second ultrasonic pulse. Because slight movement of the position of the target is anticipated, estimator 24 chooses segments of the waveforms in the vicinity of the expected position until a maximum match is achieved. Mathematically, this is known as a cross-correlation and FIG. 1 embodiment of the present invention may be characterized as the cross-correlation embodiment. It should noted that the gain of the digital signals representative of the reflections is adjusted to compensate for the differences in the acoustic intensities of the transmitted ultrasonic pulses prior to performing the cross-correlation operation.
[0024] The difference in signal location, namely the extent of movement from the starting point of the waveform segment to the point that produces the maximum waveform correlation, corresponds to the displacement of the target that has resulted for that segment. This delay or shift then is recorded. The process is repeated for each succeeding segment of the waveform of the reflection of the first ultrasonic pulse transmitted by transducer 12 with each succeeding segment compared via cross-correlation with the corresponding segment of the waveform of the reflection of the second ultrasonic pulse transmitted by transducer 12 .
[0025] In this way, estimator 24 develops a signal representative of the relative shift in the selected segments of the waveforms to achieve maximum coincidence of the selected segments of the waveforms. This signal drives a display 26 of the indicating means to present the image of the target and the deformation of the target. In particular, the amplitude of the signal developed by estimator 24 is obtained as an average of the first signal developed from the reflection of the first ultrasonic pulse transmitted by transducer 12 and the second signal developed from the reflection of the second ultrasonic pulse transmitted by transducer 12 and is used to provide a conventional ultrasonic B-mode image. Similarly, the shift in magnitude is used to develop a deformation image indicative of stiffness. Because the force differential between the first ultrasonic pulse transmitted by transducer 12 and the second ultrasonic pulse transmitted by transducer 12 is linearly related to the difference in acoustic intensities between the two transmitted pulses, the actual stiffness measurement is adjusted to compensate for the fact that the magnitude of the force difference decreases as the pulses travel through the tissue due to acoustic energy absorption.
[0026] It should be noted that the signal developed by estimator 24 , that is representative of the relative shift in the selected segments of the waveforms to achieve maximum coincidence of the selected segments of the waveforms, also can drive a meter that indicates, in either analog or digital form, the deformation of the target.
[0027] Referring to FIG. 2, a second embodiment of apparatus for indicating mechanical stiffness properties of body tissue, constructed in accordance with the present invention, includes transmitter means for transmitting to a target in a body a first ultrasonic pulse having a first acoustic intensity sufficient to deform the target and subsequently a second ultrasonic pulse having a second acoustic intensity, different from the acoustic intensity of the first ultrasonic pulse, sufficient to deform the target. For the FIG. 2 embodiment of the present invention, such transmitting means include a pulser 30 and a transducer 32 . Pulser 30 serves as the source of energy for the ultrasonic pulses that are conducted to transducer 32 and, in turn, are transmitted to a target in a body as represented by the waveform 34 .
[0028] As with the FIG. 1 embodiment of the present invention, more than two ultrasonic pulses may be transmitted by transducer 32 . Preferably, a series of ultrasonic pulses are transmitted and any two of the series are considered a transmitted first ultrasonic pulse and a transmitted second ultrasonic pulse.
[0029] As with the FIG. 1 embodiment of the present invention, to determine the relative deformations of the target caused by deformation of the target by the transmitted first ultrasonic pulse and the deformation of the target by the transmitted second ultrasonic pulse (i.e., two consecutive transmitted ultrasonic pulses), the acoustic intensities of the consecutive transmitted ultrasonic pulses are different. This can be accomplished by setting the acoustic intensity of the transmitted second ultrasonic pulse either greater or less than the acoustic intensity of the transmitted first ultrasonic pulse with only two different levels of acoustic intensity or with three or more levels of acoustic intensity.
[0030] The FIG. 2 apparatus for indicating mechanical stiffness properties of body tissue, constructed in accordance with the present invention, also includes receiver means for receiving a reflection from the target of the first ultrasonic pulse and developing a first signal representative of the position after deformation of the target caused by the first ultrasonic pulse and subsequently a reflection from the target of the second ultrasonic pulse and developing a second signal representative of the position after deformation of the target caused by the second ultrasonic pulse. Waveform 34 also represents reflections of the ultrasonic signals from the target. For the FIG. 2 embodiment of the present invention, such receiving means include transducer 32 . The reflections from the target of the transmitted first and second ultrasonic pulses, respectively, are converted to electrical signals by the transducer 32 .
[0031] The electrical signals developed by transducer 32 from the reflections from the target of the transmitted first and second ultrasonic pulses are low level and are amplified, as shown by the FIG. 2 embodiment of the present invention, by a time gain compensation amplifier 36 . Because energy is absorbed as the ultrasonic pulses propagate through tissue, the gain of time compensation gain amplifier 36 is increased with time corresponding to the increased depth within the body from which the reflections return. This equalizes the returning electrical signal amplitude to make the signals relatively independent of the depth within the body from which the reflections return.
[0032] As shown by FIG. 2, the amplified signal then is divided and the components of the divided signal individually enter mixers 38 and 40 . Mixers 38 and 40 convert the radio frequency waveform, representative of the original returning reflections, into two baseband signals that are in phase with the quadrature reference signals cos(2πf o t) and sin(2πf o t) of the mixers. These in-phase and quadrature signals are designated as I(t) and Q(t).
[0033] For the FIG. 2 embodiment of the present invention, each of the in-phase and quadrature signals individually passes through a filter 42 and 44 to remove unwanted electrical signals outside the frequency range of the returning reflections. This improves the signal to noise ratio.
[0034] In the FIG. 2 embodiment of the present invention, the in-phase and quadrature signals then pass individually to sample and hold circuits 46 and 48 that retain the signal voltages at a given instant in time. These voltages are separately converted from analog signals to digital signals by analog-to-digital converters 50 and 52 . Sequences of the I(t) and Q(t) digital signals, developed by analog-to-digital converters 50 and 52 , are representative of the received reflections of the first and second ultrasonic pulses, respectively, that are transmitted by transducer 32 . The sampling by sample and hold circuits 46 and 48 is performed sufficiently rapidly (at or exceeding the Nyquist rate) to record, in digital form, the information contained in the original analog signals developed from the reflections of the transmitted first and second ultrasonic pulses. These sequences are designated as
I 1 (n)Q 1 (n)
[0035] and
I 2 (n)Q 2 (n)
[0036] where:
[0037] the subscripts refer to the transmitted first ultrasonic pulse and the transmitted second ultrasonic pulse, respectively, and
[0038] the variable n refers to a particular sample in time.
[0039] It should be noted that modern analog to digital converters might not require the sample and hold circuits. Also, it should be noted that the digital in-phase and digital quadrature representative signals can be generated directly from a digital representation of the original signal prior to entering the analog mixers. This would obviate the need for these mixer components.
[0040] The FIG. 2 apparatus for indicating mechanical stiffness properties of body tissue, constructed in accordance with the present invention, further includes indicating means responsive to the first signal representative of the position of the target after deformation of the target caused by the transmitted first ultrasonic pulse and the second signal representative of the position of the target after deformation of the target caused by the transmitted second ultrasonic pulse for indicating the change of deformation of the target caused by the transmitted second ultrasonic pulse relative to the deformation of the target caused by the transmitted first ultrasonic pulse. For the FIG. 2 embodiment of the present invention, such indicating means include means for determining the phase of the first signal representative of the position of the target after deformation of the target by the transmitted first ultrasonic pulse relative to a reference and the phase of the second signal representative of the position of the target after deformation of the target by the transmitted second ultrasonic pulse relative to the same reference. The FIG. 2 embodiment of the present invention may be characterized as the phase difference embodiment.
[0041] In particular, for the FIG. 2 embodiment of the present invention, it can be shown that the phase difference, at any given instant in time, between the waveform of the first signal representative of the position of the target after deformation of the target by the transmitted first ultrasonic pulse and the waveform of the second signal representative of the position of the target after deformation of the target by the transmitted second ultrasonic pulse is given by:
Δ=arctan([ I 1 ( n ) Q 2 ( n )− Q 1 ( n ) I 2 ( n )]/[ I 1 ( n ) I 2 ( n )+ Q 1 ( n ) Q 2 ( n )])
[0042] where
[0043] Δ represents the phase difference, and
[0044] the remaining terms represent the in-phase and quadrature signal components
[0045] Because this phase difference is a fraction of the wavelength of the mixer reference signal (f o ), the displacement in distance is determined as follows:
Displacement=Δ C/ 2π f o
[0046] where C is the velocity of sound in the medium
[0047] In the FIG. 2 embodiment of the present invention, an estimator 54 develops a signal representative of the phase difference between the first signal representative of the position of the target after deformation of the target by the transmitted first ultrasonic pulse and the second signal representative of the position of the target after deformation of the target by the transmitted second ultrasonic pulse to drive a display 56 to present the image of the target and the deformation of the target. Specifically, estimator 54 determines the phase difference Δ and multiplies the phase difference Δ by the ratio of C divided by 2π times the mixer reference signal frequency (f o ). It should noted that the gain of the digital signals representative of the reflections is adjusted to compensate for the differences in the acoustic intensities of the transmitted ultrasonic pulses prior to performing the phase difference estimate operation.
[0048] Again, it should be noted that the signal developed by estimator 54 , that is representative of the phase difference between the first signal representative of the position of the target after deformation of the target by the transmitted first ultrasonic pulse and the second signal representative of the position of the target after deformation of the target by the transmitted second ultrasonic pulse, also can drive a meter that indicates, in either analog or digital form, the deformation of the target.
[0049] Although illustrated and described above with reference to certain specific embodiments, the present invention nevertheless is not intended to be limited to the details shown. Rather, various modifications may be made in the details within the scope and range of equivalents of the claims and without departing from the spirit of the invention. | Apparatus and method for indicating mechanical stiffness properties of body tissue employing Doppler imaging techniques. Ultrasonic signals that are transmitted to the target not only are reflected for developing images of the target from the reflections, but, by appropriate selection of the intensity of the transmitted signals, the body tissue being investigated is deformed or moved when the transmitted signals impinge on the target. The deformation or movement of the body tissue being investigated is imaged and is representative of the mechanical stiffness of this body tissue. | 0 |
[0001] The present invention relates to the subject matter disclosed in international application PCT/EP 00/06781 of Jul. 15, 2000, the entire specification of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] The invention relates to a mobile sweeping machine with a rotationally driven rotary brush which is mounted in a housing, a dirt collection container which can be detachably connected to the housing and with a dirt inlet opening located adjacent to the rotary brush in the dirt collection container.
[0003] Sweeping machines of this type are known which can be moved manually by means of a shaft-type gripping element, for example, along a surface to be cleaned. In order to empty the dirt collection container filled with collected dirt particles, the housing can be snapped down so that emptying can be achieved through the then exposed opening of the dirt collection container. This requires a relatively complicated construction, which also makes handling difficult during emptying, since the entire sweeping machine must be transported to the emptying location.
[0004] It is the object of the invention to configure a sweeping machine of this type so as to facilitate emptying of the dirt collection container.
SUMMARY OF THE INVENTION
[0005] This object is achieved according to the invention with a mobile sweeping machine of the above-described type in that the dirt collection container is configured as a drawer, which can be laterally inserted into a guide of the housing and can be fixed in its inserted position relative to the housing. This drawer can be simply pulled laterally out of the housing for emptying and then carried to the emptying location, and by simply inserting and fixing it to the housing, the sweeping machine is ready for operation again.
[0006] It is advantageous if rollers, which fully support the sweeping machine, are disposed on the housing and on the dirt collection container, so that the sweeping machine is configured, on the one hand, by the housing and by the drawer, on the other.
[0007] In a preferred embodiment it is provided that the guide is disposed on a flat support part of the housing, which, running essentially parallel to the transport surface, extends from the working part of the housing accommodating the rotary brush and its drive.
[0008] In particular, the support part can essentially completely cover the drawer on its upper side.
[0009] It is advantageous if the guide is formed by strip-type projections extending into a groove.
[0010] In a particularly preferred embodiment it is provided that the groove and the strip-type projections are semicircular, this is particularly advantageous when the drawer and possibly the support part covering it are also correspondingly semicircular in order to obtain a pleasing form for the sweeping machine and also to ensure that even locations which are difficult to access can be well cleaned with this sweeping machine.
[0011] In particular with semicircular guides it is difficult to join the guide elements reliably, since these only engage shortly before the insertion process has ended.
[0012] In order to assist in this, it is particularly advantageous if a projection pointing in the direction of the housing is disposed on the drawer, said projection extending into a guide of the housing and thus guiding the drawer during insertion before the ledge-type projections enter the groove. As a result, the advantage to the user is that he does not need to take particular care to ensure that the strip-type guide elements also extend into the grooves during the insertion movement of the drawer.
[0013] It is particularly advantageous if the projection is formed by a half shell, which extends in the direction of insertion of the drawer and is inserted into a trough-shaped depression on the upper side of the housing. Such a half shell can have the form of a half pipe connection and extend into a correspondingly shaped trough-shaped depression.
[0014] In this case, the trough-shaped depression can have guide faces engaging over the upper edge of the half shell so that in the trough-shaped depression the half shell is also secured against swivelling around the longitudinal axis of the trough-shaped depression.
[0015] It is particularly advantageous in this case if the upper edge of the half shell has a section rising from the base of the half shell and a section adjoining this running parallel to the direction of insertion of the drawer. During insertion of the half shell into the trough-shaped depression the drawer is then automatically centred with respect to the housing, in particular the drawer is also rotated around a longitudinal axis running parallel to the direction of insertion into the position in which the strip-type projections can engage into the groove.
[0016] It can be provided in particular that the half shell is open on the front side at its end remote from the housing, the half shell thus forming a grip opening into which the user can grasp in order to operate the drawer.
[0017] It is advantageous if the trough-shaped depression merges into a receiving depression for a gripping element so that the trough-shaped depression assumes a further function, i.e. that of a receiving area for a gripping element, e.g. for the base of a shaft with which the sweeping machine can be moved.
[0018] In this case, it can be provided that a gripping element is disposed to swivel on the upper side of the housing and in an end position extends into the receiving depression and into the adjoining trough-shaped depression as well as the half shell inserted therein. The base portion of a rod-type gripping element, for example, can thus be accommodated on the upper side of the sweeping machine to save space when the sweeping machine is not in operation and must be stowed.
[0019] It is provided in a preferred embodiment that an elastic catch is provided to fix the drawer on the housing.
[0020] The elastic catch can preferably be disposed on the base of the half shell and engages behind a recess on the trough-shaped depression.
[0021] In a particularly preferred embodiment it is provided in that case that the elastic catch is formed by a region of the base of the half shell, which is separated from the rest of the half shell by two U-shaped incisions and only remains connected to the base of the half shell via two deformable webs located between the ends of the opposing incisions. Such an elastic catch is very simple to mould out of the base of the half shell by provision of the two U-shaped incisions, the narrow remaining webs are deformable in accordance with the selected material of the half shell, e.g. an elastic plastic material, to such an extent that the remaining base section may be swivelled slightly in relation to the rest of the base of the half shell.
[0022] It is beneficial in this case if at a distance below the half shell the trough-shaped depression forms a stop restricting the swivelling movement of the elastic catch, thus ensuring that the elastic catch is not deformed too much during the opening movement and damaged as a result.
[0023] In addition, it can be provided that spring elements are disposed between the housing and drawer which act on the drawer in its pull-out direction. As a result, upon release of the elastic catch, the drawer is necessarily pushed out of the locking position so that further locking is only possible when the drawer is intentionally pushed into the housing. This ensures that a brief application of pressure on the elastic catch is sufficient during release of the drawer and that then the drawer remains unlocked and can be pulled out of the housing without problem.
[0024] It is beneficial in this case if the spring elements are at the same time intermeshing guide elements.
[0025] In a preferred embodiment, moreover, it can be provided that the drawer has a grip depression on its underside opposite the half shell. As a result of this, the drawer is provided in the same manner with a depression on the upper side and on the underside so that the user can grip and operate the drawer using these two depressions in a particularly advantageous manner.
[0026] The following description of preferred embodiments of the invention is for more detailed explanation in association with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] [0027]FIG. 1 is a top view onto a sweeping machine with drawer inserted;
[0028] [0028]FIG. 2 is a sectional view taken along line 2 - 2 in FIG. 1;
[0029] [0029]FIG. 3 is a view of the sweeping machine of FIG. 1 viewed from the drawer;
[0030] [0030]FIG. 4 is a view similar to FIG. 1 with the drawer pulled out of the housing, and
[0031] [0031]FIG. 5 is a partial side view of the housing with the drawer pulled out.
DETAILED DESCRIPTION OF THE INVENTION
[0032] The sweeping machine 1 shown in the drawing comprises a housing 2 with a rotary brush 3 rotatably mounted therein and projecting downwards out of the housing 2 and with rollers 4 as well as a dirt container 5 , which is connected to the housing 2 and also bears rollers 6 , so that the sweeping machine 1 is overall capable of running on a surface to be cleaned transversely to the rotational axis of the rotary brush 3 . The rotary brush 3 is set in rotation by a drive means 7 via a belt 8 and said drive means 7 can be a battery-fed electric motor, for example, in other embodiments the drive means 7 could also be a gear, which transfers the rotational movement of the rollers 4 onto the rotary brush 3 .
[0033] The housing 2 comprises a working part 9 , which accommodates the rotary brush 3 and the drive means 7 , and an essentially plate-shaped support part 10 , which projects parallel to the running plane of the sweeping machine 1 on the upper side of the work part 9 and which completely covers the dirt container 5 directly adjoining the work part 9 .
[0034] This dirt container 5 is constructed as a drawer and is only open on its front side 11 pointing towards the work part 9 . On the upper side, the dirt container 5 has a guide strip 12 , which extends in a semicircle, projects radially inwards and engages into a semicircular guide groove 13 on the outer edge of the support part 10 when the dirt container 5 has fully approached the work part 9 . As a result of this, the dirt container 5 is held on the support part 10 , namely in a position in which the open front side 11 of the drawer-type dirt container 5 lies opposite with a dirt outlet opening 14 on the side of the work part 9 of the housing 2 facing the dirt container 5 . As a result, dirt particles picked up from the surface to be cleaned by the rotary brush 3 as a result of its rotational movement can pass through the dirt outlet opening 14 via the open front side 11 and into the interior of the dirt container 5 .
[0035] On its upper side, the work part 9 of the housing 2 bears a ring-shaped oval depression 15 , which merges on both sides into a channel-shaped straight depression 16 or 17 running parallel to the direction of movement of the sweeping machine 1 , in which case both depressions 16 and 17 respectively extend as far as the edge of the housing 2 . This results in a receiving area for the fork-shaped base 18 of a rod-shaped operating grip 19 , which is disposed on the upper side of the housing 2 to swivel around a rotational axis running transversely to the direction of movement in the centre of the oval depression 15 , and which can be accommodated at both its end positions in the oval depression 15 and the adjoining depression 16 or the oval depression 15 and the adjoining depression 17 . These end positions are principally required when the sweeping machine has to be stowed after the operation has ended, during operation the operating grip 19 is swivelled into a position in which it extends upwards on an incline so that the sweeping machine 1 can be moved along the surface to be cleaned with this operating grip 19 .
[0036] The depression 17 , which extends in the support part 10 of the housing 2 , is semicircular in cross-section, the plane upper side 20 of the support part 10 projects slightly into the cross-section of this semicircular depression and with its underside forms a horizontal plane guide surface 21 , which laterally closes off the depression 17 on the upper side.
[0037] A half shell 22 open at the top is moulded onto the dirt container 5 on its upper side, and extends in the direction of insertion of the dirt container 5 , is semicircular in cross-section and its dimensions are selected so that the half shell 22 extends into the channel-shaped depression 17 upon insertion of the dirt container 5 and then abuts with its outer wall against the inner wall of this channel-shaped depression 17 .
[0038] The upper edge 23 of the half shell 22 has a section 25 , which begins and ascends at the free end of the half shell 22 in the region of its base surface 24 , and a section 26 , which adjoins it and runs parallel to the direction of insertion, said section 26 of the upper edge 23 abutting against the guide face 21 of the depression 17 when the dirt container 5 is inserted. As a result of this, the dirt container is guided and centred during insertion so that the guide strip 12 engages directly into the guide groove 13 when the dirt container 5 is fully inserted, no special adjusting movements by the user are necessary for this, even if the dirt container 5 is brought onto the housing 2 tilted or askew, it is straightened during the insertion movement as a result of the half shell 22 plunging into the channel-shaped depression 17 .
[0039] In the base surface 24 of the half shell 22 two U-shaped incisions 27 , 28 are located which lie opposite one another with their ends and have narrow webs 29 , 30 of the base material standing between them. As a result of these incisions 27 and 28 a portion of the base surface 24 is formed which serves as catch element 31 . On its underside on its end facing the work part 9 of the housing 2 , this catch element bears a catch lug 32 , which extends into a catch opening 33 in the channel-shaped depression 17 when the dirt container 5 is fully inserted (FIG. 2) and thus secures the dirt container 5 against being pulled out.
[0040] The webs 29 and 30 are very narrow and form a torsion hinge, around the longitudinal axis of these webs the catch element 31 can be swivelled slightly, as is clear from the illustration in FIG. 5. During this swivelling movement the catch lug 32 is raised out of the catch opening 33 so that the dirt container 5 can be pulled out of the insertion position.
[0041] On the base of the depression 17 an elongated depression 34 adjoins the catch opening 33 , and said elongated depression receives the lowered portion of the catch element 31 during swivelling of the catch element 31 into its open position and at the same time restricts the swivelling movement of the catch element 31 so as to prevent any damage to the webs 29 and 30 as a result of being swivelled too far. This depression 34 thus forms a stop to restrict the swivelling angle of the catch element 31 (FIG. 2).
[0042] On the dirt container 5 on both sides beside the half shell 22 , further guide elements 35 are disposed which are constructed as short ducts of square cross-section, extend parallel to the half shell 22 and bear an opening 37 on their front side 36 facing the work part 9 of the housing 2 . Wall elements 38 curved on an incline, which are held on the support part 10 of the housing 2 and point towards the dirt container 5 , enter this opening 37 when the dirt container 5 is fully inserted (FIGS. 1 and 4).
[0043] These wall elements 38 are elastically deformable so that when entering the openings 37 of the guide elements 35 , they not only centre these but also exert an elastic force onto these, which is directed in the pull-out direction of the dirt container 5 . As a result, the dirt container 5 is placed under prestress upon full insertion and locking of the catch element 31 , as soon as the catch element 31 is released, the dirt container 5 is therefore pushed out slightly so that when springing back the catch element can no longer engage behind the catch lug 32 , and locking therefore remains released. In addition, the consequence of this is that the dirt container 5 is reliable in operation and is connected to the housing 2 of the sweeping machine 1 in the exactly determined position.
[0044] Opposite the channel-shaped depression 17 on the underside of the dirt container 5 , a further depression 39 is located which facilitates the engagement of the dirt container 5 jointly with the depression 17 . The user can place a finger both in depression 39 and also in depression 37 and thus grasp the part of the dirt container located between these two depressions in the manner of a grip and therefore securely handle the dirt container 5 , whether to empty it or to insert it into the housing 2 .
[0045] The described structural parts of the sweeping machine 1 are simple to produce, they are preferably made of plastic and they are easy to detachably connect to one another so that operation is considerably easier than known sweeping machines of this type. In particular, the dirt container 5 can be connected to the housing 2 by a simple pushing movement and separated from it again by simply pressing on the catch element 31 , so that emptying can be achieved by transport of the dirt container 5 only, the sweeping machine itself does not need to be transported to the emptying site. | In order to facilitate emptying of the dirt collection container in a mobile sweeping machine with a rotationally driven rotary brush which is mounted in a housing, a dirt collection container which can be detachably connected to the housing and with a dirt inlet opening located adjacent to the rotary brush in the dirt collection container, it is proposed that the dirt collection container is configured as a drawer, which can be laterally inserted into a guide of the housing and can be fixed in its inserted position relative to the housing. | 0 |
This application is a continuation-in-part of Ser. No. 805,056 filed June 9, 1977, now abandoned.
BACKGROUND OF THE INVENTION
Double-ended stud-like fasteners consisting of a machine screw thread on one end, a pancake-type flange or head in the middle and a special thread tapping screw at the other end are commonly used in environments where the primary supporting surface is of a plastic-type material with securement therein being a blind application.
Typical applications of this type are those of automotive where plastic components are provided with boss-like protuberances having preformed bores in order to accept the tapping thread end of the stud. The studs are usually first driven into the plastic bosses with a stud driver leaving the machine screw end to be inserted later through clearance holes in sheet metal workpieces. Nuts are then used to clamp the sheet metal against the pancake head of the double-ended stud which puts all the load on the machine screw end of the stud and eliminates any added stress to the plastic during installation.
A typical manner of driving such double-ended studs has been to utilize the upwardly extending threaded shank and transmit torque to the fasteners by means of a chuck grasping the threaded section. Another method utilizes the outer periphery of the flange to drive the fastener. Such applications and tools tend to be significantly greater in diameter than the diameter of the flange and/or the boss which the stud is to be associated with. In many such applications, the bosses are in confined areas and size of the tool is a definite factor in efficiently driving such fasteners.
In addition to the application or driving problems associated with prior art systems, a substantial problem exists in securing the fastener from backing out or rotation tending to remove after the fastener has been installed. For a variety of reasons, the clamping nuts may have to be removed and/or the sheet metal removed from the installation. When torque is applied to the system to remove the nut, it is also applied to the stud tending to loosen or remove the stud itself from the plastic. A number of techniques have been suggested to eliminate this tendency to remove the stud when the nut is removed. Adhesives, special thread forms, locking means beneath the pancake head or a combination of special configurations of boss and pancake head have been suggested. However, the prior art suggestions are either costly, cumbersome or contributory to further deterioration and stressing of the plastic during installation.
SUMMARY OF THE INVENTION
The present invention is concerned with a double-ended stud having dual purpose ribs formed on the upper surface of a pancake-type flange and a tool for inserting such a stud in an associated work surface. Radially extending, sharp edged, ribs on the upper surface of the flange function to drive the fastener and to embed in the undersurface of a secondary work plate clamped over the stud/boss combination securing the fastener against retrograde movement of the stud.
A tool particularly designed to insert such a double-ended fastener in a workpiece includes an end surface with a plurality of radially extending abutment surfaces formed therein adapted to engage the ribs on the flange. An axial bore in the tool receives the upwardly extending stud shank during the driving so that the end surface of the tool may freely contact the flange.
In contrast with prior art methods of applying double-ended studs, the stud and tool described herein permit the axial driving pressure to be carefully controlled and confined while the fastener is stabilized or centered in a properly fixtured driving tool. The axial driving pressure is thus controlled and concentrated to maximize the efficient application of the torque transmitting pressures which are distributed over the surface of the flange rather than applied to the smaller diameter of the upwardly extending shank.
The tool is designed so that its mating end surface is substantially equal to the flange diameter of the stud. This allows the tool to be used in confined areas and eliminates any contact of the tool with the plastic itself.
The ribs formed on the upper surface of the flange should include at least a primary abutment surface extending perpendicular to the flange surface and a secondary camming surface extending toward the primary surface at an acute angle to the upper surface of the flange. The ribs are preferably configured to permit a rotating, mating driving tool to softly engage the primary abutment surface and the flange to insure adequate tool life.
It is, therefore, an object of the present invention to provide an improved double-ended stud with means to prevent removal of the stud upon removal of a clamping nut associated thereon.
A further object of the invention is to provide a double-ended stud with an improved means for driving into a workpiece.
Yet another object of the invention is to provide a double-ended stud with a single structural improvement that serves to both improve the driving and locking characteristics of the stud.
Yet another object of the invention is to provide a driving tool for association with the stud of the present invention and with fasteners having tamperproof features.
Another object of the invention is to provide a low profile flange surface that provides reliable driving surfaces and minimizes driving tool wear.
Other objects and advantages of the present invention will become apparent from the following description and the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a side elevational view of the double-ended stud embodying the features of the invention.
FIG. 2 is a top plan view of the stud as taken along lines 2--2 of FIG. 1.
FIG. 3 is a side view, in partial section, of the stud member inserted in a boss surface through the use of a particularly designed tool.
FIG. 4 is an enlarged side view, in partial section, of an assembly using the double-ended stud inserted in the workpiece and showing a nut member clamping a secondary work plate over the flange.
FIG. 5 is an end view of the tool taken from its work contacting surface end.
FIG. 6 is an elevational view, in partial section, of the tool of the invention in association with a fastener of modified design.
FIG. 7 is a top plan view of the fastener of modified design shown in FIG. 6.
FIG. 8 is a partial side elevational view of an alternate embodiment of a double-ended stud embodying the features of the invention.
FIG. 9 is a top plan view of the stud of FIG. 8 as taken in the direction of lines 9--9 of FIG. 8.
FIG. 10 is a cross-sectional view taken along lines 10--10 of FIG. 9 showing the rib configuration.
FIG. 11 is a cross-sectional view taken along lines 11--11 of FIG. 9 showing the rib configuration.
FIG. 12 is a top plan view, similar to that of FIG. 9, showing in dotted lines various locations of recesses on a driving tool relative to the rib surfaces.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Turning first to FIGS. 1 and 2, the double-ended stub 10 of the present invention will include a first, lower stud shank 12 coaxially arranged with a second, upper stud shank 30 with an integral, pancake-type flange 18 positioned intermediate the shanks. The first stud section 12 is designed to be associated with a blind bore in a workpiece structure, such as a plastic boss. With this in mind, it is preferably provided with a thread convolution 14 of rather sharp crested, spaced threads. A thread cutting slot 16 is formed in the extremity of the screw to facilitate the anchoring embedment of this first shank within the bore of the primary work structure. It should be noted, however, that even though a thread cutting slot is shown in the preferred embodiment, a number of alternate configurations can be used to properly form or generate an internal thread in the primary work structure.
A radially extending flange 18 is configured to provide a generally flat undersurface 22, adjacent the first stud section 12, and an upper surface 20 adjacent the second stud section 30. The upper surface 20 includes a plurality of generally radially extending protuberances formed on an otherwise flat upper surface. These protuberances form an important aspect of the invention and their dual purpose will be described in detail further herein.
The preferred embodiment of the invention shows three rib-like members extending generally radially of the axis of the fastener. The rib member 24 will comprise a primary, torque accepting surface 26, extending substantially perpendicular to the remaining surface regions of the upper flange surface 20. The surfaces 26 will also extend radially of the axis of the fastener to achieve maximum efficiency of the rotary force applied to the fastener. A secondary surface 28, in the form of a ramp, extends upwardly at an acute angle to the upper flange surface and toward the plane of the primary drive surface 26. The camming surface 28 permits an associated driver, such as 46, to be placed in operative position with a gradual and "soft" engagement onto the flange surface 20. The preferred embodiment discloses the camming surface as directly intersecting the abutment surface 26, however it should be understood that intermediate surfaces could be provided of any variety of configurations, such as the embodiment of FIGS. 8-12, and still come within the broad scope of this invention.
While the invention incorporates driving means on the upper surface of the flange, it should be understood that the total height of the flange and protuberances should be minimized to minimize the space between the secondary work plate being secured and the primary work structure. Such a low profile, efficient driving means is in part obtained by a relatively large surface area of the upper flange which cooperates with the end surface of a mating tool to align and stabilize the tool on the fastener.
A reference to FIGS. 3 and 5 will show a tool for driving the above-described fastener and the typical application for such a fastener. A typical use for double-ended fasteners of the type described is to achieve a means to clamp a secondary work structure or plate-like device to a molded plastic structure. Common applications for double-ended studs include fastener receiving bosses, such as 34, formed in an otherwise thin plastic structure. The bosses include a bore 38, of a predetermined diameter. In use, the stud member 10 is associated with a driving tool 46 with the second stud section 30 received in a bore 54 in the body 48 of the tool. The fastener member 10 may be retained in the tool prior to driving, through the use of magnets or the like (not shown). Torque transmitting surfaces, such as a socket 56, may be formed in the extremity of the tool opposite the work engaging extremity to transmit torque from a power tool to the stud driving attachment 46. It should be noted that the diameter of the body 48 is substantially that of the flange 18 and upper surface 36 of the boss. This dimensional relationship is permitted by the novel configuration of the tool herein described and becomes important in securing fasteners in confined regions or in an area where the center line to center line distance between adjacent like fasteners is small.
As best shown in FIG. 5, work engaging end surface 50 of the tool 46 is provided with a plurality of grooves 51 equal in number to the number of ribs 24 on the fastener. These grooves will easily nest with the associated ribs due in part to the cooperation of the camming ramp surface 28 of each rib with the grooves.
While the configuration of the grooves 51 may take several forms, all of them preferably will include a generally perpendicularly arranged primary abutment surface 52 adapted for operative association with the perpendicularly arranged primary driving surface 26 on the fastener. The height of the primary abutment surface 52 should preferably be at least as much as the height of mating surface 26 so that the end surface 50 engages top surface 20 of the flange. The engagement of the remainder of the surface 50 with the top flange surface 20 provides an alignment and stabilization to the fastener as it is being driven. Further attention is directed to the alignment and stabilization provided by the telescopic association of the upper stud shank 30 with the bore 54, which is dimensioned so that both the length of the stud and the diameter are received therein without abutment.
A reference to FIG. 4 will show a second important function of the ribs 24 on the fastener. Once the stud 10 is properly seated on the upper surface 36 of the boss 34, the secondary plate 40 is positioned, preferably through the use of a clearance hole, over the stud section 30. The plate 40 is then clamped against the upper surface 20 of the flange in a manner shown in FIG. 4. This clamping is achieved through the use of a nut member 44. The nut member 44 will typically have the same hand of rotation for its internal threads as that of the thread configuration 14 on the first stud shank which is driven into the boss 34. It should be noted that while the preferred embodiment shows a machine thread 32 on the second stud section 30, that it is conceivable that the stud section 30 may be void of threads and that the nut member 44 may be of a thread forming type. In any event, the problems solved by the invention are the same, that being the securement of the stud 10 from retrograde movement as the nut 44 is subjected to a torque to break the clamping engagement between the nut and member 40. It should be noted that upon tight clamping of the nut 44 against the plate 40, the sharp apex of the rib 24 embeds in the undersurface of the plate in regions 42. Due to the perpendicular arrangement of the surface 26, torque forces applied to the stud during efforts to remove the nut, are resisted due to the locking embedment of the ribs 24 with the plate 40.
While the tool of the invention has been described in connection with a double-ended stud, reference to FIGS. 6 and 7 will point out the advantages of such a tool with a fastener of modified design. Several important features of the double-ended stud could be incorporated in a fastener having a non-removable tamperproof head. For example, fastener 10a is configured to have a low profile head including a pancake-type flat flange 18a and an axially extending threaded shank 14a. The upper surface of the flange will be configured with radially extending ribs 24a comprising a perpendicular driving surface 26a and ramp surface 28a permitting driving in only one direction. A cylindrical stub shank 30a is axially disposed on the flange with side walls 32a extending a height not substantially exceeding the height of driving surface 26a.
The driving tool 46a can be associated with the tamperproof fastener 10a in a manner identical to that described above relative to double-ended fastener 10. The tool 46a is described with like reference numerals identifying like elements to 46 with the addition of a suffix "a". It should be particularly noted that bore 54a is of such a diameter as to receive stub shank 30a and support the side walls 32a therein to center and stabilize the fastener 10a during driving. The stub shank 30a will be a height great enough to accomplish this cooperation with the tool 46a but not so great as to permit the fastener to be removed through the grasping of the shank with a tool.
A further embodiment of the invention, shown in FIGS. 8-12, is configured to minimize wear of a mating driving tool. Fastener 10b incorporates an upper shank 30b, a lower shank 12b, and an intermediate flange 18b. Protuberances 24b include a primary torque accepting surface 26b and secondary camming surface 28b. A planar surface 25 intersects primary surface 26b on a radial line 35 and the upper region 39 of secondary surface 28b along a line 33 extending generally tangentially from the shank 30b. The juncture of secondary surface 28b and planar surface 25 thus extends at an acute angle to the line of intersection between surface 25 and surface 26b.
The combination of the flat surface 25 and secondary surface 28b intersecting surface 25a in a manner shown contributes greatly to decreasing wear on a tool such as 46. As shown in FIG. 12, the leading edge 53 of recess 51 in a tool, such as shown in FIG. 5, is generally aligned with juncture line 33 thus creating a gradual controlled descent of end surface 50 onto flange upper surface 20b. The position of leading edge 53' in FIG. 12 indicates that continued clockwise rotation of tool 50 still permits edge 53' to be in line contact with camming surface 39. This soft engagement provided by the controlled drop over the surface extent created by the small acute angle formed between surface 39 and the plane of upper surface 20b and flat surface 25 diminishes wear on all contacting edges of the tool. As noted in FIG. 11, surface 39 is sloped downwardly and outwardly toward the periphery of the flange. Such a structure enhances the soft controlled descent of the tool. Wear on tools, such as rounding of edges, etc., becomes critical to proper functioning of this invention because of the desire to obtain a low profile flange. Reliable positive abutting contact between surface 26b and torque imparting surface 52 on a tool is necessary to effect proper alignment of the tool with respect to the fastener. Undue wear would deleteriously affect such alignment.
The flat surface will eliminate the very sharp edge contact on the undersurface of a very thin workpanel 40 which could totally penetrate such a workpanel. However, the right angle edge 35 and limited surface areas of the surface 25 adjacent the outer periphery of the flange 18b will still permit the partial embedment and locking feature shown generally in FIG. 4.
Secondary surface 28b may be comprised of a pair of intersecting camming surfaces extending at different acute angles from the upper surface 20b. A camming surface 37 may be formed to intersect surface 39 with surface 39 intersecting the flat surface 25 along line 33 and lower surface 37 intersecting the flange upper surface 20b. Surface 37 will be at a greater acute angle to surface 20b than surface 39 permitting the tool to gradually descend downwardly. Surface 37 contributes to strength of the protuberance and efficient manufacture thereof.
Thus there is shown and described a double-ended stud which includes novel driving surfaces which also function as a means to lock the fastener from removal as the nut member is loosened therefrom. In addition, a particularly designed tool is shown for accomplishing the driving of a fastener into a work surface.
While particular embodiments of the present 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 this invention in its broader aspects and, therefore, the aim in the appended claims is to cover all such changes and modifications as fall within the true spirit and broad scope of the invention. | An integral stud member having shank portions extending from either side of a radially extending flange. A first shank portion including thread convolutions with means to form mating internal threads in an associated workpiece. The surface of the flange opposing the first shank including generally radially extending rib-like surfaces which serve as the means to drive the fastener in place. The rib structures are configured to permit a driver to softly engage the flange and to lock the fastener from backing out of the workpiece after a secondary work surface has been clamped over the flange. | 5 |
CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No. 60/561,435 filed Apr. 12, 2004.
BACKGROUND OF THE INVENTION
[0002] The present invention relates generally to a sound reduction control system and method for a cooling system. More specifically, the present invention relates to a system and method for reducing the sound generated by a compressor driven chiller system having a variable speed drive by selectively and controllably reducing the speed of the compressor, the speed of the condenser fans, or the number of operating condenser fans in the system.
[0003] In chiller, HVAC or refrigeration systems, a refrigerant gas is compressed by a compressor and passed to a condenser where it exchanges heat with another fluid, such as the ambient air forced over condenser coils by one or more condenser fans. From the condenser, the pressurized refrigerant passes through an expansion device and then to an evaporator. An environment to be cooled is cooled by refrigerant passing through the evaporator. The refrigerant returns from the evaporator back to the compressor, and the cycle is repeated.
[0004] Large capacity chiller systems are required to provide adequate cooling of the interiors of large buildings. Such systems typically include one or more compressors, as well as one or more air-cooled condensers having condenser fans for cooling the compressed refrigerant. Compressor speed and condenser fan speed, or number of condenser fans running, are interdependent on one another. When the compressor operates at a higher speed, a higher rate of compressed refrigerant is passed to the condenser. In order to cool the increased flow of compressed refrigerant, a larger rate of heat exchange by the condenser is required. One way to increase condenser heat exchange is to increase airflow across the condenser coils. Accordingly, operation of a higher number of condenser fans, or operation of the fans at a higher speed, will increase airflow around the condenser coils, resulting in higher rate of heat exchange by the condenser.
[0005] Increasingly, it is necessary to reduce the total sound generated by chillers during certain times, particularly for chillers installed near residential areas. Indeed, some localities have laws that require sound levels at property lines to be lower at nighttime than during the day. One known method of reducing the chiller noise is to disable the system during selected hours, thereby preventing the generation of noise by the chiller system. However, disabling the chiller system means that no cooling can be performed by the chiller systems, thus causing the interior building temperatures to rise to uncomfortable levels. Therefore, it would be advantageous for a building owner to be able to reduce the sound level of the chiller system at selected times, while maintaining some cooling capability within the building.
[0006] The sound generated by a typical air-cooled compressor chiller system is predominately created by the compressor and the condenser fans. Therefore, in order to reduce the amount of sound generated by the chiller system, it is desirable that the compressor and the condenser fan(s) be made to operate more quietly. This goal can be accomplished by several known ways. For example, mechanical modifications such as the application of sound-insulating coatings can be made to the compressor, condenser fans, and any housings encasing such components, to reduce operating noise. Alternatively, new compressors and new condenser fans manufactured with sound-absorbing or sound-attenuating features can be installed. However, such modifications or replacements can be expensive as a result of the materials, labor, and downtime costs that are potentially involved. Therefore, what is needed is a cost-effective method for selectively reducing the noise generated by an installed chiller system.
SUMMARY OF THE INVENTION
[0007] What is disclosed is a method of providing noise or sound control of a chiller, HVAC or refrigeration system. A chiller system includes a control panel, a compressor, a condenser arrangement, at least one condenser fan, and an evaporator arrangement. Upon receiving a sound control signal at the control panel, the sound control signal initiates a reduced sound control mode of operation. The reduced sound control mode of operation includes the steps of measuring an operating speed of the compressor; controllably reducing the operating speed of the compressor in response to the measured operating speed of the compressor being greater than a maximum operating speed; the maximum operating speed being directly related to the sound control signal; and measuring an operating speed of the compressor; determining an operating parameter of at least one condenser fan; and controllably altering an operating configuration of the at least one condenser fan in response to the determined operating parameter of the at least one condenser fan being greater than a maximum operating parameter; the maximum operating parameter being directly related to the sound control signal.
[0008] Also disclosed is a method of providing sound control in a chiller, HVAC or refrigeration system. The chiller system includes a compressor, a condenser arrangement, at least one condenser fan, and an evaporator arrangement. The method includes the steps of determining whether a sound control signal is received by the control panel; assigning a maximum operating speed for a motor powering the compressor responsive to said sound control signal; assigning a maximum operating parameter for the at least one condenser fan responsive to the sound control signal; determining whether the compressor and the at least one condenser fan are within a corresponding permissible range, wherein the corresponding permissible range has an upper limit of the corresponding maximum operating speed and maximum operating parameter; adjusting at least one of a) the speed of the compressor motor or b) the operating parameter of the at least one condenser fan, responsive to the determination that the compressor and the at least one condenser fan are outside the corresponding permissible range; wherein the step of adjusting the speed operates to reduce the noise generated by the chiller system.
[0009] The present invention is also directed to a chiller system. The chiller system includes a control panel, a compressor, a condenser arrangement, at least one condenser fan, and an evaporator arrangement. Also provided is means for receiving a sound control signal at the control panel, the sound control signal being configured to initiate a reduced sound control mode of operation. There is also provide means for measuring an operating speed of the compressor; and means for controllably reducing the operating speed of the compressor in response to the measured operating speed of the compressor being greater than a maximum operating speed. The maximum operating speed is directly related to the sound control signal. Also, means is provide for measuring an operating parameter of at least one condenser fan; and a means for controllably altering the operating configuration of the at least one condenser fan responsive to the sound control signal.
[0010] One embodiment of the present invention is directed to a method for reducing the sound level of a chiller system by selectively and periodically limiting the maximum operating speed of the compressor, maximum operating speed of at least one condenser fan, and/or of the number of fans to be operated.
[0011] Another embodiment of the present invention is directed to a chiller system having a control panel with a control algorithm for limiting the maximum operating speed of the compressor, and varying the speed of at least one condenser fan or adjusting the total number of operating condenser fans.
[0012] One advantage of the present invention is that the sound generated by an installed chiller system can be selectively reduced without requiring mechanical modifications to system components.
[0013] Another advantage of the present invention is that comfort cooling in the interior space is not completely sacrificed when the system is required to comply with periodic reduction of sound requirements, such as during nighttime operation.
[0014] Other features and advantages of the present invention will be apparent from the following more detailed description of the preferred embodiment, taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 illustrates schematically an embodiment of a heating, ventilation and air conditioning system for use with the present invention.
[0016] FIG. 2 illustrates a flow chart detailing one embodiment of the noise control methods of the present invention.
[0017] FIGS. 3-4 illustrate the effect of an input signal on the maximum frequency of a compressor and condenser fan in one embodiment of the present invention.
[0018] Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts.
DETAILED DESCRIPTION OF THE INVENTION
[0019] The present invention therefore provides systems and methods for selectively controlling the speed of the compressor and the condenser fans of a chiller system to reduce sound generated by the system at selected times. The selective operation of the condenser fans can include any combination of disabling one or more fans, operating less than all fans, operating one or more fans at lower fixed speed, operating one or more fans at a lower variable speed. It is noted that the control of fan speed, as it is describe below, also includes switching some or all of the condenser fans on or off.
[0020] FIG. 1 illustrates generally a chiller, HVAC or refrigeration system 100 that can be used with the present invention. An AC power source 102 supplies a variable speed drive (VSD) 104 , which powers one or more motors 106 . Each motor 106 is used to drive a corresponding compressor 108 that feeds high-pressure and high-temperature refrigerant gas to a condenser 110 . The compressor 108 is preferably a screw compressor or centrifugal compressor, however the compressor can be any suitable type of compressor including reciprocating compressors, scroll compressors, or rotary compressors. The output capacity of the compressor 108 can be based on the operating speed of the compressor 108 , which operating speed is dependent on the output speed of the motor 106 driven by the VSD 104 . The system 100 can include many other features that are not shown in FIG. 1 , and those features have been purposely omitted to simplify the drawings for ease of illustration.
[0021] The refrigerant vapor delivered to the condenser 110 enters into a heat exchange relationship with a fluid, preferably air. To assist in the passage of the air around the heat exchanger coils of condenser 110 , at least one fan 112 can be used to force or draw air over the coils of the condenser 110 . More preferably, a bank of multiple condenser fans 112 can be used. Each condenser fan 112 can be single speed, multiple fixed speed, or variable speed in nature, depending upon the type of fan and drive mechanism. In each embodiment, the condenser 110 is cooled by at least one condenser fan 112 .
[0022] The condensed liquid refrigerant from condenser 110 flows through an expansion device to an evaporator 114 . The evaporator 114 can include connections for a supply line and a return line of a cooling load. A secondary liquid, which is preferably water, but can be any other suitable secondary liquid, e.g. ethylene, calcium chloride brine or sodium chloride brine, travels into the evaporator 114 via return line and exits the evaporator 114 via supply line. The liquid refrigerant in the evaporator 114 enters into a heat exchange relationship with the secondary liquid to chill the temperature of the secondary liquid. The refrigerant liquid in the evaporator 114 undergoes a phase change to a refrigerant vapor as a result of the heat exchange relationship with the secondary liquid. The vapor refrigerant in the evaporator 114 then returns to the compressor 108 via a suction pipe 116 to complete the cycle. It is to be understood that any suitable configuration of condenser 110 and evaporator 114 can be used in the system 100 , provided that the appropriate phase change of the refrigerant in the condenser 110 and evaporator 114 is obtained.
[0023] A control panel 118 is provided to control operation of the VSD 104 to monitor and control operation of the motor 106 , thus controlling the operating speed of the compressor 108 . The control panel 118 further permits monitoring and control of the operation of each condenser fan 112 . The control panel 118 also allows interdependent and selective operation and control of the VSD 104 and motor 106 , as well as the condenser fans 112 . With respect to the selective operation of each condenser fan 112 , the control panel 118 can selectively disable each fan 112 , and can preferably adjust the operating speed of each fan 112 if the fan 112 is capable of multiple operating speeds. Fans 112 may be variable speed fans linked to a common VSD (not shown) dedicated to controlling the speed of condenser fans to allow nearly infinite adjustment of fan speed using the control panel 118 . Alternatively, where fixed speed fans are used in a bank of multiple condenser fans 112 , the fans 112 are configured so that less than all fans can be selectively operated at any given time. As another alternative, condenser fans 112 may also be commonly linked to VSD 104 along with motor 106 ; as yet another alternative, fans 112 may be multiple fixed speed fans, typically two-speed, configured to operate in various combinations of high-speed, low-speed and off.
[0024] In an alternative embodiment, the system can alternatively include two or more compressors incorporated in corresponding refrigerant circuits, and it is to be understood that the system can have one refrigerant circuit, two refrigerant circuits, or more than two refrigerant circuits for providing the desired system load and can have more than one compressor for each refrigerant circuit. Such an alternative system can further include a condenser arrangement wherein a single condenser is partitioned or otherwise configured to allow operation of two separate refrigerant circuits within a single condenser housing so that the refrigerant output by each compressor is not mixed with output from other compressors. Similarly, the system 100 can include an evaporator arrangement wherein a single evaporator housing is provided to serve two or more separate refrigeration circuits. For example, the condenser housing and evaporator housing can maintain the separate refrigerant circuits either through a partition or other dividing means with the evaporator housing, or by providing separate coil arrangements. In yet another embodiment of the present invention, the refrigerant output by two or more compressors can be combined into a single refrigerant circuit to travel through the components of the system before being separated to reenter the compressors.
[0025] Preferably, the control panel 118 includes a microprocessor or controller to provide control signals to the VSD 104 to control the operation of the VSD 104 . More preferably, the control panel 118 can control the output power of the VSD 104 to control the speed of the motor 106 , and the compressor 108 , to satisfy the sound requirements of the operating environment of the system during periods requiring reduced noise operation. Most preferably, the control panel 118 can control the VSD 104 to operate the motor 106 within a predetermined range of speed during periods requiring reduced noise operation, which has the effect of lowering the condenser discharge pressure. The reduced discharge pressure causes some or all condenser fans 112 to shut down due to the reduced cooling demand. If variable speed type condenser fans 112 are employed, one or more VSDs may be provided. Reducing the compressor speed in this instance causes the condenser fans 112 to operate at reduced speed, rather than shutting down a portion of the fans in the system.
[0026] In a preferred embodiment, the control panel 118 executes a control algorithm(s) or software to control operation of the system 100 , and to determine and implement an operating configuration for the VSD 104 to operate the compressor 108 . The control algorithm or software of the control panel also determines, implements, and controls the speed of each condenser fan 112 in order to satisfy the sound requirements of the operating environment, while still providing some condenser cooling. In one embodiment, the control algorithm(s) can be computer programs or software stored in the non-volatile memory of the control panel 118 and can include a series of instructions executable by the microprocessor of the control panel 118 . While it is preferred that the control algorithm be embodied in a computer program(s) and executed by the microprocessor, it is to be understood that the control algorithm may be implemented and executed using digital and/or analog hardware by those skilled in the art. If hardware is used to execute the control algorithm, the corresponding configuration of the control panel 118 can be changed to incorporate the necessary components and to remove any components that may no longer be required.
[0027] The reduced noise control process can be initiated in response to user input, or can be initiated automatically, such as by a preprogrammed instruction from a system primary control program. The reduced noise control process can be a stand-alone process or program, or it can be incorporated into a larger control process or program, such as a capacity control program for the chiller system. For example, the control process can be used to generate an industry standard 4-20 mA or 0-10V signal as a noise control signal to be sent to the VSD 104 to reduce the maximum allowed compressor 108 speed, as well as to limit the maximum operational speed of each condenser fan 112 . Alternately, the noise control signal can also be generated from a user interface such as a keypad on the control panel 118 , or the noise control signal can be automatically generated such as by a microprocessor control of the control panel 118 . The noise reduction control process prevents the VSD 104 from providing power at a frequency higher than the maximum value specified by the noise control signal. The noise control signal may also limit the maximum speed of at least one condenser fan 112 or the maximum number of condenser fans 112 that can operate. By limiting the maximum frequency or speed of the VSD 104 , compressor 108 and optionally, fan 112 , the system 100 is prevented from exceeding a given sound level during particular periods of operation. The sound reduction is due in part to the compressor 108 being quieter when operating at a lower speed within a predetermined speed range. The sound reduction is further due to quieter operation of condenser fan 112 as a result of lower fan speed. In alternative embodiments having multiple condenser fans 112 , the control panel 118 reduces total fan noise in noise control mode by selectively operating less than all fans 112 , or by operating all fans 112 at low speeds within a predetermined range of fan speeds permitted by the noise control signal.
[0028] In another embodiment, the control panel 118 can also allow the discharge pressure in the condenser 110 to rise during periods when a low system sound level is desired to be maintained. This is achieved by raising the pressure settings for some or all of the condenser fan(s) 112 to allow the pressure in the condenser 110 to rise during periods when a low system sound level is desired to be maintained. Increasing the pressure in the condenser will result in less cooling need in the condenser 110 , thereby allowing operation of condenser fans 112 at lower speed, and/or operation of fewer fans 112 within a multiplicity of provided condenser fans 112 . The pressure setting is adjusted electronically by the control algorithm, by changing the discharge pressure setpoint stored in the control panel. Raising of the discharge pressure setpoint reduces the need for cooling in the condenser as the condenser is allowed to run hotter and at a higher pressure.
[0029] A control program or algorithm executed by a microprocessor or control panel 118 is used to determine the speed of the compressor 108 , as well as to control other system parameters such as the operational status and speed of any condenser fans 112 . The control program can receive a variety of inputs, such as temperature, pressure and/or flow measurements, to be used in making the determination of when to reduce the speed of the compressor 104 and condenser fans 112 . It is to be understood that the particular control program and control criteria for reducing compressor speed and condenser fan speed can be selected based on the particular performance requirements of the system 100 .
[0030] In addition, the system 100 can include one or more sensors for detecting and measuring operating parameters of the system 100 . The signals from the sensors can be provided to a microprocessor or control panel 118 that controls the operation of the system 100 . Sensors can include pressure sensors, temperature sensors, flow sensors, or any other suitable type of sensor for evaluating the performance of the system 100 .
[0031] The operation of the system 100 in the reduced noise control mode is controlled by a control panel 118 . The control panel 118 can receive input signals from a microprocessor, or alternatively from a user interface, indicating a demand for reduced noise. The control panel 118 then processes these input signals using the control method of the present invention and generates the appropriate control signals to the components of the system 100 , including the VSD 104 , compressor 108 , and condenser fans 112 to obtain the desired reductions in operating speed to reduce noise generated by the components, and thus reducing the total noise generated by the system 100 .
[0032] In the preferred embodiment of the reduced noise control mode, the control panel 110 and noise control algorithm only overrides the normal capacity control features of the system when those capacity controls attempt to operate the compressor or the condenser fans above the limits imposed by the noise control algorithm. Simply put, in the noise control mode, cooling demand is still monitored, and capacity control features can respond to operate the compressors and condenser fans, but the noise control mode places an upper limit on system capacity. Cooling demand is independent of the chiller and is a function of the building or process being cooled. The noise control process of the present invention sets a maximum frequency for each compressor 108 , as well as a maximum speed or number of condenser fans 112 to be operated. Those frequency or speed limits are imposed on the capacity control algorithms, including the compressor and the condenser fan control algorithms. If those capacity control algorithms do not call for the controlled component to be operated above the provided limits, the noise control algorithm does not interfere with normal operation. However, if the system algorithms call for operating the components above the provided limits, they are overridden by the noise control algorithm.
[0033] FIG. 2 illustrates a flow chart detailing one embodiment of the reduced noise control process of the present invention for the exemplary system 100 shown in FIG. 1 . The process begins with a determination of whether a reduced noise control signal has been received in step 202 . The reduced noise control signal is either generated automatically such as by a microprocessor controller, timer, or user interface linked to the control panel 118 . The noise control signal can be preset or variable, and is based upon the noise profile and properties of the particular system 100 . Preferably, the noise control signal is variable so as to allow for selective reduction of total noise generated by the system and corresponding cooling effect in the reduced noise mode. More preferably, the noise control signal is variable and is automatically initiated at predetermined times and for predetermined periods. The relationship between system noise and the speed of the compressor 108 and condenser fan 112 will vary depending upon the type and number of compressors 108 and fans 112 incorporated into the system 100 . For example, FIGS. 3-4 illustrate an exemplary relationship between the maximum VSD frequency for a standard 4-20 mA input and a standard 0-10V input on a compressor 108 having a 200 Hz maximum running frequency. For each chiller system 100 , a similar relationship can be derived between sound level and operating frequency of the compressor 108 and condenser fans 112 to determine the effect of operating at given frequencies on the sound level generated by the chiller system 100 .
[0034] If a reduced noise control signal is not received in step 202 , the system 100 operates in normal mode based upon heating and cooling demand and other system control inputs. However, if a reduced noise control signal is received, the system enters noise control mode, and the process continues to step 204 . In step 204 , the control panel 118 processes the noise control input signal to assign a corresponding maximum operating speed or frequency to the compressor 108 , as well as to assign a corresponding maximum speed or frequency for the condenser fan 112 or the maximum number of fans to operate. Preferably, this variable noise control signal is generated via a straight line but can be based on any function, equation, or lookup table. When the minimum sound control signal is received in step 202 , the compressor maximum speed is allowed to reach an upper speed limit, which may correspond to the maximum speed of the compressor. The minimum sound control signal generally provides the least amount of sound reduction. When the maximum sound reduction signal is received in step 202 , the compressor maximum speed is reduced down to its minimum speed. All other sound reduction signal inputs in step 202 fall on the straight line connecting the two points, as in FIGS. 3 and 4 .
[0035] In one aspect of the system, the level of the noise control signal may be determined over the range of operating frequencies. The maximum motor operating frequency is a characteristic of the make and model of the various compressor or fan motor(s). The minimum motor operating frequency for the motor(s) is normally approximately 50 Hz. After determining the span of the frequency range associated with the analog signal, the sound levels along the range may be plotted by measuring the sound level at each operating frequency. Preferably the operating frequency may be referenced as a percentage of the maximum speed of the motor or motors by a control algorithm. A table may be constructed from the plotted sound measurements of the actual decibel level of a specified operating frequency, or for the corresponding percentage of maximum speed.
[0036] In this way, the system operator may select the level of the noise control signal to be applied when the system is in noise control mode, by reference to a table or graph representation of the noise versus frequency profile. If a desired noise level is known by the operator, the associated operating frequency may be selected, for setting the noise control signal level. Such a table may optionally be stored on a memory storage device accessible by the control panel, and a user input device may be provided either at the control panel or at a remote terminal, for entering a desired parameter, for example, the desired maximum decibel level or the maximum operating frequency. The control panel may then establish a level for the noise control signal by referencing the value of the input parameter in the table.
[0037] In the preferred embodiment, the control panel 118 processing includes relaying the processed noise control signal to a common VSD 104 configured to permit interdependent control of the speed of the motor 106 , and thus the speed of the compressor 108 . The condenser fan 112 may be controlled by a separate VSD, or a plurality of condenser fans 112 may be provided having any combination of either fixed speed fans, variable speed fans, or both so as to permit adjustable control of airflow across the condenser 110 by controlling the number and speed of operating fans 112 . If more than one variable speed condenser fan is used, two or more fans 112 may be controlled by a common VSD, or each condenser fan may be controlled by a separate VSD.
[0038] The process continues to step 206 to determine whether the current rate of speed of the compressor 108 and the speed or number of the condenser fans 112 are within a predetermined range permitted by the reduced noise control signal received in step 202 . If the compressor 108 and condenser fan 112 of the system 100 are operating within the operational speed range permitted by the reduced noise control signal received in step 202 , no adjustments are made to the speed of the compressor 108 and condenser fans 112 , and the system operates in the “normal” mode. If the compressor or any fans are operating above the permitted maximum speed, the process continues to step 208 , where the control panel adjusts the speed of the compressor 108 and/or fans 112 , to a speed that is equal to or less than the maximum speed permitted by the noise control signal. In a preferred embodiment, in step 208 , the control panel 110 continues to monitor system pressures and temperatures, such as discharge pressure and leaving chilled liquid temperature, and can adjust the speed of the compressor 108 as well as the speed of any condenser fan 112 within the operating range at or below the maximum speeds allowed by the control input signal in order to control the system 100 . By maintaining stable operation of the compressor 108 in the reduced noise mode, the system 100 maintains some cooling while operating in the reduced noise mode. In another embodiment of the reduced noise mode, in step 208 , the system 100 can permit the condenser fan 112 to initially operate at speeds in excess of the maximum operating speed permitted by the noise control signal until such time as the system temperature and pressures have stabilized for the lower operating speed of the compressor 108 .
[0039] The process next returns to step 202 to determine if a reduced noise control signal remains present. If the noise control signal remains present, the above-described process is repeated. If the noise control signal is not detected, the system returns to normal operating mode where it can respond to heating and cooling demands.
[0040] The control panel 118 determines whether there is a noise control signal present at least once during every control program loop. The various types of noise control signal include remote signal, programmed value, or other types as discussed above. If the noise control signal changes state, by increasing, decreasing or going away, the control algorithm makes a corresponding adjustment to the maximum speed of the compressor 108 . Preferable, a timer is associated with the remote system to restrict the number of adjustments that can be made to the chiller system by the remote system in a predetermined time period. For example, the timer may prevent the remote system from changing the noise control signal more often than the timer cycle, which cycle may vary from 5 minutes to 60 minutes. The timer cycle could be more or less than that range, if suitable for the design parameters of the particular chiller system. The timer prevents the chiller system from becoming unstable due to more frequent changes of the noise control signal and the system parameters affected by the noise control signal.
[0041] In another embodiment of the present invention, the user of system 100 can view the control panel 118 , such as by viewing a connected user interface (not shown) to determine the particular system operating mode. For example, if an LED provided on the control panel 118 or user interface is flashing, then the system 100 can be in noise control mode despite any demand for cooling or heating. However, if the LED on the control panel 118 or user interface is not flashing, the system 100 can be in normal operating mode to respond to any demand for cooling or heating. It is to be understood that the display method on the control panel 118 or user interface can be modified for the particular requirements or needs of the user.
[0042] As noted above, in the typical chiller system, the refrigerant vapor delivered to the condenser 110 enters into a heat exchange relationship with a fluid, preferably air. For purposes of the present invention, if heat exchange is effected by a fluid other than air, e.g., a liquid, then the system would not use fans, and noise control is be accomplished solely by regulating the frequency of the compressor motor and, thus, the speed of the compressor.
[0043] While the invention has been described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims. | A noise control method is provided for a cooling system having at least one refrigerant circuit. The refrigerant circuit includes a compressor, a condenser, at least one condenser fan, and an evaporator. Noise control is only performed periodically in response to requirements for reduced operation at predetermined times. The request for reduced noise triggers the commencement of the noise control method. The noise control method involves reducing the operating speed of the compressor, as well as reducing the operating speed of at least one condenser fan, to within a predetermined range of allowable reduced operating speeds. The noise control method temporarily overrides the ability of the cooling system to fully respond to increased cooling or heating demands. When the noise control method is terminated, such as by the end of the stated period of time requiring reduced noise generation, the system is restored to normal operation, and remains fully responsive to cooling and heating demand until commencement of the next period of reduced noise requirements. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a cognitive capacity measurement device and cognitive capacity measurement method that measures the unique cognitive capacity of individuals in order to contribute to research on brain function.
2. Description of Related Art
In the past, various intelligence tests and aptitude tests such as those indicated in Japanese Examined Patent Application Publication No. Hei 06-046989 and U.S. Pat. No. 2,506,023 were proposed as methods to measure human aptitude and capacity, and were used for education, employment and welfare, etc.
SUMMARY OF THE INVENTION
In this regard, attention is not directed toward the micro-mechanisms of the brain, and therefore, although these methods can measure the differences between individuals, the results obtained for each individual cannot reflect the brain activity involved, and for that reason, the legitimacy of the methods cannot be explained from the perspective of brain function.
Meanwhile, when showing multiple subjects a variety of images to which specified processing had been conducted and measuring the time required in order to recognize the related content, the present inventor discovered the heretofore completely unknown fact that the order of subjects based on the recognition time did not depend on the type of image, and hardly fluctuated at all; and at the same time, the order of images based on recognition time did not depend on the subjects, and hardly fluctuated at all. Close scrutiny also revealed that the frequency distribution of the number of subjects in relation to the logarithm of the recognition time of the images could approximate a normal distribution, and that the standardized scores of the subjects were nearly fixed irrespective of the type of image. Then, the present inventor identified the fact that the unique cognitive capacity of each subject and the unique challenge level of the image could be quantified into the two variables of the cognitive capacity score and the challenge level parameter respectively, and demonstrated that a specific relation expression could be established between these and the recognition time.
Further, because a simple transformation of this relation expression has the same form as the relation expression for chemical reaction velocity, the present inventor believes that the cognitive capacity score and the challenge level parameters derived by the aforementioned method reflect brain function, suggesting the possibility that a new understanding of the mechanisms of the brain could be obtained by analogy with thermodynamics.
The present invention addresses the problems of using these facts to establish a method to measure the cognitive capacity to reconstruct from incomplete data original data explainable by correspondence to brain function, of applying these results to conduct research on brain function, and, in the future, of selecting and determining the suitability of training appropriate to each individual, and of contributing to early detection, etc. of diseases related to cognitive function such as Alzheimer type dementia.
Specifically, the cognitive capacity measurement device related to the present invention is characterized by comprising: an image display unit that has a function to display to a subject a degraded image that is an image in which degradation of the data for recognizing a significant photographic object has been caused by conducting a specified process on an original image having a significant photographic object; a receiving unit to receive from the subject the fact that the aforementioned photographic object has been recognized, and to output the reception signals; a recognition time calculator that receives the aforementioned reception signals from this receiving unit and calculates the recognition time, which is the time the subject requires to recognize the aforementioned photographic object; a challenge level data memory unit that memorizes the challenge level data, which is data related to the challenge level of the aforementioned degraded image in conjunction with recognition of the photographic object; and a cognitive capacity computer that conducts specified computations using the aforementioned recognition time calculated by the aforementioned recognition time calculator and the aforementioned challenge level data memorized in the aforementioned challenge level data memory unit, and that calculates the cognitive capacity score, which is an index that digitizes the cognitive capacity of each subject. Here, significant photographic object means a photographic object that the subject can express with words.
When this kind of device, the cognitive capacity scores of individuals can be measured using a simple configuration, and moreover, the results can be explained corresponding to brain function. Further, the results can play a role in brain function research, and in the future can be used in the selection and determination of the suitability of training appropriate to each individual, and can be used in early detection, etc. of diseases related to cognitive function such as Alzheimer type dementia.
It has been confirmed that the frequency distribution of the number of subjects in relation to the logarithm of the recognition time of the degraded image acquired from multiple subjects approximates a normal distribution curve, and it appears that the standardized scores of subjects on this normal distribution express the cognitive capacities of the subjects. Moreover, because it appears that the shorter the recognition the higher the cognitive capacity, it is easier to understand and thus preferable to invert the sign of the numerical value of the standardized score and to use this number as the cognitive capacity score.
A preferable method to calculate recognition time can eliminate such factors as the physical reflex velocity of the subject by subtracting the time required for the original image from the time required for the degraded image.
Because the cognitive capacity score is unique to the individual, to effectively use this cognitive capacity score in training, etc., it is preferable to further provide a cognitive capacity memory unit that relates and memorizes the aforementioned cognitive capacity score and a subject identifier.
To improve the reliability of the measured results, it is desirable that the aforementioned image display unit selectively displays multiple types of images, and that the aforementioned cognitive capacity calculator calculate the cognitive capacity score from various recognition times obtained for each of the aforementioned degraded images.
As a specific embodiment, it is preferable to further provide an output device to output the aforementioned cognitive capacity scores.
It is preferable to segment the aforementioned original image to make aforementioned degraded image. This kind of image can be easily produced in large quantities, and the challenge level can be adjusted by adjusting the threshold value.
Moreover, in order to calculate the aforementioned challenge level data of the degraded images used in cognitive capacity measurements, a cognitive capacity measurement device of degraded images may be used that provides: an image display unit that has a function to display to a subject these degraded images; a receiving unit to receive from the subject the fact that the aforementioned photographic object has been recognized, and to output the reception signals; a recognition time calculator that receives the aforementioned reception signals from this receiving unit and calculates the recognition time, which is the time the subject requires to recognize the aforementioned photographic object; a recognition time data memory unit to memorize the respective recognition time data, which are data relating the aforementioned recognition times of multiple subjects that are calculated by this recognition time calculator; and a challenge level data computer that calculates challenge level data, which is data related to the challenge level of the aforementioned degraded image in conjunction with recognition of the photographic object, by obtaining the aforementioned recognition time data memorized in this recognition time data memory unit and approximating the aforementioned recognition time distribution form using a specified function.
Because experiments have confirmed that the frequency distribution of the number of subjects in relation to the logarithm of the recognition time of the degraded image acquired from multiple subjects closely approximates a normal distribution, it is possible to take the data that specifies this normal distribution as the challenge level data of the degraded image. Moreover, experiments have revealed that the standard deviation of this normal distribution can be approximated by a linear function of the mean value, and therefore this mean value can be used as the challenge level parameter. This way, the challenge level of the degraded image can be expressed by one variable, and the challenge levels of various degraded images are easy to compare.
Because the challenge level data is of unique degraded images, to effectively use this challenge level data in cognitive capacity measurements, it is preferable to further provide a challenge level data memory unit to relate and memorize the aforementioned challenge level data with a degraded image identifier.
According to the present invention, it is possible to measure the cognitive capacity to reconstruct original data from incomplete data. Moreover, the cognitive capacity score obtained by this method can explain the correlation to brain function, and therefore it is possible for these results to play a role in research on brain function. Further, in the future it will be possible to select and determine the suitability of training appropriate for each individual, and to contribute to the early discovery of diseases related to cognitive function such as Alzheimer type dementia.
BRIEF DESCRIPTION OF THE DRAWINGS
The objects and features of the present invention, which are believed to be novel, are set forth with particularity in the appended claims. The present invention, both as to its organization and manner of operation, together with further objects and advantages, may best be understood by reference to the following description, taken in connection with the accompanying drawings.
FIG. 1 is a schematic configuration diagram of a challenge level measurement device of a first embodiment of the present invention;
FIG. 2 is an explanatory diagram of an image displayed in the same embodiment;
FIG. 3 is a schematic configuration diagram indicating the internal configuration of a data processing device of the same embodiment;
FIG. 4 is a functional block diagram of a data processing device of the same embodiment;
FIG. 5 is a data structure diagram indicating the internal data of a subject data memory unit of the same embodiment;
FIG. 6 is a data construction diagram indicating the internal data of an image data memory unit of the same embodiment;
FIG. 7 is a data construction diagram indicating the internal data of a recognition time data memory unit of the same embodiment;
FIG. 8 is a data construction diagram indicating the internal data of a challenge level data memory unit of the same embodiment;
FIG. 9 is a flowchart indicating the operational steps of a challenge level measurement device of the same embodiment;
FIG. 10 is a schematic configuration diagram of a challenge level measurement device of a second embodiment of the present invention;
FIG. 11 is a functional block diagram of a data processing device of the same embodiment;
FIG. 12 is a data structure diagram indicating the internal data of a cognitive capacity memory unit of the same embodiment;
FIG. 13 is a flowchart indicating the operational steps of a challenge level measurement device of the same embodiment;
FIG. 14 is a cumulative histogram indicating the results of experiment 1 conducted using the challenge level measurement device of the first embodiment of the present invention;
FIG. 15 is part of the challenge level parameters that were calculated from the results of experiment 1 conducted using the challenge level measurement device of the first embodiment of the present invention; and
FIG. 16 is a diagram representing the results of experiment 2 conducted to confirm the reliability of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Reference will now be made in detail to the preferred embodiments of the invention which set forth the best modes contemplated to carry out the invention, examples of which are illustrated in the accompanying drawings. While the invention will be described in conjunction with the preferred embodiments, it will be understood that they are not intended to limit the invention to these embodiments. On the contrary, the invention is intended to cover alternatives, modifications and equivalents, which may be included within the spirit and scope of the invention as defined by the appended claims. Furthermore, in the following detailed description of the present invention, numerous specific details are set forth in order to provide a thorough understanding of the present invention. However, it will be obvious to one of ordinary skill in the art that the present invention may be practiced without these specific details. In other instances, well known methods, procedures, components, and circuits have not been described in detail as not to unnecessarily obscure aspects of the present invention.
Embodiment 1
The present embodiment was made in order to calculate the unique challenge level parameter of an image from a frequency distribution of test results of multiple subjects in relation to a logarithm of the recognition times of the photographic object of the degraded image. FIG. 1 is a schematic configuration diagram indicating the challenge level measurement device of the present embodiment. This challenge level measurement device comprises: an image display unit 1 that displays to a subject for a specified time an original image having a significant photographic object and a degraded image that is an image in which specified processing has been conducted on the aforementioned original image to alter the original image so that only a part of the original image remains in the data for providing the aforementioned photographic object has been degraded; a receiving unit 2 to receive from the subject an input that the aforementioned photographic object has been recognized; and a data processing device 3 that receives the reception signals from this receiving unit 2 and conducts specified data processing based thereon.
The image display unit 1 is configured using a display 104 , and is communicably connected to the aforementioned data processing device 3 in this embodiment, and displays one of the aforementioned original images or aforementioned degraded images based on commands from the data processing device 3 . The aforementioned original images and aforementioned degraded images are, for example, like those indicated in FIG. 2 .
The receiving unit 2 uses, for example, a push button type switch like that indicated in FIG. 1 , and when the subject pushes the aforementioned switch, a reception signal is output. Further, the subject responds with the photographic object prior to pressing the aforementioned switch, and if this response is incorrect, the operator conducts processing that makes that response invalid.
As indicated in FIG. 3 , in addition to the CPU 101 , the data processing device 3 comprises a volatile memory and a memory device such as an HDD 102 , and further has an input units 103 that are a mouse and keyboard, etc., and an input/output interface 105 , etc. for connecting to the aforementioned display 104 . Then, a specified program is installed in the aforementioned memory device, the CPU 101 and the peripheral devices are coordinated based on this program, and as indicated in the functional block diagram in FIG. 4 , this data processing device 3 is comprised to manifest the functions of a subject data acquisition unit 11 , a subject data memory unit D 1 , an image data memory unit D 2 , an image display control unit 12 , a recognition time calculator 13 , a recognition time data memory unit D 3 , a challenge level data calculator 14 , a challenge level data memory unit D 4 , etc.
Further, the aforementioned image display unit 1 , receiving unit 2 , and data processing device 3 do not have to be provided in a physically separated manner, and may be configured and used in a single unit such as, for example, a lap top computer.
Each unit will be described concretely in detail.
The subject data acquisition unit 11 receives the subject data such as the age, sex and name of the subject, provides the received subject data with an identifier (number, etc.) for identifying the subject (refer to FIG. 5 ), and stores these in the subject data memory unit D 1 provided in a specified region of the aforementioned memory device.
The image data memory unit D 2 is provided in a specified region of the aforementioned memory device, and as indicated in FIG. 2 , relates and stores the image data for displaying the various images to an image identifier for identifying the various images (refer to FIG. 6 ).
The image display control unit 12 displays the various images by using control signals to control the image display unit 1 based on the image data memorized in the aforementioned image data memory unit D 2 , and also outputs display signals to the recognition time calculator 13 .
The recognition time calculator 13 calculates the time the subject requires to look at the degraded image and to recognize the photographic object. In the present embodiment, the recognition time calculator is configured to receive display signals from the aforementioned image display unit 12 and reception signals from the reception unit 2 , to measure the times required from displaying the image to the subject pressing the switch for the degraded image and for the original image thereof, and to calculate the recognition time by subtracting the time required for the original image from the time required for the degraded image. This eliminates such factors as the physical response velocity of the subject. The calculated recognition times are related to the image identifier and the subject identifier, and stored in a specified format in the recognition time data memory unit D 3 (refer to FIG. 7 ).
The challenge level data calculator 14 receives recognition time data from the recognition time data memory unit D 4 , finds a normal distribution in the frequency distribution of the number of subjects in relation to the logarithm of the recognition time for every image, and for example, outputs the mean value m and the standard deviation σ of this normal distribution as the challenge level data.
Here, the normal distribution is represented by the formula 1 below.
f
(
x
)
=
1
2
π
σ
exp
(
-
(
x
-
m
)
2
2
σ
2
)
[
Formula
1
]
Further, because experiments by the present inventor revealed that the standard deviation σ can be approximated by the linear function of the mean value m, only the mean value m may be output as the challenge level data. The present inventor named this mean value m the challenge level parameter. This challenge level parameter is equivalent to the recognition time in logarithmic time in which half of the subjects recognize the photographic object, and is an index that expresses the cognitive difficulty of the degraded images.
The challenge level data memory unit D 4 relates and memorizes the challenge level data calculated by the challenge level data calculator 14 to the image identifier (refer to FIG. 8 ).
Next, the action of this device will be briefly explained by referring to FIG. 9 .
First, the operator manipulates the input unit to enter the subject data.
The subject data acquisition unit 11 receives the subject data input in this way (step S 1 ), and stores this in the subject data memory unit D 1 (step S 2 ).
Next, one of the degraded images or original images is displayed by the mage display unit 1 based on the command of the image display controller 12 (step S 3 ).
Meanwhile, the subject looks at the displayed image, responds regarding that photographic object, and the fact that the photographic object has been recognized is entered by manipulating the receiving unit 2 (step S 4 ).
The recognition time calculator 13 receives the display signals from the image display controller 12 and the reception signals from the receiving unit 2 , acquires the required time, relates the required time data to the image identifier and the subject identifier, and memorizes this in the required time data memory unit not indicated in the diagram (step S 5 ). When the required time data has been memorized or the specified time limit has lapsed, then steps S 3 to S 6 are repeated for all of the images.
After completing the tests for all of the images, the recognition time calculator 13 receives the required time data from the aforementioned required time memory unit, calculates the recognition time by subtracting the corresponding original image required time from the degraded image required time (step S 7 ), and memorizes this as the recognition time data in the recognition time data memory unit D 3 (step S 8 ).
The test above is repeated for all of the subjects. (Step S 9 )
After completing the tests for all of the subjects, the challenge level data calculator 14 acquires the recognition time data from the recognition time data memory D 3 , fits the frequency distribution of the number of subjects to the logarithm of the recognition time for every image into a normal distribution, calculates, for example, the mean value m and standard deviation σ of this normal distribution as the challenge level data (step S 10 ), and relates the data to an image identifier and stores this in the challenge level data memory unit D 4 (step S 11 ).
Embodiment 2
The present embodiment is configured so that the cognitive capacity of the subject is measured using challenge level data calculated by Embodiment 1. FIG. 10 is a schematic configuration diagram indicating the cognitive capacity measurement device of the present embodiment. In the same way as in Embodiment 1, this cognitive capacity measurement device comprises: an image display unit 1 that displays to a subject for a specified time an original image having a significant photographic object and a degraded image that is an image in which specified processing has been conducted on the aforementioned original image and the data for recognizing the aforementioned photographic object has been degraded; a receiving unit 2 to receive from the subject the fact that the aforementioned photographic object has been recognized; and a data processing device 3 that receives the reception signals from this receiving unit 2 and conducts specified data processing based thereon.
Here, the subject in the present embodiment is not limited to subjects for whom the recognition time is measured in order to calculate the challenge level in Embodiment 1, and may be other people. Specifically, this cognitive capacity measurement device is effective for subjects who do not contribute to the calculation of challenge level data, and if the recognition times are measured and the challenge level data of images are calculated for sufficiently many subjects according to Embodiment 1, the cognitive capacities of new subjects can be calculated using these images.
The various parts of the present embodiment will be described in detail while referring to FIG. 11 , which is a functional block diagram of the data processing unit 3 in the present embodiment, and because there are many parts of the present embodiment that are the same as in Embodiment 1, the description will be confined to the points of difference from Embodiment 1, namely, the challenge level data memory unit D 4 , the cognitive capacity calculator 15 , the cognitive capacity memory unit D 5 , and the output unit 16 .
The challenge level data memory unit D 4 relates and memorizes the challenge level data calculated in Embodiment 1 with an image identifier.
The cognitive capacity calculator 15 uses the recognition time data of the subject memorized in the recognition time data memory unit D 3 and the challenge level data memorized in the challenge level data memory unit D 4 to calculate the capacity score s of the subject based on the following Formula 2. Here, t is the recognition time, and m and σ are the challenge level data of the corresponding image, specifically, the mean value and standard deviation of the aforementioned normal distribution. The sign of the value called the standardized score is generally inverted to make this capacity score. The standardized score indicates the position at which the subject in question stands within the group of subjects that contributed to the challenge level data calculation in Embodiment 1. The present inventor discovered by experiment that the standardized score of a given subject is a nearly fixed value independent of the image. This indicates that this standardized score is an index of the cognitive capacities of the subjects. The capacity score is made by inverting the sign of the standardized score because it appears that the shorter the recognition time, the higher the cognitive capacity. For example, a subject positioned exactly at the mean would have a capacity score of 0. Further, in order to improve reliability, measurements based on multiple images are necessary, and therefore, in this case the mean value of the capacity scores calculated for every image shall be taken as the capacity score of the subject in question.
s
=
-
log
t
-
m
σ
The cognitive capacity memory unit D 5 relates and memorizes the cognitive capacity score calculated by the cognitive capacity calculator 15 with the subject identifier (refer to FIG. 12 ).
The output unit 16 uses a display or printer, etc. to output the cognitive capacity scores memorized in the cognitive capacity memory unit D 5 .
Next, the action of this device will be briefly explained by referring to FIG. 13 .
Steps S 1 to S 8 are the same as in Embodiment 1. Moreover, when calculating the cognitive capacity of a subject for whom the recognition time has already been measured in Embodiment 1, this operation may be omitted because the recognition time data memorized in the recognition time data memory unit D 3 may be used.
The cognitive capacity calculator 15 calculates the cognitive capacity score of the subject from the recognition time data memorized in the recognition time data memory unit D 3 and the challenge level data memorized in the challenge level data memory unit D 4 (step S 12 ), and stores this in the cognitive capacity memory unit D 5 (step S 13 ).
The output unit 16 outputs the cognitive capacity score (step S 14 ).
In this way, the challenge level parameters of the images are calculated by Embodiment 1, and the cognitive capacity scores of the subjects are calculated by Embodiment 2. By analogy with thermodynamics, the present inventor has indicated as follows the fact the challenge level parameter and the cognitive capacity score derived in this way reflect brain function. Specifically, the following relational equation Formula 3 may be established between the challenge level parameter, the cognitive capacity score and the recognition time. Here, A and B are constants derived by experiment.
t=A exp( m (1− Bs )) Formula 3
The recognition velocity v shall be the reciprocal of this recognition time t, and if S=1−Bs, the following Formula 4 is established.
v
=
1
t
=
1
A
exp
(
-
mS
)
[
Formula
4
]
This equation has the same form as the chemical reaction velocity equation represented in Formula 5 below. Here, v0 is the initial velocity, ΔE is the activated energy, k B is Boltzmann's constant, and T is the temperature.
v
=
v
0
exp
(
-
Δ
E
k
B
T
)
[
Formula
5
]
From the correspondence of these relational equations, the present inventor thinks that the cognitive capacity score of the subject corresponds to the temperature, that is, to the way that the number of micro-states increase, and the challenge level parameter of the images corresponds to the active energy. Further, the present inventor believes that the capacity score probably plays a role like the temperature of the search activity of the data space (memory space), and this suggests the possibility that new discoveries regarding brain function could be obtained by considering an analogy with thermodynamics.
In this way, according to the present invention, it is possible to digitize the cognitive capacity of the individual and the challenge level of the image by the heretofore unknown simple method of measuring recognition time of degraded images. Moreover, because the relational equation that determines the recognition time has been demonstrated, it will be possible to obtain new discoveries regarding brain function based on further research using the present invention. The present invention may also contribute to research on brain function, and in the future may be expected to play a role in the selection and determination of the suitability of training appropriate to individuals, and in the early discovery of illnesses related to cognitive function such as Alzheimer type dementia, etc.
Next, experiments will be explained in which the challenge level parameters and capacity scores were actual calculated according the present invention.
<Experiment 1> Calculation of the Challenge Level Parameter
The recognition times of 91 subjects (20 to 24 years) were measured using 90 groups of images, and the challenge level parameters of the images were calculated. FIG. 14 indicates the cumulative frequency distribution of the subjects in relation to the logarithm of the recognition times.
FIG. 15 indicates one part of the challenge level parameters of the images calculated in the experiment.
In addition, from the results of the experiment the approximation equation of Formula 6 below was obtained as an approximation equation that is established between the standard deviation a and the challenge level parameter m.
σ=0.315 m+ 0.443 Formula 6
<Experiment 2> Study of Calculated Capacity Scores
The measured values of the recognition times for images with pre-known challenge levels that were not used when calculating the capacity scores were compared with the estimated values obtained from Formula 3 in regard to subjects with calculated capacity scores. Here, the estimated value of the recognition times obtained from Formula 3 were A=0.0305 seconds and B=0.031 seconds.
FIG. 16 indicates the relationship between the estimated values and the measured values of the recognition times for two subjects with differing capacity scores. The straight line indicating the estimated values represented in the diagram and the distribution of the point groups indicating the measured values demonstrate that the recognition times are effectively estimated.
Further, the present invention is not limited to the embodiments above. For example, the accuracy in the calculation of the challenge level parameters and the capacity scores could be improved by suitably eliminating data that differs from the trends at the extremes.
In addition, the median value may be used as the challenge level parameter to calculate the challenge level parameters. The median value is generally not affected by extreme values, and is satisfactory.
The present invention may have a variety of other forms within the range that does not deviate from the purpose thereof.
Those skilled in the art will appreciate that various adaptations and modifications of the just-described preferred embodiment can be configured without departing from the scope and spirit of the invention. Therefore, it is to be understood that, within the scope of the amended claims, the invention may be practiced other than as specifically described herein. | A cognitive capacity measuring device utilizes an image display unit for displaying different kinds of images that have been degraded from an original photographic object. A subject can provide an input when he/she discerns the photographic object in the degraded image. Recognition time periods are recorded and matched with predetermined challenge level data parameters to calculate a cognitive capacity of the subject. A statistically significant number of test subjects provide recognition times relative to a specific degraded image so that a normal distribution from a frequency distribution of the number of subjects in relationship to a logarithm of the recognition times can be determined. The normal distribution along with the challenge level parameters can provide an indication of the subject's cognitive capabilities. | 0 |
CROSS REFERENCE TO RELATED APPLICATIONS
This is a continuation of application Ser. No. 897,105, filed Apr. 17, 1978 and now abandoned, which is a divisional of application Ser. No. 783,806, filed Apr. 1, 1977 and now U.S. Pat. No. 4,113,866.
SUMMARY OF THE INVENTION
This invention pertains to some new organic chemical compounds that are active as analgesics. The invention is more particularly directed to some new 1,4-diamino-1-arylcyclohexanes and mono- or di-acid addition salts thereof; to an integral process for preparing the same; and to a method of, and formulations for relieving pain, regardless or origin, in animals and humans.
The new 1,4-diamino-1-arylcyclohexanes are represented in their free base form by the following formula I: ##STR4## wherein R 1 is a variable consisting of hydrogen, alkyl of from 1 to 8 carbon atoms, CH 2 -alkenyl wherein alkenyl is from 2 to 4 carbon atoms, inclusive, cycloalkyl of from 3 to 6 carbon atoms, inclusive, cycloalkylmethyl of from 3 to 6 carbon atoms, inclusive, R 2 is a variable consisting of hydrogen, alkyl of from 1 to 8 carbon atoms, inclusive, with the proviso that R 1 and R 2 cannot both be hydrogen at the same time; Y is a variable consisting of alkyl of from 1 to 4 carbon atoms, inclusive, halogen, trifluoromethyl, hydroxy, alkanoyloxy from 2 to 5 carbon atoms, inclusive, alkoxy of from 1 to 4 carbon atoms, inclusive, cycloalkyloxy of from 3 to 6 carbon atoms, inclusive, benzyloxy; m is an integer 0, 1, 2; R 5 is a variable consisting of hydrogen and alkyl of from 1 to 4 carbon atoms, inclusive; R 3 is a variable consisting of alkyl of from 1 to 4 carbon atoms, inclusive; R 4 is a variable consisting of alkyl of from 1 to 4 carbon atoms, inclusive, CH 2 -alkenyl wherein alkenyl is from 2 to 4 carbon atoms, inclusive, and arylalkyl wherein alkyl is from 1 to 4 carbon atoms, inclusive, and aryl is ##STR5## wherein Y'=CF 3 , halogen, alkyl of 1 to 4 carbon atoms, inclusive, and alkoxy of from 1 to 4 carbon atoms, inclusive; and R 3 and R 4 when taken together with the nitrogen atom to which they are attached can form saturated heterocycles of from 5 to 7 ring members, one of said ring members can be a heteroatom such as oxygen or nitrogen, and said heterocycles can be monosubstituted having a total of up to 9 carbon atoms, with the proviso that when ##STR6## is pyrrolidinyl, then m=1, 2.
DETAILED DESCRIPTION OF THE INVENTION
As stated, the invention includes the acid addition salts of the new, free base 1,4-diamino-1-arylcyclohexanes of Formula I. For the analgesic action discovered, the preferred acid addition salts will be the physiologically acceptable ones. This not only means that the anion of the salt should not interfere with the analgesic action of the characteristic molecule as a free base, but it should also be free from undesirable side effects and toxic action at the dosages administered.
In standard laboratory animal tests for analgesia the preferred compounds of this invention show analgetic activity of a similar order to meperidine hydrochloride.
The physiologically acceptable acid addition salts useful for pharmacologic purposes, e.g., analgesia, are obtained by neutralizing the free bases with acids according to conventional procedures. For example, the free base compounds can be treated with at least a stoichiometric amount of an acid; and depending upon the nature of the solvent employed, the desired acid salt will precipitate spontaneously or can be made to precipitate by the addition of a solvent in which the acid salt is insoluble. Acid addition salts can also be prepared metathetically by reacting one acid addition salt with an acid which is stronger than the anion of the salt.
Representative, suitable acids for physiologically acceptable acid addition salts include mineral acids such as sulfuric, hydrochloric, hydrobromic, nitric, and phosphoric; and organic acids such as acetic, propionic, benzoic, p-toluenesulfonic, salicylic, pamoic, tartaric, citric, and succinic.
On occasion, the free bases or their acid addition salts in their crystalline state are isolated as solvates, i.e., with a discreet quantity of solvent such as water, ethanol, and the like, associated physically and thus removable without effective alteration of the chemical entity per se.
The free base compounds of the invention as depicted structurally by Formula I are prepared by heating and reacting a 4-amino-4-arylcyclohexanone with a secondary amine in the presence of acid catalyst and an inert organic solvent medium. p-Toluenesulfonic acid is a preferred catalyst, and the heating is preferably in the range of 80° to to 120° C. although higher and lower temperatures can be used. Representative suitable organic solvent media include benzene (preferred), toluene and xylene. The reflux temperature of the reaction mixture is convenient, and water produced by the reaction can be removed as it is formed as the benzene:water azeotrope.
The reaction product is the enamine, and any secondary amine could be used. Titanium trichloride can be used as catalyst, in the case of less reactive secondary amines.
The enamine is reduced to the desired 4-amino product with, for example, sodium borohydride in alchol, or diborane in aprotic solvents such as tetrahydrofuran or ether. The 1,4-diamine can exist as cis and trans stereoisomers. The substituent at the 3-position (R 5 ) can also exist in a cis or trans configuration relative to the 1- or 4-amino functionalities. These possibilities are denoted by the wavy bonds in Formula I (˜). The symbol is intended to include both stereoconfigurations.
R 5 when other than hydrogen can be introduced into position 3 by reaction at the ketone stage with alkyllithium in inert solvent followed by reaction with alkyl halide, preferably alkyl iodide.
The compounds of formula I when prepared by the methods disclosed herein are found in a cis-trans mixture; one of the isomers is present in greater proportion than the other, and these can be separated by conventional means. The means of separation practiced in this invention is chromatography on a silica gel column using as eluants solvent mixtures of increasing polarity. The active (analgetic) stereoisomer is the less polar component of the product mixture.
When R 5 is a substituent other than hydrogen, three ring carbon atoms (numbers 1, 3 and 4) possess chirality (are asymmetric), and thus the compound can also exhibit optical isomerism (dextro and levo isomers for each stereoconfiguration). These optical isomers can be resolved by methods known in the art, using commercially available optically active acids, e.g., (+)-tartaric acid, or bis-p-toluoyltartaric acid.
The product diamines of Formula I are recovered and purified by conventional techniques of solvent evaporation, chromatography, and crystallization. Variations of the recovery and purification procedures described as the best embodiments in this description of the invention will be apparent to those skilled in organic preparations.
Notwithstanding the fact that any secondary amine can be employed in the process of the invention, for purposes of analgesia a more limited scope of secondary amines is contemplated. Accordingly, ##STR7## can be dialkylamino, e.g., dimethylamino, diethylamino, dipropylamino, dibutylamino, methylisopropylamino, methyl-n-butylamino and the like.
In addition, when R 3 =methyl, then R 4 can be CH 2 -alkenyl, e.g., 2-propenyl (allyl), 2-butenyl, and the like. Further the ##STR8## group can be a saturated heterocyclic group as defined; some representative examples include 1-pyrrolidinyl, alkylpyrrolidinyl, for example, 3-butylpyrrolidinyl; piperidino, alkylpiperidino, for example, 3-methylpiperidino, 4-methylpiperidino, 3-isopropylpiperidino, and 4-tert-butylpiperidino; 4-alkylpiperazinyl, for example, 4-methylpiperazinyl, and 4-isopropylpiperazinyl; morpholino, alkylmorpholino, for example, 3-isobutylmorpholino.
A preferred group of compounds for the purposes of this invention is that wherein the heterocycle is morpholino, R 1 and R 2 are alkyl of from 1 to 4 carbon atoms, inclusive, Y is halogen, hydroxy, or alkanoyloxy of from 2 to 5 carbon atoms, inclusive, and m is zero or 1. Preferred compounds are 1-(p-chlorophenyl)-1-dimethylamino-4-N-morpholinocyclohexane and 1-phenyl-1-dimethylamino-4-N-morpholinocyclohexane.
The term "halogen" is intended to include chlorine, bromine, and fluorine.
The term "aryl" as used herein means phenyl and substituted phenyl, for example, 4-chlorophenyl, 3-benzyloxyphenyl, 2-tolyl, 3,4-diethylphenyl, 2,4-dimethoxyphenyl, and the like.
"Alkanoyloxy of 2-5 carbon atoms, inclusive" means, for example, acetoxy, butyroxy and such groups.
The limited term "alkyl from 1 to 4 carbon atoms, inclusive," means methyl, ethyl, propyl, butyl, and isomeric forms thereof, e.g., tert-butyl, i-propyl. An "alkyl" of 1 to 8 carbon atoms, inclusive, encompasses groups such as methyl, propyl, butyl, hexyl, octyl, and isomers thereof. "Alkoxy of from 1 to 5 carbon atoms, inclusive," is similarly defined to mean methoxy, ethoxy, butoxy, pentoxy, i-propoxy, and the like.
The precursor 4-amino-4-arylcyclohexanones of this invention are themselves new compounds and they can be prepared as described in the Preparations. An alternative preparation is also described which is quicker and more efficient.
PREPARATION I
Synthesis of precursor 4-(p-Chlorophenyl)-4-dimethylaminocyclohexanone and antecedent compounds
PART A
Preparation of first antecedent, the Dimethyl diester of 4-(p-chlorophenyl)-4-cyanopimelic acid
A mixture consisting of 25.0 gm. (0.165 mole) p-chlorophenyl acetonitrile, 77 ml. methyl acrylate, and 80 ml. tert-butyl alcohol is heated to the reflux temperature. The source of heat is removed, and a mixture consisting of 25 ml. of 40 percent methanolic tetramethylammonium hydroxide (Triton B®) and 37 ml. tert-butyl alcohol is quickly added. Heating at the reflux temperature is resumed and continued for four (4) hours. The reaction mixture is allowed to cool, and is then diluted with water and benzene. The organic solvent and aqueous phases that form are separated and the aqueous phase discarded. The organic phase is washed successively with 2.5 N hydrochloric acid, water, and finally with brine. It is then dried over magnesium sulfate. The organic solvent is removed by evaporation under reduced pressure, and the residue thus obtained is distilled under reduced pressure. The initial pressure is 40 mm mercury at which pressure any remaining methyl acrylate and other volatile components are removed. There is then obtained 38.06 gm. (71.4% yield) of the dimethyl ester of 4-(p-chlorophenyl)-4-cyanopimelic acid as an oil having a boiling point at 186° to 191° C. (0.05 mm Hg.).
PART B
Preparation of second antecedent, 2-Carbomethoxy-4-(p-chlorophenyl)-4-cyanocyclohexanone
A reaction mixture consisting of 34.97 g. (0.108 mole) dimethyl ester of 4-(p-chlorophenyl)-4-cyanopimelic acid (prepared in Part a, above) dissolved in 700 ml. tetrahydrofuran with 24.4 gm. (0.218 mole) potassium tert-butoxide added is heated at the reflux temperature for 41/2 hours. After cooling, the reaction mixture is chilled in an ice-bath and 175 ml. 2.5 N acetic acid is added. The organic and aqueous phases separate and the organic phase is recovered. It is diluted with 600 ml. benzene before being washed successively with aqueous sodium bicarbonate, water, and brine. The organic solvents are then removed by distillation under reduced pressure. There is thus obtained 30.2 gm. (96% yield) of 2-carbomethoxy-4-(p-chlorophenyl)-4-cyanocyclohexanone having a melting point at 139° to 143° C.
PART C
Preparation of third antecedent, 4-(p-chlorophenyl)-4-cyanocyclohexanone
A reaction mixture consisting of 29.8 gm. (0.102 mole) of 2-carbomethoxy-4-(p-chlorophenyl)-4-cyanocyclohexanone (prepared in Part b, above), 550 ml. glacial acetic acid, and 330 ml. 10 percent sulfuric acid is heated on a steam bath at about 100° C. for 24 hours. The mixture is stirred continuously. After cooling, the mixture is diluted with 1000 ml. water, and extracted with benzene. The benzene phase is recovered and washed successively with water, with aqueous sodium bicarbonate, and with brine. The benzene is then removed by evaporation under reduced pressure to give a solid residue. The solid residue is recrystallized from diethyl ether to give 12.13 gm. (82% yield) of 4-(p-chlorophenyl)-4-cyanocyclohexanone having a melting point at 94.5° to 97° C.
Analysis: Calc'd. for C 13 H 12 ClNO: C, 66.81; H, 5.18; N, 5.99. Found: C, 67.03; H, 5.16; N, 5.95.
PART D
Preparation of fourth antecedent, 4-(p-chlorophenyl)-4-cyanocyclohexanone, ethylene ketal
A reaction mixture consisting of 19.49 gm. (0.084 mole) of 4-(p-chlorophenyl)-4-cyanocyclohexanone (prepared in Part c, above), 4.8 ml. (5.33 gm.) (0.086 mole) ethylene glycol. 0.21 Gm. p-toluenesulfonic acid, and 150 ml. benzene is heated at the reflux temperature in a reaction vessel equipped with a Dean and Stark trap for six (6) hours. The reaction solution is then allowed to cool before washing it successively with aqueous sodium bicarbonate, with water, and with brine. The washed solution is then taken to dryness by evaporation of the benzene. The solid residue thus obtained is crystallized from hexane to give 21.87 gm. (79% yield) of 4-(p-chlorophenyl)-4-cyanocyclohexanone ethylene ketal having a melting point at 124° to 126.5° C.
Analysis: Calc'd. for C 15 H 16 ClNO 2 : C, 64.96; H, 5.81; N, 5.04. Found: C, 64.77; H, 5.81; N, 4.92.
PART E
Preparation of fifth antecedent, 4-Carboxy-4-(p-chlorophenyl)cyclohexanone, ethylene ketal
A reaction mixture consisting of 21.87 gm. (0.079 mole) 4-(p-chlorophenyl)-4-cyanocyclohexanone, ethylene ketal (prepared in Part d, above), 22.0 gm. (0.39 mole) potassium hydroxide and 220 ml. ethylene glycol is heated at the reflux temperature for 16 hours. After cooling and diluting with water, the solution is chilled in an ice-bath, layered with diethyl ether and cautiously acidified with concentrated hydrochloric acid. The ether layer is recovered and the acidic aqueous solution extracted two more times with ether. The ether extracts are combined and washed with brine before removing the ether by evaporation. The residue thus obtained is recrystallized from a mixture of methylene chloride and technical hexane to give 19.26 gm. (82% yield) of 4-carboxy-4-(p-chlorophenyl)cyclohexanone, ethylene ketal having a melting point at 162.6° to 164.5° C.
Analysis: Calc'd. for C 15 H 17 ClO 4 : C, 60.71; H, 5.78; Cl, 11.95. Found: C, 61.01; H, 5.77; Cl, 12.12.
PART F
Preparation of sixth antecedent, 4-(p-Chlorophenyl)-4-isocyanatocyclohexanone, ethylene ketal
To a mixture consisting of 15.79 gm. (0.0532 mole) 4-carboxy-4-(p-chlorophenyl)cyclohexanone, ethylene ketal (prepared in Part e, above) 7.4 ml. (5.36 gm., 0.532 mole) triethylamine, and 135 ml. anisole is added 14.7 gm. (0.534 mole) diphenylphosphonic azide. This reaction mixture is then heated at 90° to 100° C. in an oil bath for two (2) hours. The volatile components are then removed by evaporation under reduced pressure, and the gummy residue thus obtained is chromatographed on a 1500 ml. column of silica gel. The column is eluted with a mixture of ethyl acetate and technical hexanes (in proportion of 1:9). After combining those fractions shown by thin layer chromatography (TLC) to contain product and removing the solvents by evaporation under reduced pressure, there is obtained 7.75 gm. of crude product. Recrystallization from petroleum ether gives 6.72 gm. (43% yield) of 4-(p-chlorophenyl)-4-isocyanatocyclohexanone, ethylene ketal having a melting point at 76.5° to 80° C.
Analysis: Calc'd. for C 15 H 16 ClNO 3 : C, 61.33; H, 5.49; N, 4.77. Found: C, 61.44; H, 5.50; N, 4.59.
PART G
Preparation of seventh antecedent, 4-(p-chlorophenyl)-4-methylaminocyclohexanone, ethylene ketal
A solution consisting of 6.62 gm. (0.0226 mole) 4-(p-chlorophenyl)-4-isocyanatocyclohexanone, ethylene ketal (prepared in Part f, above) in 50 ml. tetrahydrofuran is mixed with a suspension of 1.29 gm. (0.045 mole) lithium aluminum hydride in 20 ml. tetrahydrofuran and the resulting reaction mixture heated at the reflux temperature for four (4) hours. After cooling, followed by chilling in an ice bath, 1.3 ml. water, 1.3 ml. 15 percent sodium hydroxide, and finally another 3.9 ml. water are added, successively. A gelatinous precipitate forms; the mixture is filtered. The filtrate is saved, and the volatile components are removed by evaporation under reduced pressure. The residue thus obtained is recrystallized from petroleum ether to give 5.78 gm. (91% yield) of 4-(p-chlorophenyl)-4-methylaminocyclohexanone, ethylene ketal that has a melting point at 63.5° to 66.5° C.
Analysis: Calc'd. for C 15 H 20 ClNO 2 : C, 63.93; H, 7.15; N, 4.97. Found: C, 64.14; H, 7.32; N, 5.15.
PART H
Preparation of eighth antecedent compound, 4-(p-chlorophenyl)-4-dimethylaminocyclohexanone, ethylene ketal free base and the hydrochloride thereof
A reaction solution consisting of 5.68 gm. (0.0201 mole) 4-(p-chlorophenyl)-4-methylaminocyclohexanone, ethylene ketal (prepared in Part g, above), 22 ml. 37 percent formalin, and 75 ml. methanol is heated at the reflux temperature for four (4) hours, after which heating the solution is allowed to cool and is then chilled in an ice-bath. Small portions of sodium borohydride are cautiously added with stirring to a total of 2.89 gm. (0.076 mole). Stirring is continued for two (2) hours at 25° C. when the solution is concentrated by removing most of the solvent under reduced pressure. The concentrate is diluted with methylene chloride and water. The aqueous phase that separates is discarded, and the organic phase is washed successively with water and then with brine. The methylene chloride solvent is then removed by evaporation under reduced pressure. The residue thus obtained is dissolved in the formalin and methanol as initially, heated at the reflux temperature, cooled in an ice bath, and treated again with the sodium borohydride as previously. Following the same work-up as described, the crude 4-(p-chlorophenyl)-4-dimethylaminocyclohexanone, ethylene ketal free base from the removal of the methylene chloride is dissolved in a small amount of diethyl ether, and the ether solution is treated with 3 N hydrogen chloride in ether. A precipitate forms which is recrystallized from methylene chloride to give 3.96 gm. (59% yield) of 4-(p-chlorophenyl)-4-dimethylaminocyclohexanone, ethylene ketal hydrochloride having a melting point at 261° to 262° C. (with decomposition).
Analysis: Calc'd for C 16 H 22 NO 2 .HCl: C, 57.83; H, 6.98; N, 4.27. Found: C, 58.10; H, 7.01; N, 4.41.
PART I
Preparation of an object compound, 4-(p-chlorophenyl)-4-dimethylaminocyclohexanone
A reaction solution consisting of 4.52 gm. (0.0136 mole) of 4-(p-chlorophenyl)-4-dimethylaminocyclohexanone, ethylene ketal hydrochloride (prepared in Part h, above), 22.5 ml. 2.5 N hydrochloric acid, and 45 ml. methanol is set aside at 25° C. for 48 hours. The methanol medium is substantially removed by evaporation under reduced pressure to give a concentrate that is made strongly basic by additions of 50 percent aqueous sodium hydroxide. A precipitate forms which is collected on a filter and dissolved in diethyl ether. This ether solution is washed successively with water and with brine before removing all the ether by evaporation under reduced pressure. The residue thus obtained is recrystallized from diethyl ether to give 2.30 gm. (70% yield) of 4-(p-chlorophenyl)-4-dimethylaminocyclohexanone having a melting point at 108° to 111° C.
Analysis: Calc'd. for C 24 H 28 ClNO: C, 66.79; H, 7.21; N, 5.57. Found: C, 67.10; H, 7.36; N, 5.42.
PREPARATION II
Synthesis of precursor 4-Dimethylamino-4-phenylcyclohexanone and antecedent compounds
PART A
Preparation of first antecedent compound, the Dimethyl ester of 4-cyano-4-phenylpimelic acid
Following the procedure of Preparation I, Part a, but substituting 29.26 gm. (0.25 mole) of phenyl acetonitrile for the 25.0 gm. of p-chlorophenyl acetonitrile and using 116 ml. methyl acrylate, 120 ml. tert-butyl alcohol, 38 ml. of the 40 percent methanolic tetramethylammonium hydroxide, and 56 ml. tert-butyl alcohol instead of the 77 ml., the 80 ml., the 25 ml., and the 37 ml. quantities stated, respectively, and carrying out the final distillation pressure at 0.45 mm of mercury, there is prepared 55.15 gm. (70% yield) of the dimethyl diester of 4-cyano-4-phenylpimelic acid as an oil having a boiling range from 183° to 186° C.
PART B
Preparation of second antecedent compound, 2-carbomethoxy-4-cyano-4-phenylcyclohexanone
Following the procedure of Preparation I, Part b, but substituting 2.0 gm. (0.0069 mole) of the dimethyl ester of 4-cyano-4-phenylpimelic acid (prepared in Part a, above) for the 34.97 gm. of the dimethyl ester of 4-(p-chlorophenyl)-4-cyanopimelic acid and using 45 ml. of the tetrahydrofuran, 1.57 gm. (0.014 mole) of the potassium tert-butoxide, and 10 ml. of the 2.5 N acetic acid instead of the 700 ml., the 24.4 gm., and the 175 ml., respectively, there is obtained a residue which upon recrystallization from technical hexane gives 1.07 gm. (60% yield) of the desired 2-carbomethoxy-4-cyano-4-phenylcyclohexanone having a melting point at 79.5° to 81.5° C.
Analysis: Calc'd. for C 15 H 15 NO 3 : C, 70.02; H, 5.88; N, 5.44. Found: C, 69.77; H, 5.88; N, 5.54.
PART C
Preparation of third antecedent compound, 4-cyano-4-phenylcyclohexanone
Following the procedure of Preparation I, Part c, but substituting 44.7 gm. (0.174 mole) of 2-carbomethoxy-4-cyano-4-phenylcyclohexanone (prepared as in Part b, above) for the 29.8 gm. of the 2-carbomethoxy-4-(p-chlorophenyl)-4-cyanocyclohexanone and using 1200 ml. of the glacial acetic acid, and 600 ml. of the 10 percent aqueous sulfuric acid instead of the 660 ml. and the 330 ml., respectively, and finally recrystallizing the residual solid from a mixture of ethyl acetate and hexane, there is obtained 25.75 gm. (75% yield) of the desired 4-cyano-4-phenylcyclohexanone having a melting range from 112° to 115.5° C.
PART D
Preparation of fourth antecedent compound, 4-cyano-4-phenylcyclohexanone, ethylene ketal
Following the procedure of Preparation I, part d, but substituting 10.0 gm. (0.05 mole) of 4-cyano-4-phenylcyclohexanone (prepared in Part c, above) for the 4-(p-chlorophenyl)-4-cyanocyclohexanone and using 2.85 ml. (3.17 gm., 0.051 mole) of the ethylene glycol, 0.12 gm. of the p-toluenesulfonic acid, and 90 ml. of the benzene solvent instead of the 4.8 ml., the 0.21 gm., and the 150 ml., respectively, there is obtained 11.27 gm. (92% yield) of the desired 4-cyano-4-phenylcyclohexanone, ethylene ketal as a crystalline solid having a melting range of 120° to 122.5° C.
Analysis: Calc'd. for C 15 H 17 NO 2 : C, 74.05; H, 7.04; N, 5.76. Found: C, 74.10; H, 6.98; N, 5.77.
PART E
Preparation of fifth antecedent compound, 4-carboxy-4-phenylcyclohexanone, ethylene ketal
Following the procedure of Preparation I, Part e, but substituting 11.27 gm. (0.0464 mole) of 4-cyano-4-phenylcyclohexanone, ethylene ketal (prepared in Part d, above) for the 21.87 gm. of the 4-(p-chlorophenyl)-4-cyanocyclohexanone, ethylene ketal, and using 11.3 gm. (0.2 mole) of the potassium hydroxide, and 90 ml. of the ethylene glycol instead of the 22.0 gm. and 220 ml., respectively, there is obtained 10.51 gm. (86% yield) of the desired 4-carboxy-4-phenylcyclohexanone, ethylene ketal as a crystalline solid having a melting range from 136° to 140.5° C.
Analysis: Calc'd. for C 15 H 18 O 4 : C, 68.68; H, 6.92. Found: C, 68.27; H, 6.90.
PART F
Preparation of sixth antecedent compound, 4-isocyanato-4-phenylcyclohexanone, ethylene ketal
Following the procedure of Preparation I, Part f, but substituting 2.62 gm. (0.01 mole) of 4-carboxy-4-phenylcyclohexanone ethylene ketal (prepared in Part e, above) for the 15.79 gm. of the 4-carboxy-4-(p-chlorophenyl)cyclohexanone, ethylene ketal and using 1.38 ml. (1.01 gm., 0.01 mole) of the triethylamine, 25 ml. of the anisole, 2.75 gm. of the diphenylphosphonic azide, and a 400 ml. silica gel column instead of the 7.4 ml. (5.36 gm., 0.532 mole), the 135 ml., the 14.7 gm., and the 1500 ml. column, respectively, there is obtained 1.94 gm. (75% yield) of the desired 4-isocyanato-4-phenylcyclohexanone, ethylene ketal which has a melting range from 47° to 50° C. An analytical sample recrystallized from petroleum ether has a melting range from 48° to 50° C.
Analysis: Calc'd. for C 15 H 17 NO 3 : C, 69.48; H, 6.61; N, 5.40. Found: C, 69.56; H, 7.01; N, 5.39.
PART G
Preparation of seventh antecedent compound, 4-methylamino-4-phenylcyclohexanone, ethylene ketal hydrochloride
A solution consisting of 0.96 gm. (0.0037 mole) of 4-isocyanato-4-phenylcyclohexanone, ethylene ketal (prepared in Part f, above) and 15 ml. tetrahydrofuran is added to a suspension prepared by dispersing 0.20 gm. (0.0053 mole) lithium aluminum hydride in 5 ml. tetrahydrofuran. The resulting reaction mixture is heated at the reflux temperature with stirring for four (4) hours. The mixture is then allowed to cool before chilling it in an ice-bath. To the chilled mixture is added 0.2 ml. water, 0.2 ml. 15 percent aqueous sodium hydroxide, and a further 0.6 ml. water. A gelatinous precipitate forms and the entire preparation is poured onto a filter. The filtrate is collected and the volatile components are removed by evaporation under reduced pressure. The residue thus obtained is dissolved in a small amount of diethyl ether and 3 N hydrogen chloride in ether is added to the solution in an amount judged to give the desired, insoluble acid addition salt. After collecting the crude salt on a filter and recrystallizing it from a mixture of methylene chloride and ethyl acetate, thereis obtained 0.82 gm. (78% yield) of 4-methylamino-4-phenylcyclohexanone, ethylene ketal hydrochloride having a melting point at 243° to 245° C.
Analysis: Calc'd. for C 15 H 22 ClNO 2 : C, 63.48; H, 7.82; N, 4.94. Found: C, 63.51; H, 7.89; N, 5.00.
PART H
Preparation of eighth intermediate compound, 4-Dimethylamino-4-phenylcyclohexanone, ethylene ketal hydrochloride
A reaction solution consisting of the free base from 1.0 gm. (0.0035 mole) 4-methylamino-4-phenylcyclohexanone, ethylene ketal hydrochloride (prepared as in Part g, above), 3.6 ml. 37 percent formalin, and 12 ml. methanol is heated at thereflux temperature for four (4) hours. This reaction mixture is allowed to cool to room temperature before chilling it in an ice-bath. Small portions of sodium borohydride are cautiously added with stirring to a total amount of 0.48 gm. (0.125 mole). Stirring is continued at 25° C. for two (2) hours, and then the volatile solvents are removed by evaporation under reduced pressure. The residue thus obtained is dispersed in a mixture of methylene chloride and water and the liquids are allowed to separate. The methylene chloride phase is recovered and washed with water and then with brine. After removing the methylene chloride solvent by evaporation under reduced pressure, the residue is dissolved in a small amount of ether. A solution of hydrogen chloride in ether (3N) is added so as to produce the hydrochloride acid addition salt which precipitates out. The precipitate is collected on a filter and recrystallized from a mixture of methylene chloride and ethyl acetate to give 0.72 gm. (68% yield) of the desired final product, 4-dimethylamino-4-phenylcyclohexanone, ethylene ketal hydrochloride having a melting range from 226° to 229° C. An analytical sample is obtained by recrystallization from methylene chloride:ethyl acetate and has a melting range from 236° to 238° C.
Analysis: Calc'd. for C 16 H 23 NO 2 .HCl: C, 64.52; H, 8.12; N, 4.70. Found: C, 64.47; H, 7.85; N, 4.92.
PART I
Preparation of object compound, 4-Dimethylamino-4-phenylcyclohexanone
Following the procedure of Preparation I, Part i, but substituting 13.66 gm. (0.052 mole) 4-dimethylamino-4-phenylcyclohexanone, ethylene ketal (prepared in Preparation I, Part h, above) for the 4.52 gm. of the 4-(p-chlorophenyl)-4-dimethylaminocyclohexanone, ethylene ketal hydrochloride and using 70 ml. 2.5 N hydrochloric acid and 14 ml. methanol instead of the 22.5 ml. and 45 ml. respectively, there is prepared 7.76 gm. (69% yield) of 4-dimethylamino-4-phenylcyclohexanone having a melting point at 98° to 99.5° C. An analytical sample has a melting range at 100° to 103° C.
Analysis: Calc'd. for C 14 H 19 NO: C, 77.38; H, 8.81; N, 6.45. Found: C, 77.39; H, 8.86; N, 6.41.
PREPARATION III
Alternative preparation for the compound 4-(p-chlorophenyl)-4-dimethylaminocyclohexanone, ethylene ketal free base and the hydrochloride thereof
PART A
Preparation of the first antecedent compound, Cyclohexane-1,4-dione, ethylene ketal
A reaction mixture consisting of 10 gm. (0.085 mole) 4-hydroxycyclohexanone, 4.75 ml. ethylene glycol, 0.20 gm. p-toluenesulfonic acid, and 100 ml. benzene is heated at the reflux temperature in a reaction vessel fitted with a Dean and Stark trap for 2 hours. After the reaction mixture cools, it is washed first with water and then with brine. The benzene is then removed by evaporation under reduced pressure giving the intermediate 4-hydroxycyclohexane monoketal as a viscous oil weighing 14.12 gm. The 4-hydroxycyclohexane monoketal is dissolved in 100 ml. methylene chloride and added with stirring to a suspension consisting of 55.0 gm. chromium trioxide (predried for 24 hours under reduced pressure over phosphorous pentoxide), one liter dry methylene chloride, and 52.8 gm. 3,5-dimethylpyrazole. After continued stirring for ten (10) minutes this dark reaction mixture is poured onto a two liter column of silica gel. When the reaction mixture has been completely absorbed, the chromatogram is developed with a 1:1 mixture of ethyl acetate and technical hexane (Skellysolve B-a mixture of isomeric hexanes having a boiling range between 60° and 70° C.). Fractions which are found by thin layer chromatography (TLC) to contain the product are collected and combined, after which the solvents are removed by evaporation under reduced pressure. The crystals thus obtained are recrystallized from technical hexane, and there is thus obtained 10.82 gm. (91% yield) of the desired cyclohexane-1,4-dione, ethylene monoketal having a melting point at 68° to 69° C. (The literature value is 71.5° to 72.5° C.).
PART B
Preparation of second antecedent compound, 4-Cyano-4-dimethylaminocyclohexanone, ethylene ketal
A reaction mixture consisting of 3.0 gm. (0.019 mole) of the cyclohexane-1,4-dione, ethylene ketal prepared in Part A, above, 3.0 gm. potassium cyanide, 4.6 gm. dimethylamine hydrochloride, 3.0 ml. methanol, and 25 ml. saturated aqueous dimethylamine is stirred at 25° C. for 48 hours. The reaction mixture is then extracted successively with five-40 ml. portions of diethyl ether. The ether extracts are combined and the ether removed by evaporation under reduced pressure. The residue thus obtained is dissolved in methylene chloride. Some small amount of water present is separated, and the organic solvent portion conserved for removal of the methylene chloride by evaporation under reduced pressure. The residual solid thus obtained is recrystallized from technical hexane to give 3.6 gm. (78% yield) of the desired intermediate 4-cyano-4-dimethylaminocyclohexanone, ethylene ketal having a melting point at 79° to 81° C.
Analysis: Calc'd. for C 11 H 12 N 2 O 2 : C, 62.83; H, 8.63; N, 13.33. Found: C, 62.92; H, 8.66; N, 13.58.
PART C
Preparation of object compound, 4-(p-Chlorophenyl)-4-dimethylaminocyclohexanone, ethylene ketal hydrochloride
A Grignard reagent is prepared from 2.73 gm. of p-chlorobromobenzene, 0.35 gm. magnesium and 30 ml. tetrahydrofuran; 1.50 gm. (0.0071 mole) of 4-cyano-4-dimethylaminocyclohexanone, ethylene ketal (prepared in Part b, above) is dissolved in 40 ml. tetrahydrofuran and added to it. The reaction mixture is heated for three (3) days at the reflux temperature. It is then cooled, chilled in an ice bath, and 20 ml. saturated ammonium chloride in benzene is added. The liquid is separated. It is washed initially with water and then with brine. Finally, the solvents are removed by evaporation under reduced pressure. The residue thus obtained is dissolved in diethyl ether and 4 N ethereal hydrogen chloride is added until precipitation is complete. The salt thus obtained is collected on a filter as a gummy material. It is suspended in methylene chloride and 1 N aqueous sodium hydroxide is added. The organic layer is separated and the methylene chloride removed by evaporation under reduced pressure. The residue thus obtained is transferred to a 200 ml. column of silica gel and the chromatogram developed with methylene chloride containing 3% methanol. Fractions which are shown by thin layer chromatography (TLC) to contain the product are collected and combined. The solvent is removed by evaporation under reduced pressure and the residue is dissolved in diethyl ether. The ether solution is treated with 4 N ethereal hydrogen chloride until precipitation of the desired 4-(p-chlorophenyl)-4-dimethylaminocyclohexanone ethylene ketal hydrochloride is complete. The precipitate is collected on a filter and crystallized from a mixture of methylene chloride and ethyl acetate to give 0.80 gm. (34% yield) of pure 4-(p-chlorophenyl)-4-dimethylaminocyclohexanone ethylene ketal hydrochloride having a melting point at 252° to 254° C.
PREPARATION IV
Preparation of 4-(m-hydroxyphenyl)-4-dimethylaminocyclohexanone
PART A
A reaction solution consisting of 5.0 gm. (0.029 mole) m-bromophenol, 5.0 gm. dihydropyran, 0.30 gm. p-toluenesulfonic acid, and 80 ml. anhydrous diethyl ether is stirred at 25° C. for four (4) hours. The mixture is washed successively with 25 ml. portions of 1 N aqueous sodium hydroxide, with water, and with brine. The thus washed organic layer is taken to dryness by removing the solvent by evaporation under reduced pressure. There is thus obtained 7.42 gm. of m-(tetrahydropyranyloxy)bromobenzene which is converted to the corresponding Grignard reagent by adding 0.70 gm. magnesium and 60 ml. tetrahydrofuran. To this Grignard is added 1.50 gm. (0.0071 mole) of 4-cyano-4-dimethylaminocyclohexanone ethylene ketal (prepared in Preparation III, Part b, above) dissolved in 30 ml. tetrahydrofuran. This reaction mixture is heated at the reflux temperature for 22 hours. After cooling, the mixture is treated with 10 ml. saturated aqueous ammonium chloride and benzene. The organic solvent portion is initially washed with water and then with brine. The organic solvent is then removed by evaporation under reduced pressure. The residue thus obtained is dissolved in diethyl ether and treated with 4 N ethereal hydrogen chloride until precipitation of the hydrochloride salt is complete. The salt is collected on a filter and then suspended in 25 ml. water containing 1 ml. 2.5 N hydrochloric acid. The acidified mixture is stirred at 25° C. for one hour, when sodium bicarbonate (solid) is added until the pH is 8. This slightly basic mixture is extracted thoroughly with diethyl ether. The ether extracts are combined and the ether removed by evaporation under reduced pressure. The residue thus obtained is transferred to a column of silica gel 1" in cross section by 48" long. The chromatogram is developed with a solvent medium consisting of 0.5 percent ammonia and 7.5 percent methanol in chloroform. Fractions which are shown by thin layer chromatography (TLC) to contain product are collected and combined. The solvent is removed by evaporation under reduced pressure to give 0.96 gm. (48% yield) of crude 4-(m-hydroxyphenyl)-4-dimethylaminocyclohexanone, ethylene ketal having a melting point at 169° to 175° C. An analytical sample is obtained by recrystallization from a mixture of ethyl acetate and cyclohexane. The melting point is 175° to 177° C.
Analysis: Calc'd. for C 16 H 23 NO 3 : C, 69.28; H, 8.36; N, 5.05. Found: C, 69.08; H, 8.13; N, 5.02.
PART B
Preparation of 4-(m-hydroxyphenyl)-4-dimethylaminocyclohexanone
A reaction mixture consisting of 1.92 gm. (0.0069 mole) of 4-(m-hydroxyphenyl)-4-dimethylaminocyclohexanone, ethylene ketal (prepared in Part a, above), 15 ml. 2.5 N hydrochloric acid, and 30 ml. methanol is stirred continuously for three (3) days (72 hours). The bulk of the solvent is then removed by evaporation under reduced pressure, and solid sodium bicarbonate is added until the pH is 8. This slightly basic mixture is then extracted with six 20 ml. portions of chloroform. The extracts are combined and the chloroform is removed by evaporation under reduced pressure. The residue thus obtained is recrystallized from a mixture of acetone and technical hexane to give 0.48 gm. (30% yield) of 4-(m-hydroxyphenyl)-4-dimethylaminocyclohexanone having a melting point at 127° to 130° C.
Analysis: Calc'd. for C 14 H 19 NO 2 : C, 72.07; H, 8.21; N, 6.01. Found: C, 72.02; H, 8.13; N, 5.87.
PREPARATION V
Preparation of 4-(m-anisyl)-4-dimethylaminocyclohexanone
PART A
Preparation of precursor, the Dimethyl ester of 4-(m-anisyl)-4-cyanopimelic acid
Following the procedure of Preparation I, Part a, but substituting 25.0 gm. (0.17 mole) m-anisyl acetonitrile for the 25.0 gm. of the p-chlorophenyl acetonitrile and using 79 ml. methyl acrylate, 27 ml. of the 40% methanolic tetramethylammonium hydroxide with 38 ml. tert-butyl alcohol, instead of the 77 ml., the 25 ml., and 37 ml., respectively, and decreasing the final distillation pressure to 0.07 mm, there is prepared 30.34 gm. (56% yield) of the dimethyl ester of 4-(m-anisyl)-4-cyanopimelic acid as an oil having a boiling range from 180° to 187° C.
PART B
Preparation of first intermediate, 4-(m-anisyl)-4-carbomethoxy-4-cyanocyclohexanone
Following the procedure of Preparation I, Part b, but substituting 30.34 gm. (0.0951 mole) of the dimethyl ester of 4-(m-anisyl)-4-cyanopimelic acid (prepared in Part a, above) for the 34.97 gm. of the dimethyl ester of 4-(p-chlorophenyl)-4-cyanopimelic acid and using 620 ml. of the tetrahydrofuran, 21.3 gm. (0.19 mole) of the potassium tert-butoxide, and 150 ml. of the 2.5 N glacial acetic acid instead of the 700 ml., the 24.4 gm. (0.218 mole), and the 175 ml., respectively, there is prepared 29.1 gm. (99% yield) of 4-(m-anisyl)-2-carbomethoxy-4-cyanocyclohexanone as a gum.
PART C
Preparation of second intermediate, 4-(m-anisyl)-4-cyanocyclohexanone
Following the same procedure as described in Preparation I, Part c, but substituting 29.1 gm. (0.01 mole) of 4-(m-anisyl)-2-carbomethoxy-4-cyanocyclohexanone (prepared in Part b, above) for the 29.8 gm. of 2-carbomethoxy-4-(p-chlorophenyl)-4-cyanocyclohexanone, there is obtained 14.93 gm. (64% yield) of 4-(m-anisyl)-4-cyanocyclohexanone having a melting range at 72° to 76° C.
Analysis: Calc'd. for C 14 H 15 NO 2 : C, 73.34; H, 6.59; N, 6.11. Found: C, 73.68; H, 6.76; N, 6.21.
PART D
Preparation of third intermediate, 4-(m-anisyl)-4-cyanocyclohexanone, ethylene ketal
Following the procedure of Preparation I, Part d, but substituting 14.93 gm. (0.065 mole) of 4-(m-anisyl)-4-cyanocyclohexanone (prepared in Part c, above) for the 19.49 gm. of the 4-(p-chlorophenyl)-4-cyanocyclohexanone, using 4.0 ml. ethylene glycol, 0.16 gm. p-toluenesulfonic acid, and 110 ml. benzene instead of the 4.8 ml., the 0.21 gm., and the 150 ml., respectively, and recrystallizing from technical hexane instead of cyclohexane, there is obtained 15.24 gm. (92% yield) of 4-(m-anisyl)-4-cyanocyclohexanone, ethylene ketal melting at 70° to 72° C.
Analysis: Calc'd. for C 16 H 19 NO 3 : C, 70.31; H, 7.01; N, 5.13. Found: C, 70.09; H, 7.07; N, 4.96.
PART E
Preparation of fourth intermediate 4-(m-anisyl)-4-carboxycyclohexanone, ethylene ketal
Following the procedure of Preparation I, Part e, but substituting 16.24 gm. (0.059 mole) of 4-(m-anisyl)-4-cyanocyclohexanone, ethylene ketal (prepared in Part d, above) for the 21.87 gm. of the 4-carboxy-4-(p-chlorophenyl)cyclohexanone, ethylene ketal and using 7.83 gm. (0.19 mole) sodium hydroxide and 110 ml. ethylene glycol instead of the 22.0 gm. (0.39 mole) potassium hydroxide and 220 ml., respectively, there is obtained, without recrystallization, 17.31 gm. (99% yield) of 4-(m-anisyl)-4-carboxycyclohexanone, ethylene ketal having a melting range at 102° to 107° C.
PART F
Preparation of fifth intermediate, 4-(m-anisyl)-4-isocyanatocyclohexanone, ethylene ketal
Following the procedure of Preparation I, Part f, but substituting the 17.31 gm. (0.059 mole) of 4-(m-anisyl)-4-carboxycyclohexanone, ethylene ketal (prepared in Part e, above) for the 15.79 gm. of the 4-carboxy-4-(p-chlorophenyl)cyclohexanone, ethylene ketal and using 6.0 ml. (8.23 gm., 0.059 mole) triethylamine, 160 ml. anisole, and 16.31 gm. diphenylphosphonic azide instead of the 7.4 ml., the 135 ml., and the 14.7 gm., respectively, there is obtained after elution of the silica gel column with a 1.5 percent mixture of ethyl acetate in methylene chloride, 4.07 gm. of 4-(m-anisyl)-4-isocyanatocyclohexanone ethylene ketal.
PART G
Preparation of sixth intermediate 4-(m-anisyl)-4-methylaminocyclohexanone, ethylene ketal hydrochloride
Following the procedure of Preparation I, Part g, but substituting 4.07 gm. (0.014 mole) of 4-(m-anisyl)-4-isocyanatocyclohexanone, ethylene ketal (prepared in Part f, above), for the 6.62 gm. 4-(p-chlorophenyl)-4-isocyanatocyclohexanone, ethylene ketal and using 80 ml. tetrahydrofuran, 0.76 gm. (0.02 mole) lithium aluminum hydride, and 10 ml. tetrahydrofuran instead of the 50 ml., the 1.29 gm., and the 20 ml., adding 0.76 ml. water, 0.76 ml. of 15 percent aqueous sodium hydroxide, and 2.28 ml. water instead of the 1.3 ml., the 1.3 ml., and the 3.9 ml., respectively, there is obtained a corresponding residue from the filtrate that is dissolved in a small amount of diethyl ether. The ether solution is acidified with an equivalent amount of 3 N hydrogen chloride in ether. The hydrochloride acid addition salt that precipitated is collected on a filter and recrystallized from a mixture of methylene chloride and ethyl acetate to afford 3.10 gm. (71% yield) of 4-(m-anisyl)-4-methylaminocyclohexanone, ethylene ketal hydrochloride having a melting point at 238° to 239° C.
Analysis: Calc'd. for C 16 H 23 NO 2 .HCl: C, 61.23; H, 7.71; N, 4.46. Found: C, 60.07; H, 7.52; N, 4.29.
PART H
Preparation of 4-(m-anisyl)-4-(dimethylamino)cyclohexanone, ethylene ketal hydrochloride
Following the procedure of Preparation I, Part h, but substituting the free base from 3.10 gm. (0.0099 mole) of 4-(m-anisyl)-4-methylaminocyclohexanone ethylene ketal hydrochloride (prepared in Part g, above) for the 4.68 gm. of the 4-(p-chlorophenyl)-4-methylaminocyclohexanone, ethylene ketal and using 7.5 ml. of 37 percent formalin, 22.5 ml. methanol, and adding 0.91 gm. sodium borohydride instead of the 22 ml., the 75 ml., and the 2.89 gm., respectively, there is obtained a hydrochloride precipitate that upon recrystallization from a mixture of methylene chloride and ethyl acetate gives 2.21 gm. (68% yield) of 4-(m-anisyl)-4-(dimethylamino)cyclohexanone, ethylene ketal hydrochloride having a melting point at 184° to 185.5° C.
Analysis: Calc'd. for C 17 H 25 NO 3 .HCl: C, 62.28; H, 7.99; N, 4.27. Found: C, 62.11; H, 8.24; N, 4.21.
PART I
Preparation of 4-(m-anisyl)-4-dimethylaminocyclohexanone
Following the procedure of Preparation I, Part i, but substituting 1.71 gm. (0.0052 mole) of 4-(m-anisyl)-4-dimethylaminocyclohexanone, ethylene ketal hydrochloride (prepared in Part h, above) for the 4-(p-chlorophenyl)-4-dimethylaminocyclohexanone, ethylene ketal hydrochloride, 7.5 ml. of 2.5 N hydrochloric acid for the 22.5 ml., and 15 ml. methanol for the 45 ml., there is prepared (after recrystallization from petroleum ether instead of diethyl ether) 0.54 gm. (45% yield) of 4-(m-anisyl)-4-dimethylaminocyclohexanone as the free base having a melting point at 57° to 59° C.
Analysis: Calc'd. for C 15 H 21 NO 2 : C, 72.84; H, 8.56; N, 5.66. Found: C, 72.88; H, 8.47; N, 5.72.
PREPARATION VI
Preparation of 4-(m-acetoxyphenyl)-4-(methyl-n-butylamino)cyclohexanone
PART A
4-Cyano-4-(m-hydroxyphenyl)cyclohexan-1-one
To an ice-cooled solution of 10.0 g. (0.044 mole) of 4-cyano-4-(m-anisyl)cyclohexan-1-one prepared in Preparation V, Part c, in 125 ml. methylene chloride there is added dropwise 13 ml. of boron tribromide. Following 4 hours stirring in the cold the mixture is poured onto ice and diluted with 50 ml. chloroform. The organic layer is washed with water, aqueous sodium bicarbonate and brine, and taken to dryness. The residual solid is recrystallized from acetone:Skellysolve B to give 7.60 gm. of product, m.p. 130°-133° C.
Analysis: Calc'd. for C 13 H 13 NO 2 : C, 72.54; H, 6.09; N, 6.51. Found: C, 72.50; H, 6.14; N, 6.35.
PART B
4 -Cyano-4-(m-hydroxyphenyl)cyclohexan-1-one, ethylene ketal
A mixture of 8.80 g., (0.041 mole) of 4-cyano-4-(m-hydroxyphenyl)cyclohexan-1-one, 2.50 ml. ethylene glycol and 0.26 gm. 1-toluenesulfonic acid in 170 ml. benzene is heated at reflux under a Dean-Stark trap for 4 hours. The mixture is then allowed to cool, washed with aqueous sodium bicarbonate and taken to dryness. The residual solid is recrystallized from methylene chloride:Skellysolve B to give 9.85 g. of the ketal, m.p. 109°-110.5° C.
Analysis: Calc'd. for C 15 H 17 NO 3 : C, 69.48; H, 6.61; N, 5.32. Found: C, 69.23; H, 6.69; N, 5.32.
PART C
4-Cyano-4-(m-benzyloxyphenyl)cyclohexan-1-one, ethylene ketal
To a solution of 9.85 gm. of 4-cyano-4-(m-hydroxyphenyl)cyclohexan-1-one, ethylene ketal in 40 ml. DMF and 80 ml. benzene there is added 1.85 gm. of a 50% dispersion of sodium hydride in mineral oil. The mixture is stirred for 15 mins. at room temperature and 1 hour at reflux. Benzyl chloride (6.53 gm.) is then added, the mixture is heated for an additional 4 hours and allowed to cool. The reaction mixture is washed in turn with water and brine and taken to dryness. The residual solid is recrystallized from ether:petroleum ether to give 11.70 gm. of product, m.p. 67°-69° C.
Analysis: Calc'd. for C 22 H 23 NO 3 : C, 75.62; H, 6.63; N, 4.01. Found: C, 75.34; H, 6.66; N, 4.01.
PART D
4-(m-benzyloxyphenyl)cyclohexan-1-one-4-carboxylic acid, ethylene ketal
A mixture of 7.00 gm. (0.020 mole) of 4-cyano-4-(m-benzyloxyphenyl)cyclohexan-1-one, ethylene ketal and 1.20 gm. sodium hydroxide in 50 ml. ethylene glycol is heated at reflux for 17 hours. The solution is allowed to cool, diluted to 300 ml. with water and covered with 100 ml. ether. The aqueous layer is acidified with 5 ml. concentrated hydrochloric acid and the organic layer separated. The aqueous layer is then extracted with 100 ml. portions of ether and methylene chloride. The extracts are combined, washed with water and brine and taken to dryness. There is obtained 7.22 gm. of acid, m.p. 108°-110.5° C. A small sample is recrystallized from ether to give the analytical sample, m.p. 118.5°-120.5° C.
Analysis: Calc'd. for C 22 H 24 O 5 : C, 71.72; H, 6.57. Found: C, 71.80; H, 6.89.
PART E
4-(m-Benzyloxyphenyl)-4-(methylamino)cyclohexan-1-one, ethylene ketal
A mixture of 7.22 gm. (0.020 mole) of 4-(m-benzyloxyphenyl)cyclohexan-1-one-4-carboxylic acid, ethylene ketal, 5.52 gm. of diphenylphosphonic azide and 2.8 ml. triethylamine in 50 ml. anisole is heated in an oil bath at 90° C. for 2 hours. The bulk of the solvent is then removed in vacuum and the residue chromatographed over 600 ml. silica gel. The column is eluted with 2% ethyl acetate in methylene chloride and those fractions which contain product as determined by TLC are combined. There is obtained 4.97 gm. of the intermediate isocyanate as an oil.
A solution of the product obtained above in 80 ml. THF is added to 0.78 gm. lithium aluminum hydride in 10 ml. THF. Following 6 hours heating at reflux the mixture is cooled in ice bath and treated in turn with 0.7 ml. water, 0.8 ml. 15% sodium hydroxide and 2.4 ml. water. The inorganic gel is separated on a filter and the filtrate taken to dryness. The residual solid is recrystallized from petroleum ether to afford 3.31 g. of product, m.p. 64°-66° C.
Analysis: Calc'd. for C 22 H 27 NO 3 : C, 74.75; H, 7.70; N, 3.96. Found: C, 75.03; H, 7.53; N, 3.93.
PART F
4-(methyl-n-butylamino)-4-(m-benzyloxyphenyl)cyclohexan-1-one, ethylene ketal
To an ice cold solution of 3.31 gm. (9.4 mmole) of 4-methylamino-4-(m-benzyloxyphenyl)cyclohexan-1-one, ethylene ketal and 1.30 ml. triethylamine in 40 ml. THF there is added dropwise 1.0 gm. (1.10 ml.) butyryl chloride. Following 6 hours' standing in the cold the bulk of the solvent is removed in vacuum. The residual is diluted with ice-water and ether. The organic layer is separated and washed in turn with water, saturated sodium bicarbonate and brine. The solution is taken to dryness to give the amide as a gum. Infrared spectrum is consistent with structure assigned (absorption at 1660 cm -1 ). A solution of the crude amide obtained above in 80 ml. THF is added to a suspension of 0.60 gm. lithium aluminum hydride in 10 ml. THF. Following 6 hours' heating at reflux the mixture is cooled in ice and treated in turn with 0.60 ml. water, 0.50 ml. 15% sodium hydroxide and 1.5 ml. water. The inorganic gel is collected on a filter and the filtrate taken to dryness. There is obtained 3.50 gm. of 4-(methyl-n-butylamino)-4-(m-benzyloxyphenyl)cyclohexanone, ethylene ketal as an amorphous gum which shows a single spot on TLC.
PART G
Preparation of 4-(methyl-n-butylamino)-4-(m-benzyloxyphenyl)cyclohexanone
Following the procedure of Preparation 1, Part i, but substituting 4-(methyl-n-butylamino)-4-(m-benzyloxyphenyl)cyclohexanone, ethylene ketal for 4-(p-chlorophenyl)-4-dimethylaminocyclohexanone, ethylene ketal hydrochloride there is obtained 4-(methyl-n-butylamino)-4-(m-benzyloxyphenyl)cyclohexanone.
PART H
4-(methyl-n-butylamino)-4-(m-hydroxyphenyl)cyclohexan-1-one, ethylene ketal hydrochloride
A mixture of 3.56 gm. of 4-(m-benzyloxyphenyl)-4-(methyl-n-butylamino)cyclohexanone (Preparation VI, Part f), 3.6 ml. 3 N etheral hydrogen chloride and 1.78 gm. 10% palladium on charcoal in 150 ml. ethyl acetate is shaken in an atmosphere of hydrogen for 18 hours. The catalyst and some precipitated product are then collected on a filter. The collected solid is washed thoroughly with chloroform. The combined filtrate and washes are then taken to dryness. The residual solid is recrystallized from methylene chloride:acetone to give 2.00 gm. of crystalline product, m.p. 208°-210° C.
PART I
Preparation of 4-(m-hydroxyphenyl)-4-(methyl-n-butylamino)cyclohexanone
Following the procedure of Preparation I, Part i, but substituting 4-(m-hydroxyphenyl)-4-(methyl-n-butylamino)cyclohexan-1-one, ethylene ketal hydrochloride (prepared in Part h, above) for the 4-(p-chlorophenyl)-4-dimethylaminocyclohexanone, ethylene ketal hydrochloride there is obtained the object compound, 4-(m-hydroxyphenyl)-4-(methyl-n-butylamino)cyclohexanone.
PART J
Following the procedure of Preparation XIII, but substituting 4-(m-hydroxyphenyl)-4-(methyl-n-butylamino)cyclohexanone (prepared in Preparation IV, Part i) for 4-(m-hydroxyphenyl)-4-(dimethylamino)cyclohexanone there is obtained the desired 4-(m-acetoxyphenyl)-4-(methyl-n-butylamino)cyclohexanone as the hydrochloride.
Analysis: Calc'd. for C 19 H 27 NO 3 .HCl.2/3H 2 O: C, 62.36; H, 8.17; N, 3.82. Found: C, 62.07; H, 7.81; N, 3.80.
PREPARATION VIIA
Preparation of 4-(p-chlorophenyl)-2-methyl-4-dimethylaminocyclohexanone
A solution consisting of 0.51 gm. (0.005 mole) diisopropylamine in 10 ml. tetrahydrofuran is chilled in an ice: methanol bath and 3 ml. of 1.68 N butyllithium in pentane is added. To this mixture is then added a solution consisting of 1.25 gm. (0.005 mole) 4(p-chlorophenyl)-4-dimethylaminocyclohexanone (prepared in Preparation I, above) in 20 ml. tetrahydrofuran. After 5 min. stirring, 1.42 gm. methyl iodide is added. The reaction mixture is stirred for another 30 min. in the cold, and then it is allowed to warm up to 25° C. Stirring is continued for 21/2 hours when 20 ml. saturated aqueous ammonium chloride is added. Benzene is also added. The organic solvent phase is separated, washed initially with water and then with brine. The organic solvents are removed by evaporation under reduced pressure. The residue thus obtained is transferred to a chromatographic column containing 200 ml. silica gel. The chromatogram is developed with 2 liters of a mixture of 3% methanol in methylene chloride followed by 2 liters of a mixture of 5% methanol in methylene chloride. Fractions which are shown by TLC to contain product are collected and combined. The solvents are removed by evaporation under reduced pressure giving the desired 4-(p-chlorophenyl)-2-methyl-4-dimethylaminocyclohexanone. The compound is recrystallized from diethyl ether to give an analytical sample having a melting point at 110° to 111° C. This is recognized to be the cis isomer with respect to the 4-amino substituent, by NMR spectroscopy.
Analysis: Calc'd for C 15 H 20 ClNO: C, 67.78; H, 7.59; N, 5.27. Found: C, 67.75; H, 7.59; N, 5.56.
The corresponding trans isomer is obtained from subsequent fractions eluted from the same column. It is recrystallized from a mixture of diethyl ether and technical hexane to give 0.52 gm. of the isomer having a melting point at 103° to 105° C.
PREPARATION VIIB
Following the same procedures as in Preparation VIIA, but substituting, e.g., ethyl iodide, n-propyl iodide, and n-butyl iodide for methyl iodide, there are prepared the corresponding
4-(p-chlorophenyl)-2-ethyl-4-dimethylaminocyclohexanone,
4-(p-chlorophenyl)-4-dimethylamino-2-n-propylcyclohexanone, and
2-n-butyl-4-(p-chlorophenyl)-4-dimethylaminocyclohexanone, respectively.
PREPARATION VIII
PART A
Following the procedure as described in Preparation III, Part b, but separately substituting diethylamine, di-n-propylamino, di-n-butylamine, N-n-propyl-N-2-butenylamine, N-methyl-N-cyclopropylamine, and N-allyl-N-cyclopropylmethylamine, as the hydrochlorides, for dimethylamine hydrochloride, there are prepared the corresponding intermediates:
4-cyano-4-diethylaminocyclohexanone, ethylene ketal,
4-cyano-4-dipropylaminocyclohexanone, ethylene ketal,
4-cyano-4-di-n-butylaminocyclohexanone, ethylene ketal,
4-cyano-4-(N-propyl-N-2-butenylamino)cyclohexanone, ethylene ketal,
4-cyano-4-(N-methyl-N-cyclopropylamino)cyclohexanone, ethylene ketal,
4-cyano-4-(N-allyl-N-cyclopropylmethylamino)cyclohexanone, ethylene ketal.
PART B
Following the procedure as described in Preparation III, Part c, but separately substituting each intermediate prepared in Part a (above) for the 4-cyano-4-dimethylaminohexanone, ethylene ketal, there are prepared the corresponding object compounds:
4-(p-chlorophenyl)-4-diethylaminocyclohexanone, ethylene ketal hydrochloride,
4-(p-chlorophenyl)-4-di-n-propylaminocyclohexanone, ethylene ketal hydrochloride,
4-(p-chlorophenyl)-4-di-n-butylaminocyclohexanone, ethylene ketal hydrochloride,
4-(p-chlorophenyl)-4-(N-propyl-N-2-butenylamino)cyclohexanone, ethylene ketal hydrochloride,
4-(p-chlorophenyl)-4-(N-methyl-N-cyclopropylamino)cyclohexanone, ethylene ketal hydrochloride, and
4-(p-chlorophenyl)-4-(N-allyl-N-cyclopropylmethylamino)cyclohexanone, ethylene ketal hydrochloride, respectively.
PART C
Following the procedure as described in Preparation IV, Part b, but separately substituting each intermediate prepared in Part b (above) for the 4-(m-hydroxyphenyl)-4-dimethylaminocyclohexanone, ethylene ketal, there are prepared the corresponding:
4-(p-chlorophenyl)-4-diethylaminocyclohexanone,
4-(p-chlorophenyl)-4-di-n-propylaminocyclohexanone,
4-(p-chlorophenyl)-4-di-n-butylaminocyclohexanone,
4-(p-chlorophenyl)-4-(N-propyl-N-2-butenylamino)cyclohexanone,
4-(p-chlorophenyl)-4-(N-methyl-N-cyclopropylamino)cyclohexanone, and
4-(p-chlorophenyl)-4-(N-allyl-N-cyclopropylmethylamino)cyclohexanone, respectively.
PREPARATION IX
Preparation of 2-Methyl-4-dimethylamino-4-(p-tolyl)cyclohexanone
A solution consisting of 1.02 gm. (0.010 mole) diisopropylamine in 20 ml. tetrahydrofuran is chilled in an ice-methanol bath before 6 ml. of 1.68 N butyllithium in pentane is added. To this mixture is then added a solution consisting of 2.31 gm. of 4-dimethylamino-4-(p-tolyl)cyclohexanone (prepared according to the procedure of Preparation I, Parts a through i, above) and 40 ml. tetrahydrofuran. Five minutes later, 2.82 gm. methyl iodide is added, and the mixture is stirred for 45 min. in the cold. It is allowed to warm up to 25° C. and stirring is continued for 5 hours, when the reaction mixture is diluted with a mixture of water and benzene. The organic layer is separated and washed first with water and then with brine. The organic solvents are removed by evaporation under reduced pressure, and the residual waxy solid thus obtained transferred to a column of silica gel 1" by 4 ft. The chromatogram is developed with a solvent medium consisting of 7.5% methanol in chloroform. Fractions which are shown by TLC to contain product are collected and combined. The solvent is removed by evaporation under reduced pressure, and the residue thus obtained is recrystallized from ether. There is thus obtained 1.01 gm. (39% yield) of the object compound 2-methyl-4-dimethylamino-4-(p-tolyl)cyclohexanone having a melting point at 102° to 104.5° C.
Analysis: Calc'd for C 16 H 23 NO: C, 78.32; H, 9.45; N, 5.71. Found: C, 78.03; H, 9.51; N, 5.65.
PREPARATION X
Following the procedure of Preparation IX, above, but separately substituting each compound prepared in Preparation VIII, Part c for the 4-dimethylamino-4-(p-tolyl)cyclohexanone, there are prepared the corresponding object compounds:
4-(p-chlorophenyl)-4-diethylamino-2-methylcyclohexanone,
4-(p-chlorophenyl)-4-di-n-propylamino-2-methylcyclohexanone,
4-(p-chlorophenyl)-4-di-n-butylamino-2-methylcyclohexanone,
4-(p-chlorophenyl)-4-(N-propyl-N-2-butenylamino)-2-methylcyclohexanone,
4-(p-chlorophenyl)-4-(N-methyl-N-cyclopropylamino)-2-methylcyclohexanone, and
4-(p-chlorophenyl)-4-(N-allyl-N-cyclopropylmethylamino)-2-methylcyclohexanone, respectively.
PREPARATION XI
Following the procedure of Preparation I, Parts a through i, but initially substituting
p-methoxyphenyl acetonitrile,
o-methylphenyl acetonitrile,
p-bromophenyl acetonitrile,
p-ethoxyphenyl acetonitrile,
m-benzyloxyphenyl acetonitrile,
2,4-diethylphenyl acetonitrile,
3,5-dichlorophenyl acetonitrile,
(3-methoxy-4-chloro)phenyl acetonitrile,
(2-methyl-4-n-butyl)phenyl acetonitrile, for p-chlorophenyl acetonitrile, and subsequently substituting the respective intermediates at each step there are obtained the following compounds:
4-(p-methoxyphenyl)-4-dimethylaminocyclohexanone,
4-(p-methylphenyl)-4-dimethylaminocyclohexanone,
4-(p-bromophenyl)-4-dimethylaminocyclohexanone,
4-(p-ethoxyphenyl)-4-dimethylaminocyclohexanone,
4-(m-benzyloxyphenyl)-4-dimethylaminocyclohexanone,
4-(2,4-diethylphenyl)-4-dimethylaminocyclohexanone,
4-(3,5-dichlorophenyl)-4-dimethylaminocyclohexanone,
4-(3-methoxy-4-chlorophenyl)-4-dimethylaminocyclohexanone, and
4-(2-methyl-4-n-butylphenyl)-4-dimethylaminocyclohexanone, respectively.
PREPARATION XII
Following the procedure of Preparation VI (Part f) but substituting acetyl chloride, propionyl chloride, valeryl chloride, cyclopropanecarbonyl chloride, cyclohexylacetyl chloride, benzoyl chloride and 2,2-dimethylpropionyl chloride for butyryl chloride there are obtained the following compounds:
4-(methylethylamino)-4-(m-benzyloxyphenyl)cyclohexanone,
4-(methyl-n-propylamino)-4-(m-benzyloxyphenyl)cyclohexanone,
4-(n-pentylmethylamino)-4-(m-benzoyloxyphenyl)cyclohexanone,
4-(N-methyl-N-cyclopropylmethylamino)-4-(m-benzyloxyphenyl)cyclohexanone,
4-(N-β-cyclohexylethyl-N-methylamino)-4-(m-benzyloxyphenyl)cyclohexanone,
4-(N-benzyl-N-methylamino)-4-(m-benzyloxyphenyl)cyclohexanone, and
4-(N-methyl-N-pivalylamino)-4-(m-benzyloxyphenyl)cyclohexanone.
PREPARATION XIII
Preparation of 4-(m-acetoxyphenyl)-4-dimethylaminocyclohexan-1-one
To a solution of 0.96 gm. (4.1 mmole) of 4-(m-hydroxyphenyl)-4-dimethylaminocyclohexan-1-one (prepared in Preparation IV, Part b) in 20 ml. THF there is added 0.46 gm. (0.63 ml.) triethylamine and 0.46 gm. (0.42 ml.) acetic anhydride. Following 6 hours standing at room temperature the mixture is concentrated in vacuum and the residue diluted with ice:water. The precipitated gum is extracted with methylene chloride. The extract is washed with saturated sodium bicarbonate and brine and taken to dryness. The residue is chromatographed over a 1"×48" column of TLC grade silica gel. These fractions shown by TLC to contain product are collected and taken to dryness. The solid which remains is recrystallized from petroleum ether to give 0.30 gm. of 4-(m-acetoxyphenyl)-4-dimethylaminocyclohexan-1-one, m.p. 51°-53° C.
Analysis: Calc'd. for C 16 H 21 NO 3 : C, 69.79; H, 7.69; N, 5.09. Found: C, 69.47; H, 7.89; N, 5.21.
EXAMPLE 1
Preparation of 1-dimethylamino-4-N-morpholino-1-phenylcyclohexane
A reaction mixture consisting of 2.31 gm. (0.01 mole) 4-dimethylamino-4-phenylcyclohexanone, (prepared in Preparation II, Part i, above) 0.87 gm. (0.01 mole) morpholine, 0.05 gm. p-toluenesulfonic acid, and 40 ml. benzene is heated at the reflux temperature, in a reaction vessel fitted with a Dean and Stark trap, for six (6) hours. The benzene is then removed by evaporation under reduced pressure, and the residue is dissolved in 60 ml. absolute ethanol. To this solution is added 0.76 gm. (0.02 mole) sodium borohydride. The mixture is heated at the reflux temperature for eighteen (18) hours, after which interval the ethanol is allowed to evaporate. The residue thus obtained is dissolved in a mixture of diethyl ether and water. The ether phase is separated from the water phase, and washed with water followed by a brine solution. After removing the ether by evaporation, the gummy residue is transferred to a chromatographic column having 300 ml. silica gel. Development of the chromatogram with a solvent mixture consisting of methanol and methylene chloride (1:4) gives eluate fractions which are combined. Crystals form on evaporation. Two recrystallizations from aqueous methanol give 1.13 gm. (39% yield) of the object compound 1-dimethylamino-4-N-morpholino- 1-phenylcyclohexane (less polar isomer) having a melting point at 84° to 85° C.
Analysis: Calc'd. for C 18 H 28 N 2 O: C, 74.95; H, 9.78; N, 9.71. Found: C, 74.75; H, 9.83; N, 9.67.
Further development of the chromatogram with a solvent mixture consisting of methanol and methylene chloride in proportions of 2:3, respectively, gives fractions from which an oil is recovered. The oil thus obtained is dissolved in methanol and the methanolic solution is treated with an excess of 3 N hydrogen chloride in diethyl ether. After removing the methanol and excess hydrogen chloride under reduced pressure, and recrystallizing the residue from a mixture of methanol and ethyl acetate, there is obtained 0.37 gm. of the more polar isomeric form of 1-dimethylamino-4-morpholino-1-phenylcyclohexane dihydrochloride as the monohydrate, having a melting point at 267° to 268° C.
Analysis: Calc'd. for C 18 H 28 N 2 O.2HCl.H 2 O: C, 56.98; H, 8.50; N, 7.39. Found: C, 57.14; H, 8.82; N, 7.39.
EXAMPLE 2
Preparation of 1-dimethylamino-4-(1-pyrrolidinyl)-1-phenylcyclohexane dihydrochloride
A reaction mixture consisting of 2.30 gm. (0.010 mole) 4-dimethylamino-4-phenylcyclohexanone, (prepared in Preparation II, Part i, above) 2.0 ml. pyrrolidine, 0.50 gm. p-toluenesulfonic acid, and 40 ml. benzene is heated at the reflux temperature, in a vessel fitted with a Dean and Stark trap, for eighteen (18) hours. The benzene is then removed by evaporation under reduced pressure, and the residue is dissolved in 30 ml. tetrahydrofuran (THF). To this solution is added 0.76 gm. (0.020 mole) sodium borohydride in 10 ml. ethanol. This mixture is heated at the reflux temperature for sixteen (16) hours, after which interval, most of the ethanol is allowed to evaporate under reduced pressure. The ethanolic concentrate thus obtained is dispersed in a mixture of diethyl ether and water. After vigorous shaking, and after allowing the aqueous and organic phases to separate, the ether layer is recovered. It is washed first with water and then with brine. The ether is then removed by evaporation. The residue thus obtained is transferred for purposes of chromatographic purification onto a 250 ml. column of silica gel. The chromatogram is developed with a solvent mixture consisting of 1% ammonia and 10% methanol in methylene chloride. The first material obtained in the eluate is a waxy solid. It is dissolved in methanol and treated with an excess of 3 N ethereal hydrogen chloride. After removing the ether methanol and excess hydrogen chloride by evaporation, the residue is recrystallized two times from a mixture of methanol and ethyl acetate. There is thus obtained 0.86 gm. of 1-dimethylamino-4-(1-pyrrolidinyl)-1-phenylcyclohexane dihydrochloride monohydrate having a melting point at 200°-204° C.
Analysis: Calc'd. for C 18 H 28 N 2 O.2HCl.H 2 O: C, 59.49; H, 8.79; N, 7.71. Found: C, 58.90; H, 8.79; N, 7.22.
The more polar isomer of the 1-dimethylamino-4-(1-pyrolidinyl)-1-phenylcyclohexane free base is obtained by further elution of the column with the same solvent mixture. It is recovered from the eluate and recrystallized several times from aqueous methanol to give a 60.0 mg. amount which has a melting point at 83° to 84° C.
Analysis: Calc'd. for C 18 H 28 N 2 : C, 79.35; H, 10.36; N, 10.29. Found: C, 79.36; H, 9.92; N, 10.01.
EXAMPLE 3
Preparation of 1-Dimethylamino-4-(N-piperidino)-1-phenylcyclohexane dihydrochloride
A reaction mixture consisting of 2.30 gm. (0.01 mole) 4-dimethylamino-4-phenylcyclohexanone (prepared in Preparation II, Part i, above) 1.6 ml. piperidine, 0.05 gm. paratoluenesulfonic acid, and 40 ml. benzene is heated for eighteen (18) hours at the reflux temperature in a reaction vessel fitted with a Dean and Stark trap. The benzene is then removed by evaporation under reduced pressure. The residue thus obtained is dissolved in 25 ml. of THF that has been chilled to 0° C. To this solution is added 0.76 gm. (0.02 mole) sodium borohydride in 10 ml. ethanol. This reaction mixture is heated at the reflux temperature for another interval of 18 hours, after which the ethanol is substantially all removed by evaporation under reduced pressure. The concentrate thus obtained is dissolved in a mixture of diethyl ether and water. After vigorous mixing and shaking the organic and aqueous phases are allowed to separate, and the organic phase is recovered. It is washed first with water and then with brine. The ether is then allowed to evaporate. The residue thus obtained is transferred onto a 250 ml. column of silica gel in order to effect a chromatographic purification. The column is developed with a solvent system consisting of 15% methanol in methylene chloride with 1% ammonium hydroxide present.
The substance obtained from the first eluate fractions is recovered by evaporating the solvents under reduced pressure. It is dissolved in methanol and the methanolic solution is treated with 10 ml. of 3 N ethereal hydrogen chloride. After removing the methanol, diethyl ether, and excess hydrogen chloride by evaporation under reduced pressure, the residue is recrystallized from a mixture of methanol and ethyl acetate to give 1.92 gm. (53% yield) of 1-dimethylamino-4-piperidino-1-phenylcyclohexane dihydrochloride having a melting point at 245° to 246° C.
Analysis: Calc'd. for C 19 H 30 N 2 .2HCl: C, 63.50; H, 8.98; N, 7.80. Found: C, 63.25; H, 9.27; N, 7.72.
Further elution of the column with 40% methanol in methylene chloride containing 4% ammonium hydroxide affords a more polar isomer that upon recrystallization from aqueous methanol amounts to 90 mg. of 1-dimethylamino-4-(N-piperidino)-1-phenylcyclohexane free base having a melting point at 89° to 91° C.
Analysis: Calc'd. for C 19 H 30 N 2 : C, 79.66; H, 10.56; N, 9.78. Found: C, 78.95; H, 10.74; N, 9.64.
EXAMPLE 4
Preparation of 1-(p-Chlorophenyl)-1-dimethylamino-4-N-morpholinocyclohexane
A reaction mixture consisting of 2.63 gm. (0.01 mole) 4-(p-chlorophenyl)-4-dimethylaminocyclohexanone (prepared as in Preparation I, Part i, above), 0.87 ml. morpholine, 0.05 gm. para-toluenesulfonic acid, and 40 ml. benzene is heated at the reflux temperature for seven (7) hours in a reaction vessel fitted with a Dean and Stark trap. The benzene is then removed by evaporation under reduced pressure. The residue thus obtained is dissolved in 10 ml. tetrahydrofuran, to which solution is added 0.76 gm. (0.02 mole) sodium borohydride in 35.0 ml. absolute ethanol. This reaction mixture is heated at the reflux temperature for seventeen (17) hours, after which heating the tetrahydrofuran and ethanol are removed by evaporation under pressure. The residue thus obtained is dispersed in a mixture of water and diethyl ether. After vigorous shaking and allowing the aqueous and organic phases to separate, the organic phase is recovered. It is washed first with water and then with brine. The ether is then allowed to evaporate. The residue thus obtained is transferred onto a 1 inch by 4 foot column of silica gel averaging 20 to 50 microns in size, for purposes of high pressure liquid chromatographic (HPLC) purification. The chromatogram is developed with a solvent system consisting of 5% methanol in chloroform with 1% triethylamine. The fractions of eluate containing the object compound yield a solid which is recrystallized from aqueous methanol to give 0.95 gm. (30% yield) of 1-(p-chlorophenyl)-1-dimethylamino-4-morpholinocyclohexane having a melting point at 103° to 105° C.
Analysis: Calc'd for C 18 H 27 ClN 2 O: C, 66.95; H, 8.43; N, 8.68. Found: C, 66.73; H, 8.52; N, 8.54.
EXAMPLE 5
Preparation of 1-Dimethylamino-4-(N-allyl-N-methylamino)-1-(p-chlorophenyl)cyclohexane and its dihydrochloride hydrate
A mixture of 1.50 gm. (6 mmole) of 4-(p-chlorophenyl)-4-dimethylaminocyclohexanone, 2.5 ml. N-allyl-N-methylamine and 0.05 gm. p-toluenesulfonic acid in 40 ml. benzene is stirred at reflux temperature under molecular sieve trap for 30 hours. The mixture is taken to dryness and the residue is dissolved in 25 ml. of tetrahydrofuran. To this ice-cooled solution is added 0.25 gm. of sodium borohydride in 25 ml. of ethanol. Following eighteen (18) hours' heating at reflux, the bulk of the solvent is removed under vacuum and the residue partitioned between water and ether as described in Example 4. The organic phase is washed sequentially with water and with brine and the ether is removed by evaporation. The residue is placed on a 1 inch by 48 inch silica gel column and eluted by high pressure liquid chromatography using a solvent system consisting of 0.5% ammonium hydroxide and 5% methanol in chloroform. The less polar isomer is eluted first; it is converted to the dihydrochloride salt by reaction with 3 N alcoholic hydrogen chloride. The salt is recrystallized from a methanol-ethyl acetate solvent mixture to give 0.95 gm. (41% yield) of 1-(p-chlorophenyl)-1-dimethylamino-4-(N-methyl-N-allylamino)cyclohexane dihydrochloride hydrate having a melting point of 224° -226° C.
Analysis: Calc'd. for C 18 H 27 ClN.2HCl.H 2 O: C, 54.34; H, 7.85; N, 7.04. Found: C, 54.44; H, 7.80; N, 7.04.
Further elution of the chromatographic column with 10% methanol in chloroform gives the more polar isomer form. As with the less polar isomer, the dihydrochloride is prepared and recrystallized from a methanol-acetonitrile solvent mixture. A 0.20 gm. (8.7% yield) quantity of compound is obtained as the hemihydrate having a melting point of 253°-254° C.
Analysis: Calc'd. for C 18 H 27 ClN.2HCl.1/2H 2 O: C, 55.60; H, 7.78; N, 7.21. Found: C, 55.54; H, 7.71; N, 7.46.
EXAMPLE 6
Following the procedure of Example 4, but separately substituting each of the intermediates prepared according to Preparation VIII for 4-(p-chlorophenyl)-4-dimethylaminocyclohexanone, and
methylethylamine,
N-allyl-N-propylamine,
N-β-phenethyl-N-methylamine,
N-(2-methoxy-4-chlorophenyl)-N-ethylamine,
N-(3,5-dimethylphenyl)-N-propylamine,
morpholine,
4-ethylpiperidine,
4-methylpiperazine,
3-propylpyrrolidine for morpholine, and reacting each amine independently with each ketone there are obtained the following compounds:
1-(p-chlorophenyl)-1-diethylamino-4-methylethylaminocyclohexane;
1-(p-chlorophenyl)-1-diethylamino-4-(N-allyl-N-propylamino)cyclohexane;
1-(p-chlorophenyl)-1-diethylamino-4-(N-β-phenethyl-N-methylamino)cyclohexane;
1-(p-chlorophenyl)-1-diethylamino-4-[N-(2-methoxy-4-chlorophenyl)-N-ethylamino]cyclohexane;
1-(p-chlorophenyl)-1-diethylamino-4-(N-3,5-dimethylphenyl-N-propylamino)cyclohexane;
1-(p-chlorophenyl)-1-diethylamino-4-N-morpholinocyclohexane;
1-(p-chlorophenyl)-1-diethylamino-4-(4-ethyl-N-piperidino)cyclohexane;
1-(p-chlorophenyl)-1-diethylamino-4-(4-methylpiperazino)cyclohexane; and
1-(p-chlorophenyl)-1-diethylamino-4-(3-propyl-N-pyrrolidino)cyclohexane;
1-(p-chlorophenyl)-1-di-n-propylamino-4-methylethylaminocyclohexane;
1-(p-chlorophenyl)-1-di-n-propylamino-4-(N-allyl-N-propylamino)cyclohexane;
1-(p-chlorophenyl)-1-di-n-propylamino-4-(N-β-phenethyl-N-methylamino)cyclohexane;
1-(p-chlorophenyl)-1-di-n-propylamino-4-[N-(2-methoxy-4-chlorophenyl)-N-ethylamino]cyclohexane;
1-(p-chlorophenyl)-1-di-n-propylamino-4-(N-3,4-dimethylphenyl-N-propylamino)cyclohexane;
1-(p-chlorophenyl)-1-di-n-propylamino-4-N-morpholinocyclohexane;
1-(p-chlorophenyl)-1-di-n-propylamino-4-(4-ethyl-N-piperidino)cyclohexane;
1-(p-chlorophenyl)-1-di-n-propylamino-4-(4-methylpiperazino)cyclohexane; and
1-(p-chlorophenyl)-1-di-n-propylamino-4-(3-propyl-N-pyrrolidino)cyclohexane;
1-(p-chlorophenyl)-1-di-n-butylamino-4-methylethylaminocyclohexane;
1-(p-chlorophenyl)-1-di-n-butylamino-4-(N-allyl-N-propylamino)cyclohexane;
1-(p-chlorophenyl)-1-di-n-butylamino-4-(N-β-phenethyl-N-methylamino)cyclohexane;
1-(p-chlorophenyl)-1-di-n-butylamino-4-[N-(2-methoxy-4-chlorophenyl)-N-ethylamino]cyclohexane;
1-(p-chlorophenyl)-1-di-n-butylamino-4-(N-3,5-dimethylphenyl-N-propylamino)cyclohexane;
1-(p-chlorophenyl)-1-di-n-butylamino-4-N-morpholinocyclohexane;
1-(p-chlorophenyl)-1-di-n-butylamino-4-(4-ethyl-N-piperidino)cyclohexane;
1-(p-chlorophenyl)-1-di-n-butylamino-4-(4-methylpiperazino)cyclohexane; and
1-(p-chlorophenyl)-1-di-n-butylamino-4-(3-propyl-N-pyrrolidino)cyclohexane;
1-(p-chlorophenyl)-1-(N-propyl-N-2-butenylamino)-4-methylethylaminocyclohexane;
1-(p-chlorophenyl)-1-(N-propyl-N-2-butenylamino)-4-(N-allyl-N-propylamino)cyclohexane;
1-(p-chlorophenyl)-1-(N-propyl-N-2-butenylamino)-4-(N-β-phenethyl-N-methylamino)cyclohexane;
1-(p-chlorophenyl)-1-(N-propyl-N-2-butenylamino)-4-[N-(2-methoxy-4-chlorophenyl)-N-ethylamino]cyclohexane;
1-(p-chlorophenyl)-1-(N-propyl-N-2-butenylamino)-4-(N-3,5-dimethylphenyl-N-propylamino)cyclohexane;
1-(p-chlorophenyl)-1-(N-propyl-N-2-butenylamino)-4-N-morpholinocyclohexane;
1-(p-chlorophenyl)-1-(N-propyl-N-2-butenylamino)-4-(4-ethyl-N-piperidino)cyclohexane;
1-(p-chlorophenyl)-1-(N-propyl-N-2-butenylamino)-4-(4-methylpiperazino)cyclohexane; and
1-(p-chlorophenyl)-1-(N-propyl-N-2-butenylamino)-4-(3-propyl-N-pyrrolidino)cyclohexane;
1-(p-chlorophenyl)-1-(N-methyl-N-cyclopropylamino)-4-methylethylaminocyclohexane;
1-(p-chlorophenyl)-1-(N-methyl-N-cyclopropylamino)-4-(N-allyl-N-propylamino)cyclohexane;
1-(p-chlorophenyl)-1-(N-methyl-N-cyclopropylamino)-4-(N-β-phenethyl-N-methylamino)cyclohexane;
1-(p-chlorophenyl)-1-(N-methyl-N-cyclopropylamino)-4-[N-(2-methoxy-4-chlorophenyl)-N-ethylamino]cyclohexane;
1-(p-chlorophenyl)-1-(N-methyl-N-cyclopropylamino)-4-(N-3,5-dimethylphenyl-N-propylamino)cyclohexane;
1-(p-chlorophenyl)-1-(N-methyl-N-cyclopropylamino)-4-N-morpholinocyclohexane;
1-(p-chlorophenyl)-1-(N-methyl-N-cyclopropylamino)-4-(4-ethyl-N-piperidino)cyclohexane;
1-(p-chlorophenyl)-1-(N-methyl-N-cyclopropylamino)-4-(4-methylpiperazino)cyclohexane; and
1-(p-chlorophenyl)-1-(N-methyl-N-cyclopropylamino)-4-(3-propyl-N-pyrrolidino)cyclohexane;
1-(p-chlorophenyl)-1-(N-allyl-N-cyclopropylmethyl-amino)-4-methylethylaminocyclohexane;
1-(p-chlorophenyl)-1-(N-allyl-N-cyclopropylmethylamino)-4-(N-allyl-N-propylamino)cyclohexane;
1-(p-chlorophenyl)-1-(N-allyl-N-cyclopropylmethylamino)-4-(N-β-phenethyl-N-methylamino)cyclohexane;
1-(p-chlorophenyl)-1-(N-allyl-N-cyclopropylmethylamino)-4-[N-(2-methoxy-4-chlorophenyl)-N-ethylamino]cyclohexane;
1-(p-chlorophenyl)-1-(N-allyl-N-cyclopropylmethylamino)-4-(N-3,5-dimethoxyphenyl-N-propylamino)cyclohexane;
1-(p-chlorophenyl)-1-(N-allyl-N-cyclopropylmethylamino)-4-N-morpholinocyclohexane;
1-(p-chlorophenyl)-1-(N-allyl-N-cyclopropylmethylamino)-4-(4-ethyl-N-piperidino)cyclohexane;
1-(p-chlorophenyl)-1-(N-allyl-N-cyclopropylmethylamino)-4-(4-methylpiperazino)cyclohexane; and
1-(p-chlorophenyl)-1-(N-allyl-N-cyclopropylmethylamino)-4-(3-propyl-N-pyrrolidino)cyclohexane.
EXAMPLE 7
Following the procedure of Example 4 but separately substituting each of the compounds prepared according to Preparations VIIB and X for 4-(p-chlorophenyl)-4-dimethylaminocyclohexanone and
methylethylamine,
N-allyl-N-propylamine,
N-β-phenethyl-N-methylamine,
N-(2-methoxy-4-chlorophenyl)-N-ethylamine,
N-(3,5-dimethylphenyl)-N-propylamine,
morpholine,
4-ethylpiperidine,
4-methylpiperazine,
3-propylpyrrolidine for morpholine, and reacting each amine independently with each ketone there are obtained the following compounds:
1-(p-chlorophenyl)-1-dimethylamino-3-ethyl-4-methylethylaminocyclohexane;
1-(p-chlorophenyl)-1-dimethylamino-3-ethyl-4-(N-allyl-N-propylamino)cyclohexane;
1-(p-chlorophenyl)-1-dimethylamino-3-ethyl-4-(N-β-phenethyl-N-methylamino)cyclohexane;
1-(p-chlorophenyl)-1-dimethylamino-3-ethyl-4-[N-(2-methoxy-4-chlorophenyl)-N-ethylamino]cyclohexane;
1-(p-chlorophenyl)-1-dimethylamino-3-ethyl-4-(N-3,5-dimethylphenyl-N-propylamino)cyclohexane;
1-(p-chlorophenyl)-1-dimethylamino-3-ethyl-4-N-morpholinocyclohexane;
1-(p-chlorophenyl)-1-dimethylamino-3-ethyl-4-(4-ethyl-N-piperidino)cyclohexane;
1-(p-chlorophenyl)-1-dimethylamino-3-ethyl-4-(4-methylpiperazino)cyclohexane; and
1-(p-chlorophenyl)-1-dimethylamino-3-ethyl-4-(3-propyl-N-pyrrolidino)cyclohexane;
1-(p-chlorophenyl)-1-dimethylamino-3-n-propyl-4-methylethylaminocyclohexane;
1-(p-chlorophenyl)-1-dimethylamino-3-n-propyl-4-(N-allyl-N-propylamino)cyclohexane;
1-(p-chlorophenyl)-1-dimethylamino-3-n-propyl-4-(N-β-phenethyl-N-methylamino)cyclohexane;
1-(p-chlorophenyl)-1-dimethylamino-3-n-propyl-4-[N-(2-methoxy-4-chlorophenyl)-N-ethylamino]cyclohexane;
1-(p-chlorophenyl)-1-dimethylamino-3-n-propyl-4-(N-3,5-dimethylphenyl-N-propylamino)cyclohexane;
1-(p-chlorophenyl)-1-dimethylamino-3-n-propyl-4-N-morpholinocyclohexane;
1-(p-chlorophenyl)-1-dimethylamino-3-n-propyl-4-(4-ethyl-N-piperidino)cyclohexane;
1-(p-chlorophenyl)-1-dimethylamino-3-n-propyl-4-(4-methylpiperazino)cyclohexane; and
1-(p-chlorophenyl)-1-dimethylamino-3-n-propyl-4-(3-propyl-N-pyrrolidino)cyclohexane;
1-(p-chlorophenyl)-1-dimethylamino-3-n-butyl-4-methylethylaminocyclohexane;
1-(p-chlorophenyl)-1-dimethylamino-3-n-butyl-4-(N-allyl-N-propylamino)cyclohexane;
1-(p-chlorophenyl)-1-dimethylamino-3-n-butyl-4-(N-β-phenethyl-N-methylamino)cyclohexane;
1-(p-chlorophenyl)-1-dimethylamino-3-n-butyl-4-[N-(2-methoxy-4-chlorophenyl)-N-ethylamino]cyclohexane;
1-(p-chlorophenyl)-1-dimethylamino-3-n-butyl-4-(N-3,5-dimethylphenyl-N-propylamino)cyclohexane;
1-(p-chlorophenyl)-1-dimethylamino-3-n-butyl-4-N-morpholinocyclohexane;
1-(p-chlorophenyl)-1-dimethylamino-3-n-butyl-4-(4-ethyl-N-piperidino)cyclohexane;
1-(p-chlorophenyl)-1-dimethylamino-3-n-butyl-4-(4-methylpiperazino)cyclohexane; and
1-(p-chlorophenyl)-1-dimethylamino-3-n-butyl-4-(3-propyl-N-pyrrolidino)cyclohexane;
1-(p-chlorophenyl)-1-diethylamino-3-methyl-4-methylethylaminocyclohexane;
1-(p-chlorophenyl)-1-diethylamino-3-methyl-4-(N-allyl-N-propylamino)cyclohexane;
1-(p-chlorophenyl)-1-diethylamino-3-methyl-4-(N-β-phenethyl-N-methylamino)cyclohexane;
1-(p-chlorophenyl)-1-diethylamino-3-methyl-4-[N-(2-methoxy-4-chlorophenyl)-N-ethylamino]cyclohexane;
1-(p-chlorophenyl)-1-diethylamino-3-methyl-4-(N-3,5-dimethylphenyl-N-propylamino)cyclohexane;
1-(p-chlorophenyl)-1-diethylamino-3-methyl-4-N-morpholinecyclohexane;
1-(p-chlorophenyl)-1-diethylamino-3-methyl-4-(4-ethyl-N-piperidino)cyclohexane;
1-(p-chlorophenyl)-1-diethylamino-3-methyl-4-(4-methylpiperazino)cyclohexane; and
1-(p-chlorophenyl)-1-diethylamino-3-methyl-4-(3-propyl-N-pyrrolidino)cyclohexane;
1-(p-chlorophenyl)-1-di-n-propylamino-3-methyl-4-methylethylaminocyclohexane;
1-(p-chlorophenyl)-1-di-n-propylamino-3-methyl-4-(N-allyl-N-propylamino)cyclohexane;
1-(p-chlorophenyl)-1-di-n-propylamino-3-methyl-4-(N-β-phenethyl-N-methylamino)cyclohexane;
1-(p-chlorophenyl)-1-di-n-propylamino-3-methyl-4-[N-(2-methoxy-4-chlorophenyl)-N-ethylamino]cyclohexane;
1-(p-chlorophenyl)-1-di-n-propylamino-3-methyl-4-(N-3,5-dimethylphenyl-N-propylamino)cyclohexane;
1-(p-chlorophenyl)-1-di-n-propylamino-3-methyl-4-N-morpholinocyclohexane;
1-(p-chlorophenyl)-1-di-n-propylamino-3-methyl-4-(4-ethyl-N-piperidino)cyclohexane;
1-(p-chlorophenyl)-1-di-n-propylamino-3-methyl-4-(4-methylpiperazino)cyclohexane; and
1-(p-chlorophenyl)-1-di-n-propylamino-3-methyl-4-(3-propyl-N-pyrrolidino)cyclohexane;
1-(p-chlorophenyl)1-1-di-n-butylamino-3-methyl-4-methylethylaminocyclohexane;
1-(p-chlorophenyl)-1-di-n-butylamino-3-methyl-4-(N-allyl-N-propylamino)cyclohexane;
1-(p-chlorophenyl)-1-di-n-butylamino-3-methyl-4-(N-β-phenethyl-N-methylamino)cyclohexane;
1-(p-chlorophenyl)-1-di-n-butylamino-3-methyl-4-[N-(2-methoxy-4-chlorophenyl)-N-ethylamino]cyclohexane;
1-(p-chlorophenyl)-1-di-n-butylamino-3-methyl-4-(N-3,5-dimethylphenyl-N-propylamino)cyclohexane;
1-(p-chlorophenyl)-1-di-n-butylamino-3-methyl-4-N-morpholinocyclohexane;
1-(p-chlorophenyl)-1-di-n-butylamino-3-methyl-4-(4-ethyl-N-piperidino)cyclohexane;
1-(p-chlorophenyl)-1-di-n-butylamino-3-methyl-4-(4-methylpiperazino)cyclohexane; and
1-(p-chlorophenyl)-1-di-n-butylamino-3-methyl-4-(3-propyl-N-pyrrolidino)cyclohexane;
1-(p-chlorophenyl)-1-(N-propyl-N-2-butenylamino)-3-methyl-4-methylethylaminocyclohexane;
1-(p-chlorophenyl)-1-(N-propyl-N-2-butenylamino)-3-methyl-4-(N-allyl-N-propylamino)cyclohexane;
1-(p-chlorophenyl)-1-(N-propyl-N-2-butenylamino)-3-methyl-4-(N-β-phenethyl-N-methylamino)cyclohexane;
1-(p-chlorophenyl)-1-(N-propyl-N-2-butenylamino)-3-methyl-4-[N-(2-methoxy-4-chlorophenyl)-N-ethylamino]-cyclohexane;
1-(p-chlorophenyl)-1-(N-propyl-N-2-butenylamino)-3-methyl-4-(N-3,5-dimethylphenyl-N-propylamino)cyclohexane;
1-(p-chlorophenyl)-1-(N-propyl-N-2-butenylamino)-3-methyl-4-N-morpholinocyclohexane;
1-(p-chlorophenyl)-1-(N-propyl-N-2-butenylamino)-3-methyl-4-(4-ethyl-N-piperidino)cyclohexane;
1-(p-chlorophenyl)-1-(N-propyl-N-2-butenylamino)-3-methyl-4-(4-methylpiperazino)cyclohexane; and
1-(p-chlorophenyl)-1-(N-propyl-N-2-butenylamino)-3-methyl-4-(3-propyl-N-pyrrolidino)cyclohexane;
1-(p-chlorophenyl)-1-(N-methyl-N-cyclopropylamino)-3-methyl-4-methylethylaminocyclohexane;
1-(p-chlorophenyl)-1-(N-methyl-N-cyclopropylamino)-3-methyl-4-(N-allyl-N-propylamino)cyclohexane;
1-(p-chlorophenyl)-1-(N-methyl-N-cyclopropylamino)-3-methyl-4-(N-β-phenethyl-N-methylamino)cyclohexane;
1-(p-chlorophenyl)-1-(N-methyl-N-cyclopropylamino)-3-methyl-4-[N-(2-methoxy-4-chlorophenyl)-N-ethylamino]-cyclohexane;
1-(p-chlorophenyl)-1-(N-methyl-N-cyclopropylamino)-3-methyl-4-(N-3,5-dimethylphenyl-N-propylamino)cyclohexane;
1-(p-chlorophenyl)-1-(N-methyl-N-cyclopropylamino)-3-methyl-4-N-morpholinocyclohexane;
1-(p-chlorophenyl)-1-(N-methyl-N-cyclopropylamino)-3-methyl-4-(4-ethyl-N-piperidino)cyclohexane;
1-(p-chlorophenyl)-1-(N-methyl-N-cyclopropylamino)-3-methyl-4-(4-methylpiperazino)cyclohexane; and
1-(p-chlorophenyl)-1-(N-methyl-N-cyclopropylamino)-3-methyl-4-(3-propyl-N-pyrrolidino)cyclohexane;
1-(p-chlorophenyl)-1-(N-allyl-N-cyclopropylmethylamino)-3-methyl-4-methylethylaminocyclohexane;
1-(p-chlorophenyl)-1-(N-allyl-N-cyclopropylmethylamino)-3-methyl-4-(N-allyl-N-propylamino)cyclohexane;
1-(p-chlorophenyl)-1-(N-allyl-N-cyclopropylmethylamino)-3-methyl-4-(N-.beta.-phenethyl-N-methylamino)cyclohexane;
1-(p-chlorophenyl)-1-(N-allyl-N-cyclopropylmethylamino)-3-methyl-4-[N-(2-methoxy-4-chlorophenyl)-N-ethylamino]cyclohexane;
1-(p-chlorophenyl)-1-(N-allyl-N-cyclopropylmethylamino)-3-methyl-4-(N-3,5-dimethylphenyl-N-propylamino)cyclohexane;
1-(p-chlorophenyl)-1-(N-allyl-N-cyclopropylmethylamino)-3-methyl-4-N-morpholinocyclohexane;
1-(p-chlorophenyl)-1-(N-allyl-N-cyclopropylmethylamino)-3-methyl-4-(4-ethyl-N-piperidino)cyclohexane;
1-(p-chlorophenyl)-1-(N-allyl-N-cyclopropylmethylamino)-3-methyl-4-(4-methylpiperazino)cyclohexane; and
1-(p-chlorophenyl)-1-(N-allyl-N-cyclopropylmethylamino)-3-methyl-4-(3-propyl-N-pyrrolidino)cyclohexane.
EXAMPLE 8
Following the procedure of Example 4 but separately substituting each of the compounds prepared in Preparation XI for 4-(p-chlorophenyl)-4-dimethylaminocyclohexanone, and
methylethylamine,
N-allyl-N-propylamine,
N-β-phenethyl-N-methylamine,
N-(2-methoxy-4-chlorophenyl)-N-ethylamine,
N-(3,4-dimethylphenyl)-N-propylamine,
morpholine,
4-ethylpiperidine,
4-methylpiperazine,
3-propylpyrrolidine for morpholine, and reacting each amine independently with each ketone, there are obtained the following compounds:
1-(p-methoxyphenyl)-1-dimethylamino-4-methylethylaminocyclohexane;
1-(p-methoxyphenyl)-1-dimethylamino-4-(N-allyl-N-propylamino)cyclohexane;
1-(p-methoxyphenyl)-1-dimethylamino-4-(N-β-phenethyl-N-methylamino)cyclohexane;
1-(p-methoxyphenyl)-1-dimethylamino-4-[N-(2-methoxy-4-chlorophenyl)-N-ethylamino]cyclohexane;
1-(p-methoxyphenyl)-1-dimethylamino-4-(N-3,5-dimethylphenyl-N-propylamino)cyclohexane;
1-(p-methoxyphenyl)-1-dimethylamino-4-N-morpholinocyclohexane;
1-(p-methoxyphenyl)-1-dimethylamino-4-(4-ethyl-N-piperidino)cyclohexane;
1-(p-methoxyphenyl)-1-dimethylamino-4-(4-methylpiperazino)cyclohexane; and
1-(p-methoxyphenyl)-1-dimethylamino-4-(3-propyl-N-pyrrolidino)cyclohexane;
1-(o-methylphenyl)-1-dimethylamino-4-methylethylaminocyclohexane;
1-(o-methylphenyl)-1-dimethylamino-4-(N-allyl-N-propylamino)cyclohexane;
1-(o-methylphenyl)-1-dimethylamino-4-(N-β-phenethyl-N-methylamino)cyclohexane;
1-(o-methylphenyl)-1-dimethylamino-4-[N-(2-methoxy-4-chlorophenyl)-N-ethylamino]cyclohexane;
1-(o-methylphenyl)-1-dimethylamino-4-(N-3,5-dimethylphenyl-N-propylamino)cyclohexane;
1-(o-methylphenyl)-1-dimethylamino-4-N-morpholinocyclohexane;
1-(o-methylphenyl)-1-dimethylamino-4-(4-ethyl-N-piperidino)cyclohexane;
1-(o-methylphenyl)-1-dimethylamino-4-(4-methylpiperazino)cyclohexane; and
1-(o-methylphenyl)-1-dimethylamino-4-(3-propyl-N-pyrrolidino)cyclohexane;
1-(p-bromophenyl)-1-dimethylamino-4-methylethylaminocyclohexane;
1-(p-bromophenyl)-1-dimethylamino-4-(N-allyl-N-propylamino)cyclohexane;
1-(p-bromophenyl)-1-dimethylamino-4-(N-β-phenethyl-N-methylamino)cyclohexane;
1-(p-bromophenyl)-1-dimethylamino-4-[N-(2-methoxy-4-chlorophenyl)-N-ethylamino]cyclohexane;
1-(p-bromophenyl)-1-dimethylamino-4-(N-3,5-dimethylphenyl-N-propylamino)cyclohexane;
1-(p-bromophenyl)-1-dimethylamino-4-N-morpholinocyclohexane;
1-(p-bromophenyl)-1-dimethylamino-4-(4-ethyl-N-piperidino)cyclohexane;
1-(p-bromophenyl)-1-dimethylamino-4-(4-methylpiperazino)cyclohexane;
1-(p-bromophenyl)-1-dimethylamino-4-(3-propyl-N-pyrrolidino)cyclohexane;
1-(p-ethoxyphenyl)-1-dimethylamino-4-methylethylaminocyclohexane;
1-(p-ethoxyphenyl)-1-dimethylamino-4-(N-allyl-N-propylamino)cyclohexane;
1-(p-ethoxyphenyl)-1-dimethylamino-4-(N-β-phenethyl-N-methylaminocyclohexane;
1-(p-ethoxyphenyl)-1-dimethylamino-4-[N-(2-methoxy-4-chlorophenyl)-N-ethylamino]cyclohexane;
1-(p-ethoxyphenyl)-1-dimethylamino-4-(N-3,5-dimethylphenyl-N-propylamino)cyclohexane;
1-(p-ethoxyphenyl)-1-dimethylamino-4-N-morpholinocyclohexane;
1-(p-ethoxyphenyl)-1-dimethylamino-4-(4-ethyl-N-piperidino)cyclohexane;
1-(p-ethoxyphenyl)-1-dimethylamino-4-(4-methylpiperazino)cyclohexane; and
1-(p-ethoxyphenyl)-1-dimethylamino-4-(3-propyl-N-pyrrolidino)cyclohexane;
1-(m-benzyloxyphenyl)-1-dimethylamino-4-methylethylaminocyclohexane;
1-(m-benzyloxyphenyl)-1-dimethylamino-4-(N-allyl-N-propylamino)cyclohexane;
1-(m-benzyloxyphenyl)-1-dimethylamino-4-(N-β-phenethyl-N-methylamino)cyclohexane;
1-(m-benzyloxyphenyl)-1-dimethylamino-4-[N-(2-methoxy-4-chlorophenyl)-N-ethylamino]cyclohexane;
1-(m-benzyloxyphenyl)-1-dimethylamino-4-(N-3,5-dimethylphenyl-N-propylamino)cyclohexane;
1-(m-benzyloxyphenyl)-1-dimethylamino-4-N-morpholinocyclohexane;
1-(m-benzyloxyphenyl)-1-dimethylamino-4-(4-ethyl-N-piperidino)cyclohexane;
1-(m-benzyloxyphenyl)-1-dimethylamino-4-(4-methylpiperazino)cyclohexane; and
1-(m-benzyloxyphenyl)-1-dimethylamino-4-(3-propyl-N-pyrrolidino)cyclohexane;
1-(2,4-diethylphenyl)-1-dimethylamino-4-methylethylaminocyclohexane;
1-(2,4-diethylphenyl)-1-dimethylamino-4-(N-allyl-N-propylamino)cyclohexane;
1-(2,4-diethylphenyl)-1-dimethylamino-4-(N-β-phenethyl-N-methylamino)cyclohexane;
1-(2,4-diethylphenyl)-1-dimethylamino-4-[N-(2-methoxy-4-chlorophenyl)-N-ethylamino]cyclohexane;
1-(2,4-diethylphenyl)-1-dimethylamino-4-(N-3,5-dimethylphenyl-N-propylamino)cyclohexane;
1-(2,4-diethylphenyl)-1-dimethylamino-4-N-morpholinocyclohexane;
1-(2,4-diethylphenyl)-1-dimethylamino-4-(4-ethyl-N-piperidino)cyclohexane;
1-(2,4-diethylphenyl)-1-dimethylamino-4-(4-methylpiperazino)cyclohexane; and
1-(2,4-diethylphenyl)-1-dimethylamino-4-(3-propyl-N-pyrrolidino)cyclohexane;
1-(3,5-dichlorophenyl)-1-dimethylamino-4-methylethylaminocyclohexane;
1-(3,5-dichlorophenyl)-1-dimethylamino-4-(N-allyl-N-propylamino)cyclohexane;
1-(3,5-dichlorophenyl)-1-dimethylamino-4-(N-β-phenethyl-N-methylamino)cyclohexane;
1-(3,5-dichlorophenyl)-1-dimethylamino-4-[N-(2-methoxy-4-chlorophenyl)-N-ethylamino]cyclohexane;
1-(3,5-dichlorophenyl)-1-dimethylamino-4-(N-3,5-dimethylphenyl-N-propylamino)cyclohexane;
1-(3,5-dichlorophenyl)-1-dimethylamino-4-N-morpholinocyclohexane;
1-(3,5-dichlorophenyl)-1-dimethylamino-4-(4-ethyl-N-piperidino)cyclohexane;
1-(3,5-dichlorophenyl)-1-dimethylamino-4-(4-methylpiperazino)cyclohexane; and
1-(3,5-dichlorophenyl)-1-dimethylamino-4-(3-propyl-N-pyrrolidino)cyclohexane;
1-(3-methoxy-4-chlorophenyl)-1-dimethylamino-4-methylethylaminocyclohexane;
2-(3-methoxy-4-chlorophenyl)-10dimethylamino-4-(N-allyl-N-propylamino)cyclohexane;
1-(3-methoxy-4-chlorophenyl)-1-dimethylamino-4-(N-β-phenethyl-N-methylamino)cyclohexane;
1-(3-methoxy-4-chlorophenyl)-1-dimethylamino-4-[N-(2-methoxy-4-chlorophenyl)-N-ethylamino]cyclohexane;
1-(3-methoxy-4-chlorophenyl)-1-dimethylamino-4-(N-3,5-dimethylphenyl-N-propylamino)cyclohexane;
1-(3-methoxy-4-chlorophenyl)-1-dimethylamino-4-N-morpholinocyclohexane;
1-(3-methoxy-4-chlorophenyl)-1-dimethylamino-4-(4-ethyl-N-piperidino)cyclohexane;
1-(3-methoxy-4-chlorophenyl)-1-dimethylamino-4-(4-methylpiperazino)cyclohexane; and
1-(3-methoxy-4-chlorophenyl)-1-dimethylamino-4-(3-propyl-N-pyrrolidino)cyclohexane;
1-(2-methyl-4-n-butylphenyl)-1-dimethylamino-4-methylethylaminocyclohexane;
1-(2-methyl-4-n-butylphenyl)-1-dimethylamino-4-(N-allyl-N-propylamino)cyclohexane;
1-(2-methyl-4-n-butylphenyl)-1-dimethylamino-4-(N-β-phenethyl-N-methylamino)cyclohexane;
1-(2-methyl-4-n-butylphenyl)-1-dimethylamino-4-[N-(2-methoxy-4-chlorophenyl)-N-ethylamino]cyclohexane;
1-(2-methyl-4-n-butylphenyl)-1-dimethylamino-4-(N-3,5-dimethylphenyl-N-propylamino)cyclohexane;
1-(2-methyl-4-n-butylphenyl)-1-dimethylamino-4-N-morpholinocyclohexane;
1-(2-methyl-4-n-butylphenyl)-1-dimethylamino-4-(4-ethyl-N-piperidino)cyclohexane;
1-(2-methyl-4-n-butylphenyl)-1-dimethylamino-4-(4-methylpiperazino)cyclohexane; and
1-(2-methyl-4-n-butylphenyl)-1-dimethylamino-4-(3-propyl-N-pyrrolidino)cyclohexane;
EXAMPLE 9
Synthesis of 1-(m-hydroxyphenyl)-1-dimethylamino-4-N-morpholinocyclohexane
PART A
Following the procedure of Example 4 but substituting 4-(m-methoxyphenyl)-4-dimethylaminocyclohexanone (prepared as in Preparation V) for 4-(p-chlorophenyl)-4-dimethylaminocyclohexanone there is obtained 1-(m-methoxyphenyl)-1-dimethylamino-4-morpholinocyclohexane.
PART B
Following the procedure of Preparation VI, Part a, but substituting 1-dimethylamino-1-(m-methoxyphenyl)-4-morpholinocyclohexane (prepared in Part a, above) for 4-cyano-4-(m-anisyl)cyclohexanone [same as 4-(methoxyphenyl)-4-cyanocyclohexanone)] there is obtained 1-(m-hydroxyphenyl)-1-dimethylamino-4-morpholinocyclohexane.
EXAMPLE 10
Preparation of 1-(m-hydroxyphenyl)-1-(n-butylmethylamino)-4-morpholinocyclohexane
PART A
Following the procedure of Example 4 but substituting 4-(n-butylmethylamino)-4-(m-benzyloxyphenyl)cyclohexanone (prepared in Preparation VI, part g) for 4-dimethylamino-4-(p-chlorophenyl)cyclohexanone, there is obtained 1-(m-benzyloxyphenyl)-1-(n-butylmethylamino)-4-morpholinocyclohexane.
PART B
Following the procedure of Preparation VI, Part h, but substituting 1-(m-benzyloxyphenyl)-1-(n-butylmethylamino)-4-morpholinocyclohexane for 4-(m-benzyloxyphenyl)-4-(n-butylmethylamino)cyclohexanone there is obtained 1-(m-hydroxyphenyl)-1-(n-butylmethylamino)-4-morpholinocyclohexane.
EXAMPLE 11
Following the procedure of Example 9, Parts a and b, but initially substituting methylethylamine,
N-allyl-N-propylamine,
N-β-phenethyl-N-methylamine,
N-(2-methoxy-4-chlorophenyl)-N-ethylamine,
N-3,5-dimethylphenyl-N-propylamine,
4-ethylpiperidine,
4-methylpiperazine,
3-propylpyrrolidine for morpholine, there are obtained:
1-(m-hydroxyphenyl)-1-dimethylamino-4-methylethylaminocyclohexane;
1-(m-hydroxyphenyl)-1-dimethylamino-4-(N-allyl-N-propyl)aminocyclohexane;
1-(m-hydroxyphenyl)-1-dimethylamino-4-(N-β-phenethyl-N-methylamino)cyclohexane;
1-(m-hydroxyphenyl)-1-dimethylamino-4-[N-(2-methoxy-4-chlorophenyl)-N-ethylamino]cyclohexane;
1-(m-hydroxyphenyl)-1-dimethylamino-4-(N-3,5-dimethylphenyl-N-propylamino)cyclohexane;
1-(m-hydroxyphenyl)-1-dimethylamino-4-(4-ethyl-N-piperidino)cyclohexane;
1-(m-hydroxyphenyl)-1-dimethylamino-4-(4-methylpiperazino)cyclohexane; and
1-(m-hydroxyphenyl)-1-dimethylamino-4-(3-propyl-N-pyrrolidino)cyclohexane, respectively.
EXAMPLE 12
Following the procedure of Example 10, Parts a and b, but initially substituting
methylethylamine,
N-allyl-N-propylamine,
N-β-phenethyl-N-methylamine,
N-(2-methoxy-4-chlorophenyl)-N-ethylamine,
N-3,5-dimethylphenyl-N-propylamine,
4-ethylpiperidine,
4-methylpiperazine,
3-propylpyrrolidine for morpholine, there are obtained:
1-(m-hydroxyphenyl)-1-n-butylmethylamino-4-methylethylaminocyclohexane;
1-(m-hydroxyphenyl)-1-n-butylmethylamino-4-(N-allyl-N-propyl)aminocyclohexane;
1-(m-hydroxyphenyl)-1-n-butylmethylamino-4-(N-β-phenethyl-N-methylamino)cyclohexane;
1-(m-hydroxyphenyl)-1-n-butylmethylamino-4-[N-(2-methoxy-4-chlorophenyl)-N-ethylamino]cyclohexane;
1-(m-hydroxyphenyl)-1-n-butylmethylamino-4-(N-3,5-dimethylphenyl-N-propylamino)cyclohexane;
1-(m-hydroxyphenyl)-1-n-butylmethylamino-4-(4-ethyl-N-piperidino)cyclohexane;
1-(m-hydroxyphenyl)-1-n-butylmethylamino-4-(4-methylpiperazine)cyclohexane; and
1-(m-hydroxyphenyl)-1-n-butylmethylamino-4-(3-propyl-N-pyrrolidino)cyclohexane, respectively.
EXAMPLE 13
PART A
Following the procedure of Preparation VIIA but substituting 4-(m-benzyloxyphenyl)-4-n-butylmethylamino)cyclohexanone (prepared according to Preparation VI) for 4-(p-chlorophenyl)-4-dimethylaminocyclohexanone there is obtained 4-(m-benzyloxyphenyl)-4-(n-butylmethylamino)-2-methylcyclohexanone.
PART B
Following the procedure of Example 10, Parts a and b but substituting 4-(m-benzyloxyphenyl)-4-n-butylmethylamino-2-methylcyclohexanone for 4-(m-benzyloxyphenyl)-4-n-butylmethylaminocyclohexanone there is obtained 1-(m-hydroxyphenyl)-1-n-butylmethylamino-3-methyl-4-morpholinocyclohexane.
EXAMPLE 14
Following the procedure of Example 10, Parts a and b but separately substituting each of the compounds prepared in Preparation XII for 4-(methyl-n-butylamino)-4-(m-benzyloxyphenyl)cyclohexanone initially and each of the followng amines:
methylethylamine,
N-allyl-N-propylamine,
N-β-phenethyl-N-methylamine,
N-(2-methoxy-4-chlorophenyl)-N-ethylamine,
N-3,5-dimethylphenyl-N-propylamine,
morpholine,
4-ethylpiperidine,
4-methylpiperazine,
3-propylpyrrolidine for morpholine, and reacting each amine independently with each ketone, there are obtained the following compounds:
1-(methylethylamino)-1-(m-hydroxyphenyl)-4-methylethylaminocyclohexane;
1-(methylethylamino)-1-(m-hydroxyphenyl)-4-(N-allyl-N-propylamino)cyclohexane;
1-(methylethylamino)-1-(m-hydroxyphenyl)-4-(N-β-phenethyl-N-methylamino)cyclohexane;
1-(methylethylamino)-1-(m-hydroxyphenyl)-4-[N-(2-methoxy-4-chlorophenyl)-N-ethylamino]cyclohexane;
1-(methylethylamino)-1-(m-hydroxyphenyl)-4-(N-3,5-dimethylphenyl-N-propylamino)cyclohexane;
1-(methylethylamino)-1-(m-hydroxyphenyl)-4-N-morpholinocyclohexane;
1-(methylethylamino)-1-(m-hydroxyphenyl)-4-(4-ethyl-N-piperidino)cyclohexane;
1-(methylethylamino)-1-(m-hydroxyphenyl)-4-(4-methylpiperazino)cyclohexane;
1-(methylethylamino)-1-(m-hydroxyphenyl)-4-(3-propyl-N-pyrrolidino)cyclohexane;
1-(methyl-n-propylamino)-1-(m-hydroxyphenyl)-4-methylethylaminocyclohexane;
1-(methyl-n-propylamino)-1-(m-hydroxyphenyl)-4-(N-allyl-N-propylamino)cyclohexane;
1-(methyl-n-propylamino)-1-(m-hydroxyphenyl)-4-(N-β-phenethyl-N-methylamino)cyclohexane;
1-(methyl-n-propylamino)-1-(m-hydroxyphenyl)-4-[N-(2-methoxy-4-chlorophenyl)-N-ethylamino]cyclohexane;
1-(methyl-n-propylamino)-1-(m-hydroxyphenyl)-4-(N-3,5-dimethylphenyl-N-propylamino)cyclohexane;
1-(methyl-n-propylamino)-1-(m-hydroxyphenyl)-4-N-morpholinocyclohexane;
1-(methyl-n-propylamino)-1-(m-hydroxyphenyl)-4-(4-ethyl-N-piperidino)cyclohexane;
1-(methyl-n-propylamino)-1-(m-hydroxyphenyl)-4-(4-methylpiperazino)cyclohexane; and
1-(methyl-n-propylamino)-1-(m-hydroxyphenyl)-4-(3-propyl-N-pyrrolidino)cyclohexane;
1-(n-pentylmethylamino)-1-(m-hydroxyphenyl)-4-methylethylaminocyclohexane;
1-(n-pentylmethylamino)-1-(m-hydroxyphenyl)-4-(N-allyl-N-propylamino)cyclohexane;
1-(n-pentylmethylamino)-1-(m-hydroxyphenyl)-4-(N-β-phenethyl-N-methylaminocyclohexane;
1-(n-pentylmethylamino)-1-(m-hydroxyphenyl)-4-[N-(2-methoxy-4-chlorophenyl)-N-ethylamino]cyclohexane;
1-(n-pentylmethylamino)-1-(m-hydroxyphenyl)-4-(N-3,5-dimethylphenyl-N-propylamino)cyclohexane;
1-(n-pentylmethylamino)-1-(m-hydroxyphenyl)-4-N-morpholinocyclohexane;
1-(n-pentylmethylamino)-1-(m-hydroxyphenyl)-4-(4-ethyl-N-piperidino)cyclohexane;
1-(n-pentylmethylamino)-1-(m-hydroxyphenyl)-4-(4-methylpiperazino)cyclohexane; and
1-(n-pentylmethylamino)-1-(m-hydroxyphenyl)-4-(3-propyl-N-pyrrolidino)cyclohexane;
1-(N-methyl-N-cyclopropylmethylamino)-1-(m-hydroxyphenyl)-4-methylethylaminocyclohexane;
1-(N-methyl-N-cyclopropylmethylamino)-1-(m-hydroxyphenyl)-4-(N-allyl-N-propylamino)cyclohexane;
1-(N-methyl-N-cyclopropylmethylamino)-1-(m-hydroxyphenyl)-4-(N-β-phenethyl-N-methylamino)cyclohexane;
1-(N-methyl-N-cyclopropylmethylamino)-1-(m-hydroxyphenyl)-4-[N-(2-methoxy-4-chlorophenyl)-N-ethylamino]cyclohexane;
1-(N-methyl-N-cyclopropylmethylamino)-1-(m-hydroxyphenyl)-4-(N-3,5-dimethylphenyl-N-propylamino)cyclohexane;
1-(N-methyl-N-cyclopropylmethylamino)-1-(m-hydroxyphenyl)-4-N-morpholinocyclohexane;
1-(N-methyl-N-cyclopropylmethylamino)-1-(m-hydroxyphenyl)-4-(4-ethyl-N-piperidino)cyclohexane;
1-(N-methyl-N-cyclopropylmethylamino)-1-(m-hydroxyphenyl)-4-(4-methylpiperazino)cyclohexane; and
1(N-methyl-N-cyclopropylmethylamino)-1-(m-hydroxyphenyl)-4-(3-propyl-N-pyrrolidino)cyclohexane;
1-(N-β-cyclohexylethyl-N-methylamino)-1-(m-hydroxyphenyl)-4-methylethylaminocyclohexane;
1-(N-β-cyclohexylethyl-N-methylamino)-1-(m-hydroxyphenyl)-4-(N-allyl-N-propylamino)cyclohexane;
1-(N-β-cyclohexylethyl-N-methylamino)-1-(m-hydroxyphenyl)-4-(N-β-phenethyl-N-methylamino)cyclohexane;
1-(N-β-cyclohexylethyl-N-methylamino)-1-(m-hydroxyphenyl)-4-[N-(2-methoxy-4-chlorophenyl)-N-ethylamino]cyclohexane;
1-(N-β-cyclohexylethyl-N-methylamino)-1-(m-hydroxyphenyl)-4-(N-3,5-dimethylphenyl-N-propylamino)cyclohexane;
1-(N-β-cyclohexylethyl-N-methylamino)-1-(m-hdyroxyphenyl)-4-N-morpholinocyclohexane;
1-(N-β-cyclohexylethyl-N-methylamino)-1-(m-hydroxyphenyl)-4-(3-ethyl-N-piperidino)cyclohexane;
1-(N-β-cyclohexylethyl-N-methylamino)-1-(m-hydroxyphenyl)-4-(4-methylpiperazino)cyclohexane;
1-(N-β-cyclohexylethyl-N-methylamino)-1-(m-hydroxyphenyl)-4-(3-propyl-N-pyrrolidino)cyclohexane;
1-(N-benzyl-N-methylamino)-1-(m-hydroxyphenyl)-4-methylethylaminocyclohexane;
1-(N-benzyl-N-methylamino)-1-(m-hydroxyphenyl)-4-(N-allyl-N-propylamino)cyclohexane;
1-(N-benzyl-N-methylamino)-1-(m-hydroxyphenyl)-4-(N-β-phenethyl-N-methylamino)cyclohexane;
1-(N-benzyl-N-methylamino)-1-(m-hydroxyphenyl)-4-[N-(2-methoxy-4-chlorophenyl)-N-ethylamino]cyclohexane;
1-(N-benzyl-N-methylamino)-1-(m-hydroxyphenyl)-4-(N-3,4-dimethylphenyl-N-propylamino)cyclohexane;
1-(N-benzyl-N-methylamino)-1-(m-hydroxyphenyl)-4-N-morpholinocyclohexane;
1-(N-benzyl-N-methylamino)-1-(m-hydroxyphenyl)-4-(4-ethyl-N-piperidino)cyclohexane;
1-(N-benzyl-N-methylamino)-1-(m-hydroxyphenyl)-4-(4-methylpiperazino)cyclohexane;
1-(N-benzyl-N-methylamino)-1-(m-hydroxyphenyl)-4-(3-propyl-N-pyrrolidino)cyclohexane, respectively.
EXAMPLE 15
Preparation of 1-(m-hydroxyphenyl)-1-(methyl-n-butylamino)-4-(N-pyrrolidinyl)cyclohexane
Following the procedure of Example 2 but substituting 1.28 gm. (0.045 mole) of 4-(m-hydroxyphenyl)-4-(methyl-n-butylamino)cyclohexanone (prepared in Preparation VI, Part i) for 4-phenyl-4-dimethylaminocyclohexanone there is obtained 0.34 gm. of 1-(m-hydroxyphenyl)-1-(methyl-n-butylamino)-4-(N-pyrrolidinyl)cyclohexane having a m.p. 174°-178° C.
Analysis: Calc'd. for C 21 H 34 N 2 O: C, 76.31; H, 10.37; N, 8.48. Found: C, 75.97; H, 10.43; N, 8.55.
Further elution of the chromatography column (as in Example 2) followed by recrystallization from Skellysolve B® gives 0.11 gm. of the more polar isomer of the title compound having a m.p. 140°-144° C.
Analysis: Calc'd. for C 21 H 34 N 2 O: C, 76.31; H, 10.37; N, 8.48. Found: C, 76.22; H, 10.46; N, 8.45.
EXAMPLE 16
Following the procedure of Preparation VI, Part j, but substituting 1-(m-hydroxyphenyl)-1-(methyl-n-butylamino)-4-(N-morpholinocyclohexane (prepared in Example 9b) for 4-(m-hydroxyphenyl)-4-(methyl-n-butylamino)cyclohexanone there is obtained 1-(m-acetoxyphenyl)-1-(methyl-n-butylamino)-4-(N-morpholino)cyclohexane.
EXAMPLE 17
Preparation of 1-(m-methoxyphenyl)-1-methyl-n-butylamino)-4-N-pyrrolidinylcyclohexane
PART A
Following the procedure of Preparation V, Part i, but substituting 4-(m-methoxyphenyl)-4-methylaminocyclohexanone ethylene ketal hydrochloride (prepared in Preparation V, Part g) for 4-(m-methoxyphenyl)-4-dimethylaminocyclohexanone ethylene ketal hydrochloride there is obtained 4-(m-methoxyphenyl)-4-methylaminocyclohexanone.
PART B
Following the procedure of Preparation VI, part f, but substituting 4-(m-methoxyphenyl)-4-methylaminocyclohexanone for 4-(m-benzyloxyphenyl)-4-methylaminocyclohexanone ethylene ketal there is obtained, after workup, the corresponding 4-(m-methoxyphenyl)-4-(methyl-n-butylamino)cyclohexanone.
PART C
A mixture of 2.0 gm. (6.9 mmole) of the ketone from part b, 0.54 gm. (0.63 ml.) pyrrolidine, and 50 mg. of p-toluenesulfonic acid in 40 ml. benzene is heated at reflux temperature under a Dean-Stark trap for 3 hours. The solvent is then removed under vacuum. To a solution of the residue in 30 ml. of THF there is added a slurry of 0.30 gm. of sodium borohydride in 10 ml. of absolute ethanol. Following 13 hours' stirring at reflux, the bulk of the solvent is removed in vacuo; the residue is partitioned between water and diethyl ether; the organic layer is washed with water and brine and taken to dryness. The residue is chromatographed on a 250 ml. silica gel column, eluted initially with a solvent mixture of 0.5% NH 4 OH:5% methanol:CH 2 Cl 2 followed by 0.5% NH 4 OH:10% MeOH:CH 2 Cl 2 . The material obtained is converted to the hydroiodide salt and recrystallized from CH 2 Cl 2 :ethyl acetate solvent mixture to yield 0.88 gm. (22% yield) of the title compound (less polar isomer), m.p. 181°-184° C.
Analysis: Calc'd. for C 22 H 36 N 2 O.2HI: C, 44.01; H, 6.38; N, 4.67; I, 42.28. Found: C, 43.87; H, 6.63; N, 4.87; I, 42.71.
Further elution of the silica gel column affords a second (the more polar) isomer which after recrystallization from CH 2 Cl 2 :ethyl acetate is converted to and isolated as its dihydrochloride salt (0.38 gm., 9.4% yield) m.p. 207°-209° C.
Analysis: Calc'd. for C 22 H 36 N 2 O.2HCl: Cl, 16.99. Found: Cl, 16.69.
EXAMPLE 18
Following the procedure of Example 16, but substituting propionic anhydride and butyric anhydride for acetic anhydride there are prepared the corresponding 1-(m-propionoxyphenyl)-1-(methyl-n-butylamino)-4-(N-morpholino)cyclohexane and 1-(m-butyroxyphenyl)-1-(methyl-n-butylamino)-4-(N-morpholino)cyclohexane, respectively.
The compounds of the Formula I have analgetic activity and can be used for the relief of pain without loss of consciousness. The compounds can be used to treat the pain of headache, muscle spasm, arthritis and other musculoskeletal conditions, e.g., bursitis, relieve mild to moderate post-operative and post-partum pain; dysmenorrhea and pain of traumatic origin. Additionally, the compounds of Formula I can be administered for the treatment of severe pain, e.g., pain associated with adenocarcinoma, amputation of a limb, and third degree burns over a major portion of the body in animals and humans.
The dosage of the compound of the Formula I for analgetic purposes is from about 0.1 to about 7 mg./kg. body weight of the patient. The compounds of the Formula I are conveniently prepared in 5, 10, 25, 50, 75, 100, 250, and 500 mg. dosage units for administration for 1 to 4 times a day. Preferred unit dosages are from 0.3 to 3.5 mg./kg. body weight of the patient.
The compounds are administered orally, parenterally and rectally for systemic action.
The compositions of the present invention are presented for administration to humans and animals in unit dosage forms, such as tablets, capsules, pills, powders, granules, sterile parenteral solutions or suspensions, and oral solutions or suspensions, and oil-water emulsions containing suitable quantities of a compound of Formula I or its pharmacologically acceptable salts.
Pharmaceutical dosage unit forms are prepared in accordance with the subsequent general specific descriptions to provide from about 5 mg. to about 500 mg. of the essential active ingredient per dosage unit form (preferred 15-250 mg.).
Oral pharmaceutical dosage forms are either solid or liquid. The solid dosage forms are tablets, capsules, granules, and bulk powders. Types of oral tablets are, for example, compressed (including chewable and lozenge), tablet triturates, enteric-coated, sugar-coated, film-coated, and multiple compressed. Capsules are either hard or soft elastic gelatin. Granules and powders are either effervescent or non-effervescent.
Pharmaceutically acceptable substances utilized in compressed tablets are binders, lubricants, diluents, disintegrating agents, coloring agents, flavoring agents, flow inducing agents, and wetting agents. Tablet triturates (either molded or compressed) utilize diluents and binders. Enteric-coated tablets, due to their enteric-coating, resist the action of stomach acid and dissolve or disintegrate in the alkaline intestine. Sugar-coated tablets are compressed tablets to which usually four different layers of pharmaceutically acceptable substances have been applied. Film-coated tablets are compressed tablets which have been coated with a water soluble cellulose polymer. Multiple compressed tablets are compressed tablets made by more than one compression cycle utilizing the pharmaceutically acceptable substances previously mentioned. Coloring agents are utilized in the above dosage forms. Flavoring and sweetening agents are utilized in compressed tablets, tablet triturates, sugar coated, multiple compressed and chewable tablets. Flavoring and sweetening agents are especially useful in the formation of chewable tablets and lozenges.
Examples of binders include glucose solution (25-50%), acacia mucilage (10-20%), gelatin solution (10-20%), sucrose and starch paste. Lubricants include, for example, talc, starch, magnesium or calcium stearate, lycopodium and stearic acid. Diluents include, for example, lactose, sucrose, starch, kaolin, salt, mannitol and dicalcium phosphate. Disintegrating agents include, for example, corn starch, potato starch, bentonite, methylcellulose, agar and carboxymethylcellulose. Coloring agents include, for example, any of the approved certified water soluble FD and C dyes, mixtures thereof, and water insoluble FD and C dyes suspended on alumina hydrate. Sweetening agents include, for example, sucrose, lactose, mannitol, and artificial sweetening agents such as sodium cyclamate and saccharin, and any number of spray dried flavors. Flavoring agents include natural flavors extracted from plants such as fruits and synthetic blends of compounds which produce a pleasant sensation. Flow inducing agents include, for example, silicon dioxide and talc. Wetting agents include, for example, propylene glycol monostearate, sorbitan monooleate, diethylene glycol monolaurate and polyoxyethylene laural ether. Enteric-coatings include, for example, fatty acids, fats, waxes, shellac, ammoniated shellac and cellulose acetate phthalates. Pharmaceutically acceptable substances for the first layer, an undercoating, of sugar-coated tablets, include, for example, dextrin and gelatin. The second layer, an opaque zone, includes, for example, starch, talc, calcium carbonate, magnesium oxide and magnesium carbonate. The third layer, a translucaent zone, includes, for example, sucrose. The fourth layer, a glaze, includes, for example, beeswax, carnauba wax, or a mixture of these waxes. Film-coatings include, for example, hydroxyethylcellulose, sodium carboxymethylcellulose, polyethylene glycol 4000 and cellulose acetate phthalate.
Hard gelatin capsules, sizes 5 through 1000, are made largely from gelatin and may be either clear or colored. These capsules may be filled with either a powder or coated pellets (sustained release).
The diluents utilized in powder filled capsules are the same as those illustrated above for tablets. Pharmaceutically acceptable substances utilized for coating pellets include, for example, stearic acid, palmitic acid, glyceryl myristate, cetyl alcohol, fats, waxes, polymeric substances sensitive to small changes in pH of the gastrointestinal tract, polyvinyl alcohol, ethyl cellulose and mixtures of beeswax, carnauba wax or bayberry wax with glyceryl monostearate.
Soft elastic gelatin capsules contain sufficient glycerine so that they are permanently flexible. Pharmaceutically acceptable liquid diluents used in soft elastic gelatin capsules are those which do not dissolve or harm the capsule and which are non-toxic, including, for example, corn oil, cottonseed oil, polysorbate 80, DMA and triacetin.
Pharmaceutically acceptable substances utilized in non-effervescent granules, for solution and/or suspension, include diluents, wetting agents, flavoring agents and coloring agents. Examples of diluents, wetting agents, flavoring agents and coloring agents include those previously exemplified.
Pharmaceutically acceptable substances utilized in effervescent granules and powders include organic acids, a source of carbon dioxide, diluents, wetting agents, flavoring agents and coloring agents.
Examples of organic acids include, for example, citric acid and tartaric acid. Sources of carbon dioxide include, for example, sodium bicarbonate and sodium carbonate. Examples of sweetening agents include, for example, sucrose, calcium cyclamate and saccharin. Examples of diluents, wetting agents and coloring agents include those previously exemplified.
Bulk powders have the compound of the Formula I uniformly dispersed throughout a pharmaceutically acceptable powdered carrier diluent. Examples of the diluent include those previously exemplified.
The individual oral solid pharmaceutical dosage forms, tablets and capsules, are packaged individually, unit-dose, or in quantity, multiple-dose containers, for example, bottles of 50, 100, 500, 1000, or 5000.
The amount of compound of the Formula I analog per dose unit is adjusted so that it provides the patient with an effective amount. The exact dose depends on the age, weight and condition of the patient or animal as is known in the art. For example, tablets and capsules are given in sufficient number and frequency to obtain the desired pharmacological effect.
The sustained release tablets and capsules provide an effective amount upon ingestion and continue to release a sufficient amount of the active material to keep the concentration at an effective level for increased periods of time, for example, 12 hours.
Non-effervescent granules and powders are packaged in predetermined amounts, such that when reconstituted with a specified quantity of an apropriate liquid vehicle, usually distilled water water, a solution and/or suspension results, providing a uniform concentration of the compound of the Formula I after shaking, if necessary. The concentration of the solution is such that a teaspoonful (5 ml.), a tablespoonful (one-half ounce or 15 ml.) or a fraction or a multiple thereof will provide an effective amount to produce the desired pharmacological effect. The exact dose depends on the age, weight and condition of the patient or animal, as is known in the art.
Effervescent granules and powders are packaged either in unit-dose, for example, tin foil packets, or in bulk, for example, in 4 oz. and 8 oz. amounts, such that a specific amount, either a unit-dose or, for example, a teaspoonful, tablespoonful or a fraction or a multiple thereof of bulk granules, when added to a specific amount of liquid vehicle, for example, water, yields a container of liquid dosage form to be ingested. The concentration of the active material in the granules is adjusted so that a specified amount when mixed with a specific amount of water yields an effective amount of the active material and produces the desired pharmacological effect. The exact amount of granules to be used depends on age, weight and condition of the patient as is known in the art.
Liquid oral dosage forms include, for example, aqueous solutions, emulsions, suspensions, solutions and/or suspensions reconstituted from non-effervescent granules and effervescent preparations reconstituted from effervescent granules. Aqueous solutions include, for example, elixirs and syrups. Emulsions are either oil-in-water (o/w) or water-in-oil (w/o).
Elixirs are clear, sweetened, hydroalcoholic preparations. Pharmaceutically acceptable substances utilized in elixirs include, for example, solvents. Syrups are concentrated aqueous solutions of a sugar, for example, sucrose, and may contain a preservative. An emulsion is a two-phase system in which one liquid is dispersed in the form of small globules throughout another liquid. O/w emulsions are much preferred for oral administration over w/o emulsions. Pharmaceutically acceptable substances utilized in emulsions are non-aqueous liquids, emulsifying agents and preservatives. Suspensions utilize pharmaceutically acceptable suspending agents and preservatives. Pharmaceutically acceptable substances utilized in non-effervescent granules, to be reconstituted into a liquid oral dosage form, include, for example, diluents, sweeteners, and wetting agents. Pharmaceutically acceptable substances utilized in effervescent granules, to be reconstituted into a liquid oral dosage form, include, for example, organic acids and a source of carbon dioxide. Coloring and flavoring agents are utilized in all of the above dosage forms.
Solvents include, for example, glycerin, sorbitol, ethyl alcohol and syrup. Examples of preservatives include glycerin, methyl and propylparaben, benzoic acid, sodium benzoate and alcohol. Examples of non-aqueous liquids utilized in emulsions include, for example, mineral oil and cottonseed oil. Examples of emulsifying agents include for example, gelatin, acacia, tragacanth, bentonite, and surfactants such as polyoxyethylene sorbitan monooleate. Suspending agents include, for example, sodium carboxymethylcellulose, pectin, tragacanth, Veegum and acacia. Diluents include, for example, lactose and sucrose. Sweetening agents include, for example, sucrose, syrups, glycerin, and artificial sweetening agents such as sodium cyclamate and saccharin. Wetting agents include, for example, propylene glycol monostearate, sorbitan momooleate, diethylene glycol monolaurate and polyoxyethylene lauryl ether. Organic acids include, for example, citric and tartaric acid. Sources of carbon dioxide include, for example, sodium bicarbonate and sodium carbonate. Coloring agents include, for example, any of the approved, certified water soluble FD and C dyes, and mixtures thereof. Flavoring agents include, for example, natural flavors extracted from plants such as fruits, and synthetic blends of compounds which produce a pleasant taste sensation.
The concentration of the compound of the Formula I throughout the solutions must be uniform. Upon shaking, the concentration of the compound of the Formula I throughout the emulsions and suspensions must be uniform.
The concentration of the compound of the Formula I is adjusted so that a teaspoonful (5 ml.), a tablespoonful (one-half ounce or 15 ml.) or a fraction or multiple thereof, will provide an effective amount to produce the desired pharmacological effect. The exact dose depends on the age, weight and condition of the patient or animal as is known in the art.
The liquid oral dosage forms may be packaged, for example, in unit-dose sizes of 5 ml. (teaspoonful), 10 ml., 15 ml. (tablespoonful) and 30 ml. (one ounce), and multiple dose containers, including, for example, 2 oz., 3 oz., 4 oz., 6 oz., 8 oz., pint, quart, and gallon sizes.
Parenteral administration includes intravenous, subcutaneous, intramuscular, and the like.
Preparations for parenteral administration include sterile solutions ready for injection, sterile dry soluble products ready to be combined with a solvent just prior to use, including hypodermic tablets, sterile suspensions ready for injection, sterile dry insoluble products ready to be combined with a vehicle just prior to use and sterile emulsions. The solutions may be either aqueous or non-aqueous.
Pharmaceutically acceptable substances utilized in parenteral preparations include aqueous vehicles, non-aqueous vehicles, antimicrobial agents, isotonic agents, buffers, antioxidants, local anesthetics, suspending and dispersing agents, emulsifying agents, sequestering or chelating agents and other pharmaceutical necessities.
Examples of aqueous vehicles include Sodium Chloride Injection, Ringers Injection, Isotonic (5 percent) Dextrose Injection, Sterile Water for Injection, Dextrose and Sodium Chloride Injection and Lactated Ringers Injection. Non-aqueous parenteral vehicles include fixed oils of vegetable origin, for example, cottonseed oil, corn oil, sesame oil and peanut oil. Antimicrobial agents in bacteriostatic or fungistatic concentrations must be added to parenteral preparations packaged in multiple-dose containers (vials) which include phenol or cresols, mercurials, benzyl alcohol, chlorobutanol, methyl and propyl p-hydroxybenzoic acid esters, thimerosal, benzalkonium chloride and benzethonium chloride. Isotonic agents include, for example, sodium chloride and dextrose. Buffers include, for example, ph phate and citrate. Antioxidants include, for example, sodium bisulfite. Local anesthetics include, for example, procaine hydrochloride. Suspending and dispersing agents include, for example, sodium carboxymethylcellulose, hydroxypropyl methylcellulose and polyvinylpyrrolidone. Emulsifying agents include, for example, Polysorbate 80 (Tween 80). A sequestering or chelating agent of metal ions include, for example, EDTA ethylenediaminetetraacetic acid). Pharmaceutical necessities include, for example, ethyl alcohol, polyethylene glycol and propylene glycol for water miscible vehicles and sodium hydroxide, hydrochloric acid, citric acid or lactic acid for pH adjustment.
The concentration of the pharmaceutically active ingredient is adjusted so that an injection, for example, 0.5 ml., 1.0 ml., 2.0 ml., and 5.0 ml. or an intraarterial or intravenous infusion, for example, 0.5 ml./min., 1.0 ml./min., 1.0 ml./min., and 2.0 ml./min. provides an effective amount to produce the desired pharmacological effect. The exact dose depends on the age, weight and condition of the patient or animal as is known in the art.
The unit-dose parenteral preparations are packaged, for example, in an ampul or a syringe with a needle. The multiple-dose package, for example, is a vial.
All preparations for parenteral administration must be sterile, as is known and practiced in the art.
Illustratively, intravenous or intraarterial infusion of a sterile aqueous solution containing an active material is an effective mode of administration. Another embodiment is a sterile aqueous or oily solution or suspension containing an active material injected as necessary to produce the desired pharmacological effect.
Pharmaceutical dosage forms for rectal administration are rectal suppositories, capsules, tablets for systemic effect.
Rectal suppositories as used herein mean solid bodies for insertion into the rectum which melt or soften at body temperature releasing one or more pharmacologically or therapeutically active ingredients.
Pharmaceutically acceptable substances utilized in rectal suppositories are bases or vehicles and agents to raise the melting point.
Examples of bases or vehicles include, for example, cocoa butter (theobroma oil), glycerin-gelatin, carbowax, (polyoxyethylene glycol) and appropriate mixtures of mono-, di- and triglycerides of fatty acids. Combinations of the various bases may be used. Agents to raise the melting point of suppositories include, for example, spermaceti and wax. Rectal suppositories may be prepared either by the compressed method or by molding. The usual weight of a rectal suppository is about 2.0 gm.
Tablets and capsules for rectal administration are manufactured utilizing the same pharmaceutically acceptable substance and by the same methods as for formulations for oral administration.
Rectal suppositories, tablets or capsules are packaged either individually, in unit-dose, or in quantity, multiple dose, for example, 2, 6, or 12.
The pharmaceutically therapeutically active compounds of the Formula I are administered orally, parenterally or rectally in unit-dosage forms or multiple dosage forms. Unit-dose forms as used in the specification and claims refers to physically discrete units suitable for human and animal subjects and packaged individually as is known in the art. Each unit-dose contains a predetermined quantity of the therapeutically active compound sufficient to produce the desired therapeutic effect, in association with the required pharmaceutical carrier, vehicle or diluent. Examples of unit-dose forms include ampuls and syringes (parenteral), individually packaged tablet or capsule (oral-solid) or individually packaged teaspoonful or tablespoonful (oral-liquid). Unit-dose forms may be administered in fractions or multiples thereof. A multiple-dose form is a plurality of identical unit-dosage forms packaged in a single container to be administered in segregated unit-dose form. Examples of multiple-dose forms include vials (parenteral), bottles of tablets or capsules (oral solid) or bottles of pints or gallons (oral-liquid). Hence, multiple dose form is a multiple of unit-doses which are not segregated in packaging. The specifications for the unit-dosage form and the multiple dosage form are dictated by and directly dependent on (a) the unique characteristics of the therapeutically active compound and the particular therapeutic effect to be achieved and (b) the limitations inherent in the art of compounding such a therapeutically active compound for therapeutic or prophylactic.
In addition to the administration of a compound of Formula I as the principal active ingredient of compositions for the treatment of the conditions described herein, the said compound can be included with other types of compounds to obtain advantageous combinations of properties. Such combinations include a compound of Formula I with other analgesics such as aspirin, phenacetin, acetaminophen, propoxyphen, pentazocine, codeine, meperidine, oxycodone, mefenamic acid, and ibuprofen; muscle relaxants such as methocarbamol, orphenadrine, carisoprodol, meprobamate, chlorphenesin carbamate, diazepam, chlordiazepoxide, and chlorzoxazone; analeptics such as caffeine, methylphenidate and pentylenetetrazol; corticosteroids such as methylprednisolone, prednisone, prednisolone and dexamethasone, antihistamines such as chlorpheniramine, cyproheptadine, promethazine and pyrilamine.
EXAMPLE 19
Capsules
One thousand two-piece hard gelatin capsules for oral use, each containing 5 mg. of 1-(p-chlorophenyl)-1-dimethylamino-4-(N-morpholino)cyclohexane are prepared from the following types and amounts of materials:
1-(p-chlorophenyl)-1-dimethylamino-4-(N-morpholino)cyclohexane: 5 g.
Lactose: 150 g.
Corn starch: 25 g.
Talc: 20 g.
Magnesium stearate: 2.0 g.
The materials are thoroughly mixed and then encapulated in the usual manner.
The foregoing capsules are useful for the treatment of headache in adult humans by the oral administration of 1 capsule every 4 hours.
Using the procedure above, capsules are similarly prepared containing 1-(p-chlorophenyl)-1-dimethylamino-4-(N-morpholino)cyclohexane in 50, 75, 100, and 200 mg. amounts by substituting 50, 75, 100, and 200 gm. of 1-(p-chlorophenyl)-1-dimethylamino-4-(N-morpholino)cyclohexane for the 5 gm. used above.
EXAMPLE 20
Capsules
One thousand two-piece hard gelatin capsules for oral use, each containing 50 mg. of 1-(p-chlorophenyl)-1-dimethylamino-4-(N-morpholino)cyclohexane and 325 mg. of aspirin, are prepared from the following types and amounts of ingredients:
1-(p-chlorophenyl)-1-dimethylamino-4-(N-morpholino)cyclohexane: 50 g.
Aspirin: 325 g.
Talc: 35 g.
Magnesium stearate: 2.5 g.
The ingredients are thoroughly mixed and then encapsulated in the usual manner.
The foregoing capsules are useful for the treatment of headache in adult humans by the oral administration of 1 capsule every 6 hours.
EXAMPLE 21
Tablets
One thousand tablets for oral use, each containing 250 mg. of 1-(p-chlorophenyl)-2-dimethylamino-4-(N-morpholino)cyclohexane are prepared from the following types and amounts of materials:
1-(p-chlorophenyl)-1-dimethylamino-4-(N-morpholino)cyclohexane: 250 g.
Lactose: 125 g.
Corn starch: 65 g.
Magnesium stearate: 2.5 g.
Light liquid petrolatum: 3 g.
The ingredients are thoroughly mixed and slugged. The slugs are broken down by forcing through a number sixteen screen. The resulting granules are then compressed into tablets, each tablet containing 250 mg. of 1-(p-chlorophenyl)-1-dimethylamino-4-(N-morpholino)cyclohexane.
The foregoing tablets are useful for treatment of arthritic pain in adult humans by oral administration of 1 tablet every 12 hours.
EXAMPLE 22
Tablets
One thousand oral tablets, each containing 50 mg. of 1-(p-chlorophenyl)-1-dimethylamino-4-(N-morpholino)cyclohexane and a total of 400 mg. of chlorphenesin carbamate are prepared from the following types and amounts of materials:
1-(p-chlorophenyl)-1-dimethylamino-4-(N-morpholino)cyclohexanone: 50 g.
Chlorophenesin Carbamate: 400 g.
Lactose: 50 g.
Corn starch: 50 g.
Calcium stearate: 2.5 g.
Light liquid petrolatum: 5 g.
The ingredients are thoroughly mixed and slugged. The slugs are broken down by forcing through a number sixteen screen. The resulting granules are then compressed into tablets, each containing 50 mg. of 1-(p-chlorophenyl)-1-dimethylamino-4-(N-morpholino)cyclohexane and 400 mg. of chlorophenesin carbamate.
The foregoing tablets are useful for treatment of low back pain by the oral administration of 1 tablet every six hours.
EXAMPLE 23
Oral syrup
One thousand ml. of an aqueous suspension for oral use, containing in each 5 ml. dose, 100 mg. of 1-(p-chlorophenyl)-1-dimethylamino-4-(N-morpholino)cyclohexane is prepared from the following types and amounts of ingredients:
1-(p-chlorophenyl)-1-dimethylamino-4-(N-morpholino)cyclohexane: 20 g.
Citric acid: 2 g.
Benzoic acid: 1 g.
Sucrose: 700 g.
Tragacanth: 5 g.
Lemon oil: 2 ml.
Deionized water q.s.: 1000 ml.
The citric acid, benzoic acid, sucrose, tragacanth, and lemon oil are dispersed in sufficient water to make 850 ml. of solution. The 1-(p-chlorophenyl)-1-dimethylamino-4-(N-morpholino)cyclohexane is stirred into the syrup until uniformly distributed. Sufficient water is added to make 1000 ml.
The composition so prepared is useful in the treatment of headache in adult humans at a dose of 1 teaspoonful 4 times a day.
EXAMPLE 24
Parenteral solution
A sterile aqueous solution for intramuscular use, containing in 1 ml. 25 mg. of 1-(p-chlorophenyl)-1-dimethylamino-4-(N-morpholino)cyclohexane is prepared from the following types and amounts of materials:
1-(p-chlorophenyl)-1-dimethylamino-4-(N-morpholino)cyclohexane hydrochloride: 30 g.
Lidocaine hydrochloride: 4 g.
Methylparagen: 2.5 g.
Propylparaben: 0.17 g.
Water for injection q.s.: 1000 ml.
The ingredients are dissolved in the water and the solution sterilized by filtration. The sterile solution is filled into vials and the vials sealed.
EXAMPLE 25
Suppository, rectal
One thousand suppositories, each weighing 2.5 g. and containing 100 mg. of 1-(p-chlorophenyl)-1-dimethylamino-4-(N-morpholino)cyclohexane are prepared from the following types and amounts of ingredients:
1-(p-chlorophenyl)-1-dimethylamino-4-(N-morpholino)cyclohexane: 100 g.
Propylene glycol: 162.5 g.
Polyethylene glycol 4000 q.s.: 2300 g.
The 1-(p-chlorophenyl-1-dimethylamino-4-(N-morpholino)cyclohexane is added to the propylene glycol and the mixture milled until the powders are finely divided and uniformly dispersed. The polyethylene glycol 4000 is melted and the propylene glycol dispersion added slowly with stirring. The suspension is poured into unchilled molds at 40° C. The composition is allowed to cool and solidify and then removed from the mold and each suppository foil wrapped.
The suppositories are useful in the treatment of headache by the insertion rectally of 1 suppository every six hours.
EXAMPLE 26
Compositions are similarly prepared following the procedure of the preceding Examples 19 through 25 substituting an equimolar amount each of
1-dimethylamino-4-N-morpholino-1-phenylcyclohexane;
1-dimethylamino-4-(N-piperidino)-1-phenylcyclohexane;
1-dimethylamino-4-(N-allyl-N-methylamino)-1-(p-chlorophenyl)cyclohexane;
1-(m-hydroxyphenyl)-1-dimethylamino-4-morpholinocyclohexane;
1-n-butylmethylamino-1-(p-chlorophenyl)-4-N-morpholinocyclohexane;
1-(m-hydroxyphenyl)-1-(n-butylmethylamino)-4-N-morpholinocyclohexane; or
1-(m-hydroxyphenyl)-1-(methyl-n-butylamino)-4-(N-pyrrolidinyl)cyclohexane or their pharmacologically acceptable salts for the 1-(p-chlorophenyl)-1-dimethylamino-4-(N-morpholino)cyclohexane of the Examples. | Novel compounds of the formula: ##STR1## wherein R 1 is a variable consisting of hydrogen, alkyl of from 1 to 8 carbon atoms, CH 2 -alkenyl wherein alkenyl is from 2 to 4 carbon atoms, inclusive, cycloalkyl of from 3 to 6 carbon atoms, inclusive, cycloalkylmethyl of from 3 to 6 carbon atoms, inclusive; R 2 is a variable consisting of hydrogen, alkyl of from 1 to 8 carbon atoms, inclusive, with the proviso that R 1 and R 2 cannot both be hydrogen at the same time; Y is a variable consisting of alkyl of from 1 to 4 carbon atoms, inclusive, halogen, trifluoromethyl, hydroxy, alkanoyloxy from 2 to 5 carbon atoms, inclusive, alkoxy of from 1 to 4 carbon atoms, inclusive, cycloalkyloxy of from 3 to 6 carbon atoms, inclusive, benzyloxy; m is an integer 0, 1, 2; R 5 is a variable consisting of hydrogen and alkyl of from 1 to 4 carbon atoms, inclusive; R 3 is a variable consisting of alkyl of from 1 to 4 carbon atoms, inclusive; R 4 is a variable consisting of alkyl of from 1 to 4 carbon atoms, inclusive, CH 2 -alkenyl wherein alkenyl is of from 2 to 4 carbon atoms, inclusive, and arylalkyl wherein alkyl is from 1 to 4 carbon atoms, inclusive, and aryl is ##STR2## wherein Y' is CF 3 , halogen, alkyl of 1 to 4 carbon atoms, inclusive, and alkoxy of from 1 to 4 carbon atoms, inclusive; and R 3 and R 4 when taken together with the nitrogen atom to which they are attached can form saturated heterocycles of from 5 to 7 ring members, a second hetero atom of said ring can be oxygen or nitrogen, e.g., morpholine, piperazine, and said heterocycles can be monosubstituted having a total of up to 9 carbon atoms, with the proviso that when ##STR3## is pyrrolidinyl, then m=1, 2, having analgetic activity in humans and animals are prepared in unit dosage forms. The compositions are useful in relieving pain by administering orally, parenterally, and rectally to humans and animals. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to devices for altering the area of a rocket nozzle and thus controlling thrust while the rocket is in flight.
2. Description of the Prior Art
It is known that it is sometimes desirable to adjust the exhaust area of the nozzle of a rocket which utilizes solid propellant during flight. Adjustment of the exhaust area provides control over thrust which cannot be accomplished by merely varying the amount of propellant burned in a solid rocket as it can in a liquid or hybrid rocket. Decreasing the exhaust area increases pressure within the motor and thus boosts thrust.
Variable-area rocket nozzles which permit thrust change substantially throughout the flight of the rocket are known. Such nozzles are very sophisticated. However, thrust control throughout the entire flight of a rocket is not always necessary. Also, the sophisticated variable-area nozzles have a drawback in that they utilize complicated and delicate pressure sensing, hydraulic and electrical parts and such parts are subject to frequent failure.
Since continuous thrust control is often not necessary and variable-area nozzles have drawbacks, research has been conducted on simplified two area rocket nozzles in which a relatively large throat area is provided at launch time and in which the throat area is decreased some time during flight to provide increased thrust.
In the most closely related device for decreasing the exhaust area of a solid rocket nozzle during flight known to the inventor, a housing containing a piston held pintle is suspended within the combustion chamber of the rocket just in front of the nozzle throat. The piston which holds the pintle is held in position by a shear pin at launch and retains the pintle out of (forward from) the nozzle throat. During flight, a gas generator produces gas which presses rearwardly on the piston, causes the shear pin to shear and forces the piston rearwardly. When the piston moves rearwardly, the pintle, which is held by the piston, moves into the throat of the nozzle and decreases the exhaust area.
The above-described device has two primary drawbacks. First, shear pins are somewhat unreliable in that they must be strong enough to retain when they are supposed to retain (e.g. retaining the pintle should the motor be inadvertently dropped in handling) and weak enough to shear when they are supposed to shear and this delicate balance between strength and weakness is hard to obtain even in this day and age of sophisticated metallurgy. Second, the above-described device relies on several O-rings to prevent exhaust gas from the burning propellant from entering the housing in which the piston held pintle is retained. One of the O-rings in particular is to prevent exhaust gas from leaking into the housing and exerting rearward pressure on the forward end of the pintle while the pintle is being retained forward. On the other hand, the pintle is designed in such a way that, once it has been released and forced rearwardly to decrease the exhaust area, exhaust gas is encouraged to leak into the housing, exert rearward pressure on its forward end, and retain it in its rearward position. At this time, the particular O-ring in question is bypassed by the exhaust gas due to the construction of the device. At any rate, a failure of the O-ring in question while it is supposed to be keeping gas out of the housing can result in premature shearing of the shear pin due to undesirable rearward pressure being placed on the forward end of the pintle.
It is the objective of this invention to overcome the drawbacks of the above-described device.
SUMMARY OF THE INVENTION
The present invention utilizes a housing suspended within the combustion chamber of a rocket motor in front of the nozzle throat, an explosive bolt mounted within the housing and a pintle retained forward at launch by the explosive bolt. During flight, the explosive bolt is exploded and releases the pintle rearwardly to a position where the pintle decreases the exhaust area of the nozzle throat.
BRIEF DESCRIPTION OF THE DRAWING
The single FIGURE is a cross-section through a device according to this invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The invention may be best understood by referring to the single FIGURE of the drawing. The single FIGURE is a cross-section of the device of the invention showing a nozzle 10 adapted to screw into or be otherwise affixed into the rear of the combustion chamber or tube of a rocket motor (not shown). Suspended, by suspension means 11, from the nozzle is a housing 12. A fitting 16 is screwed into housing 12 and carries and positions the pintle assembly. Fitting 16 contains an explosive bolt 13 onto which a second fitting 14 is screwed. A pintle 15 is screwed into fitting 14. Thus it may be said that fitting 14 is utilized to mount pintle 14 on explosive bolt 13.
The assembly is designed such that when explosive bolt 13 fractures at fracture plane 17, fitting 14 and pintle 15 are released so that they can move rearwardly into nozzle throat area 18, shoulder 19 of fitting 16 and shoulder 20 of fitting 14 prevent fitting 14 and pintle 15 from simply sliding out of the rear end of the rocket. A crush ring 21 is utilized to absorb shock as shoulders 20 and 19 meet each other.
The head 22 of explosive bolt 13 resides in a recess 23 in the housing 12. The recess 23 is to prevent the head 22 from turning as the pintle 15 is being screwed into fitting 14 or as fitting 14 is being screwed onto explosive bolt 13 during assembly.
An opening 24 is provided through nozzle 10, suspension means 11 and housing 12 for a detonation wire for explosive bolt 13. Means for exploding an explosive bolt are well known and need not be gone into in detail here. It is sufficient to say that it is possible to either explode the explosive bolt at some predetermined set time after firing of the rocket or to remotely explode the explosive bolt whenever it is desired to do so.
In operation, pintle 15 is retained out of throat area 18 at launch time by explosive bolt 13 (and fitting 14). Then, at a desired time, the explosive bolt is detonated, fractures at fracture plane 17 and pintle 15 moves rearwardly until the meeting of shoulders 19 and 20 (buffered by crush ring 21) stop it. At this time, pintle 15 is in a position where it decreases the flow area for gas which may pass through throat area 18 of the nozzle. | A pintle screwed into an explosive bolt and released when the bolt is exped is used to alter the area of a rocket nozzle while the rocket is in flight. | 5 |
CROSS REFERENCES TO RELATED APPLICATIONS
This is a continuation-in-part application of my co-pending application Ser. No. 088,126, filed Oct. 25, 1979, now abandoned.
BACKGROUND OF THE INVENTION
The invention relates to compositions for the preparation of polymeric gels, the polymeric gels and their uses, and more particularly to a composition including adequate proportions of certain polymers, aldehydes and amines to form a polymeric gel. Such polymeric gels with appropriate gelation times are useful for reducing or eliminating the flow of water through surfaces and earthen formations, as adhesives and for the formation of fibers, filaments, films and membranes; and in soil stabilization.
A primary utilization of gels in accordance with this invention is the reduction of water infiltration in structures such as tunnels, sewer lines, or the like. The name commonly given to such a material is "grout". A variety of compositions have been utilized for this purpose. Mixtures of acrylamide and N,N'methylenebisacrylamide have been commonly used for controlling water infiltration into these structures over the past twenty years. Such mixtures are usually injected in the form of an aqueous solution into the earthen formation adjacent to the tunnel, well, sewer lines, and the like along with a catalyst which, after a short period of time, causes these vinyl type monomers to polymerize. The result is a fragile gel-like material containing 80 to 95% water which, in effect, stops or reduces water infiltration. The process is described, in part, in several U.S. patents such as U.S. Pat. Nos. 2,801,983, 2,940,729, 3,223,163, and 4,094,150. Certain disadvantages of the process have been recognized in the art, including the toxicity of the monomers, the fragile nature of the resultant gel, and poor adhesive qualities. The toxicity of the monomers becomes a problem through unavoidable handling practices, spills and through contamination of ground water caused by incomplete polymerization.
More recent art (U.S. Pat. No. 4,155,405) has shown that polyacrylamide with a molecular weight of at least two million will react with dialdehydes to form gels in not less than 24 hours at pH values of about 6.5 to 8.5. When the pH is increased, gels with set times in the order of 10-15 minutes are formed. Such gels, however, are ultimately unstable.
Gel set time is a very important parameter for many applications of grout and very often the only parameter used to characterize gels. It is often desirable to have a gel form and become rigid in times as short as a few seconds. In other applications, a preferred time might be several minutes. For example, in the sewer grouting process, it is desirable to have gel times of 15 to 60 seconds thereby reducing the cost per mile of treating the sewer. If the gel does not form and achieve adequate strength quickly (i.e., have a short gel time), there is danger of the material being expelled or washed away by the hydrostatic head of ground water when the injection equipment is moved. Some gel forming compositions cannot be adjusted to give desirable ranges of set times under the different conditions encountered in the particular application. Such conditions include summer and winter temperatures, sunlight which can trigger premature gelation, and dilution by ground water. Some compositions produce fragile gels whose sealing action fails when the earth around the structure shifts. Other compositions produce gels which have poor adhesion to the structure or surrounding formation or which, as indicated above, are unstable.
Accordingly, there exists a need in the art for a polymeric gel that is formed from nontoxic materials, that has a wide range of set times, that has good adhesion to common structural materials, that is stable and that is tough and yet plastic. It is an object of my invention to provide novel polymeric gels which satisfy this need. Other objects and advantages of the invention will be apparent from the following description.
SUMMARY OF THE INVENTION
I have found that the above-stated objects of my invention are achieved by preparing polymeric gels from a uniform dispersion of a water soluble acrylamide polymer or copolymer having a molecular weight of from about 10 2 to about 10 7 in the water insoluble reaction product of a water soluble adhehyde of the formula
(OHC).sub.a R.sub.b
wherein
(a) R is selected from the group consisting of H, aliphatic, and substituted aliphatic and arylaliphatic wherein the aryl group is not adjacent an OHC group,
(b) a is an integer of 1 or more, and
(c) b is 0 or 1, with the proviso that
(d) a is 1 when R is H and
(e) when b is 0, a is 2
with a water soluble primary amine of the formula
(H.sub.2 N).sub.c R'.sub.d
wherein
(a) R' is selected from the group consisting of H, aliphatic and substituted aliphatic and arylaliphatic wherein the aryl group is not adjacent an H 2 N group,
(b) c is an integer of 1 or more, and
(c) d is 0 or 1, with the proviso that
(d) c is 1 when R' is H, and
(e) when d is 0, c is 2,
which polymer or copolymer, aldehyde and amine components are present in adequate proportions to form a polymeric gel.
The polymeric gels of my invention are prepared by forming a uniform dispersion as described above and allowing the dispersion to react to form a polymeric gel.
The aldehyde and the amine components may not be premixed as such a mixture forms a precipitate or suspension. There are specific ranges of component concentrations which form stable gels in relatively short times under ambient temperature conditions.
Gels prepared according to this invention have many desirable properties such as preparation from relatively non-toxic components, superior adhesion, toughness and water impermeability. The gels may be tailored to have set times from a few seconds to a few hours. The gels have many used such as adhesives, sealing cracks and joints in pipes, stabilizing earthen formations, water proofing subgrade construction and as intermediates in the preparation of films, filaments, fibers and membranes. In addition, the novel gels may be treated with carbon dioxide to provide a color change and additional surface hardness.
DETAILED DESCRIPTION
The invention results from the discovery that an intimate uniform dispersion of certain water soluble acrylamide polymers or copolymers in the water insoluble reaction products of certain aldehydes and primary amines produces polymeric gels having unique properties. A convenient method of preparing such dispersions is to contact the selected aldehydes and amines in aqueous solution in the presence of dissolved polyacrylamide. The reaction between the aldehydes and amines is very rapid at substantially ambient temperatures and produces a gel which incorporates all the water present.
Investigation has revealed that not all aldehydes and amines produce materials useful in accordance with the invention. Only primary amines function in accordance with the invention and only aliphatic or aliphatic behaving aldehydes and amines are operable. Thus aldehydes and amines having aromatic groups not adjacent the reactive aldehyde (CHO) or amine (H 2 N) group behave as aliphatic groups.
In accordance with the invention, a uniform dispersion of the polymer or copolymer in the water insoluble reaction product of the selected aldehyde and amine is prepared. This may be accomplished by first preparing dilute (aqueous) solutions of the polymer or copolymer, the aldehyde and the amine. Generally it is desirable to use as few liquids or solutions as possible. Thus, the polymer or copolymer may be included in one or the other of the solutions, or both, if desired. Gel formation is initiated by bringing the solutions together in proper proportions whereupon a chemical reaction occurs. The elapsed time between when the components are mixed and the gel formation is known as "gel time".
The reaction producing the gel depends upon the formation of chemical bonds between the aldehyde and amine and, in general, requires adequate mixing. This is in contrast to free radical polymerization which can be initiated at some point of a given mass and the reaction proceeds throughout the mass. In the present invention, however, complete mixing and complete stoichiometry are not necessary to produce a gel since the effect depends upon dispersing the polymer in some minimum quantity of insoluble reaction product of the aldehyde and amine.
The polymer, i.e., the acrylamide polymer, may be used in the form of a homopolymer of the amide:
CH.sub.2 ═CR.sup.2 --CONH.sub.2
in which R 2 may be H, CH 3 , or other alkyl group. The acrylamide polymer may also be reacted with the aldehyde to produce a new polymer thereby requiring only the amine to produce gels according to the invention. The polymer may also be used in the form of copolymers of such an amide with another unsaturated compound as, for example, styrene, vinyl acetate, alkyl acrylate or alkyl methacrylate, acrylic acid or methacrylic acid, acrylonitrile, acrolein, and N,N-methylenebisacrylamide. The polymers which may be employed in the process may have a molecular weight from about 10 2 to about 10 7 . The concentration of the polymer in the gel may range from about 0.05% to about 20% by weight, with the upper limit being established by the difficulty in pumping viscous solutions and the ability to achieve adequate mixing.
Aldehydes useful in accordance with the invention are water soluble and have the formula
(OHC).sub.a R.sub.b
wherein
(a) R is selected from the group consisting of H, aliphatic, and substituted aliphatic and arylaliphatic wherein the aryl group is not adjacent an OHC group,
(b) a is an integer of 1 or more, and
(c) b is 0 or 1, with the proviso that
(d) a is 1 when R is H and
(e) when b is 0, a is 2.
There is no limitation on the carbon content for the R groups as long as the resultant molecule is water soluble. Generally 1-20 carbon atoms is the preferred carbon content with 1-6 being still preferred. When R is substituted aliphatic or arylaliphatic any substituents may be present which are non-reactive with the aldehyde groups and which do not interfere with the gel forming reaction. Illustrative of such groups are amino, ether and ketone groups. In the formula there is no limitation on the value of "a" except as is governed by the length of the carbon content of R. Illustrative useful aldehydes within the preferred practice of the invention include formaldehyde, glyoxal, glutaraldehyde and adipaldehyde.
Primary amines useful in accordance with the invention are water soluble and have the formula
(H.sub.2 N).sub.c R'.sub.d
wherein
(a) R' is selected from the group consisting of H, aliphatic and substituted aliphatic and arylaliphatic wherein the aryl group is not adjacent an H 2 N group,
(b) c is an integer of 1 or more, and
(c) d is 0 or 1, with the proviso that
(d) c is 1 when R' is H, and
(e) when d is 0, c is 2.
There is no limitation on the carbon content for the R' group as long as the resultant molecule is water soluble. Generally, 1-20 carbon atoms is the preferred carbon content with 1-6 being still preferred. When R' is substituted aliphatic and arylaliphatic, any substituents may be present which are non-reactive with the amine groups and which do not interfere with the gel forming reaction. Illustrative of such groups are amino, ether and ketone groups. In the formula there is no limitation on the value of c except as governed by the length of the carbon content of R'.
The concentration of the aldehyde and amine may vary widely. In certain of the experiments performed with this invention, for example, a gel was produced even when hexamethylenediamine and glutaraldehyde were present in as little as 0.43 wt. % concentration. This was accomplished with a 0.38 wt. % polymer solution, the polymer being polyacrylamide having a molecular weight of 600,000. Relatively less aldehydes and amines can be used if higher molecular weight polymers are used. The limits will also vary with the type of aldehydes and amines chosen. In general, and as practiced within this invention, the concentration limits of the aldehydes and amines in the final gel are between 0.4 wt. % and 50 wt. % (dry basis). As will be seen in the Examples, the desirable range of concentrations is between about 0.4 wt. % and about 25 wt. %.
The water soluble polymer, either straight chain or branched, may be used in the form of an emulsion, or of a solution. It may be mixed, as stated above, with either or both the aldehyde and amine and as shown in subsequent examples. The minimum acceptable concentration of polymer is determined by that concentration at which the aldehyde and amine no longer produce a precipitate but produce a gel for a given chemical system. This, too, is illustrated in the examples, particularly Example 5. The limits of concentration of polymer in the final gel, on a dry weight basis, are of the order of 0.05% to 20%, with the upper limit being established mainly by the molecular weight, the inherent difficulty of pumping viscous solutions, and the ability to achieve adequate mixing. In some cases it may be convenient to employ relatively high concentrations of low molecular weight polymers which have lower inherent viscosity and thereby avoid the difficulty of handling viscous solutions. In other cases, such as where it is desired to control a high rate groundwater infiltration in a well or mine, it may be desirable to employ high molecular weight polymers thereby producing a viscous fluid not easily displaced by the rapid influx of water prior to gel formation. Hence, the useful range of molecular weights may range from 100 (10 2 ) to greater than 10 million (10 7 ). However, in general, the desirable range is from about 2000 to about 1 million.
In soil stabilization or sewer grouting, the components are usually mixed and then conducted to the desired site in the soil or pipe in a time less than the gel time where the gel forms an intimate mixture with the gravel, sand, rock or soil as the case may be. In other cases, the gel may be formed and then further processed or applied at a different location.
The gel time is influenced by factors other than the specific components and their concentrations, temperature, and the like. It may also be influenced by the addition of reagents such as fillers, catalysts, plant growth inhibitors and moisture retention aids of the type known in the art.
The gels described in the examples below were characterized by gel time, color, syneresis or lack thereof, adherence to various materials, and resistance to penetration. It was observed that the gels did not allow penetration in the manner as do tars and greases but, rather, deformed. This was interpreted as a resistance to deformation and was measured by the deformation caused by metal rods having a surface area of 0.22 sq cm and various weights. By calibration, all the penetration data were converted to that corresponding to a deformation caused by a rod whose weight corresponded to a pressure of 180 g/sq cm, a value not unlike that encountered in many applications. The value of the deformation is reported as "d" in the examples.
All of the gels formed by using glutaraldehyde, as typically illustrated in Examples 1-3, exhibited striking color changes over a period of several days. Except in cases where the amine was colored, the gels were white when initially formed, but within 24 hours an intense color began to form. This was always bright red if the amine itself was colorless. If the amine was colored, such as the polyamide HPA No. 2 (dark brown), the red color was influenced by the original amine color. This color change always began to be exhibited on the surface of the gel exposed to air and gradually penetrated to the interior. As time progressed, the surface color would become more intense with the interior exhibiting various shades of red and pink. Eventually the whole mass would become the same intense color, this generally requiring 7 to 10 days. In the early stages, a marked increase in the toughness of the surface exposed to the air was also noted.
The red color was found to be the result of the reaction of carbon dioxide. This was confirmed by allowing the surface of a freshly prepared white gel (glutaraldehyde+hexanediamine+polyacrylamide) to become wet with a thin film of a dilute solution of hydrochloric acid and then placing thereon a small quantity of solid sodium bicarbonate. All areas of the gel adjacent to the sodium bicarbonate took on the characteristic intense red color immediately, but other areas of the gel remained unchanged over the next few minutes. The role of carbon dioxide was further confirmed by the preparation of a sample of gel in a glass tube which was promptly sealed. A sample prepared from the same solutions and in the same proportions, when exposed to air, became pink within minutes and gradually red. The sample sealed in glass was yellowish-white but became slightly pink after 2 days, due to the carbon dioxide in air sealed in the tube with the gel. No further color change occurred over the next 30 days.
Use of the gels of the invention to seal cracks or joints with a water impermeable polymeric gel or to prevent water permeation of a porous structural material is accomplished by either injecting into the cracks or joints or applying to the structural material a gel forming dispersion in accordance with the invention and allowing the dispersion to react to form a polymeric gel The reaction takes place readily over a wide range of ambient temperature conditions.
Filaments and films can be easily formed from compositions prepared in accordance with the invention at their gel point--that is, at the point just before complete solidification occurs. Formation of such filaments and films was accomplished by conventional fiberdrawing and film-casting techniques well known by those skilled in the art. Glutaraldehyde was particularly useful as the aldehyde for this purpose. Polyamines with molecular weight up to 260 are preferable over simple alkylamines for this purpose and use of an excess of amine is preferred. Uses for such filaments and films include textile materials, fire-resistant materials, separation membranes, and also in temperature sensing devices and devices for conversion of chemical energy to mechanical energy at the critical point of the gels.
The polymeric gels in accordance with the invention were also found to be useful as adhesives. Gels prepared from n-butylamine were particularly effective as adhesives.
The invention will be further illustrated by consideration of the following examples, which are intended to be purely exemplary of the invention and its uses. Certain information is common to most or all of the examples, and therefore is summarized as follows: All concentrations are based upon dry weight. The designation PAM in the tables is for polyacrylamide having a molecular weight of 520,000 to 600,000 (except where designated otherwise). All polyacrylamide samples were prepared by the well-known persulfate-sulfite catalyzed polymerization of the monomer. The term "molemer" in the table is the weight of the polymer divided by the molecular weight of the monomer unit. The resultant number indicates the relative number of amine groups in the polymer. In certain of the tables, the term "mole ratio" is used. This is the ratio of the moles of a dialdehyde to the sum of the moles of a diamine plus 1/2 the molemer of the polymer. The term "matrix concentration" is derived from the combined weight of aldehyde and amine.
Although the source of the reactants is not critical to the invention, for a full explanation of the examples: the 1,6-hexanediamine was a commercial 70% solution obtained from Celanese Chemical Co.; the commercial grade glutaraldehyde was obtained from Union Carbide Corp. as a 50% solution; 1,3-propanediamine was obtained from Jefferson Chemical Co.; n-butylamine from Eastman Kodak Co.; and all other amines from Union Carbide Corp. The very high molecular weight polymer in Example 9 was obtained from Aldrich Chemical Company.
EXAMPLE 1
Five ml of a 5% aqueous solution of polyacrylamide, having a molecular weight of 75,000, were mixed with five ml of tap water and 0.03 ml of a 70% aqueous solution of 1,6-hexanediamine and stirred well to accomplish complete dissolution of the polyacrylamide. Then 0.69 ml of a 50% aqueous glutaraldehyde solution was rapidly injected into the polymer-amine solution, with mixing. The mixture, a liquid, turned to a white gel in 25 seconds. The temperature of both solutions prior to mixing was 27° C., and there was no significant change in temperature during the reaction. (A rise of 4°-5° C. occurs when more concentrated solutions are mixed.) There was no residual liquid, and no liquid was released when stored in a sealed container for over a month at room temperature.
EXAMPLE 2
Five ml of a 5% aqueous solution of polyacrylamide having a molecular weight of 600,000 were mixed with twenty ml of tap water and 0.3 ml of a 70% aqueous solution of 1,6-hexanediamine and stirred well to accomplish complete dissolution of the polyacrylamide. Then a solution of 0.55 ml of 50% aqueous solution of glutaraldehyde, in 20 ml of additional tap water, was rapidly transferred into the first solution with gentle agitation. The liquid mixture turned to a white gel in 40 seconds. The initial temperature of both solutions was 18° C. There was no residual liquid, and no liquid was released during a period of over 6 weeks when stored in a sealed container at room temperature.
EXAMPLE 3
Five ml of a 10% aqueous solution of polyacrylamide, having a molecular weight of 600,000 were mixed with 15 ml of tap water and 1.3 ml of 50% aqueous solution of glutaraldehyde. The mixture was stirred well to accomplish complete dissolution of the polyacrylamide. Then 1.2 ml of 70% aqueous solution of 1,6-hexanediamine were added rapidly with gentle agitation. The mixed liquid solution became a white gel in 25 seconds. The initial temperature of the solutions was 26° C. No residual liquid was noted, and no liquid was released over a period of 62 days.
EXAMPLE 4
A series of tests was performed using two different aldehydes and two different amines with and without the presence of the polymer (PAM). Where the PAM was used, it was pre-mixed with the amine prior to contact with the aldehyde. All tests were conducted at 25° C. The data for these tests are shown in Table 1. As can be seen, mixing of the two matrix-forming materials without the polymer produced an insoluble solid (precipitate) which could readily be separated from the water by filtration.
TABLE 1__________________________________________________________________________Matrix Forming Components PolymerA B C Conc. % Reaction Products__________________________________________________________________________Formaldehyde (3.0%) Polyamine (4.4%) -- None Brown precipitate in 5 hours " (2.5%) " (2.2%) PAM 1.7 Clear brown gel in 53-68 hoursGlutaraldehyde (9.4%) 1,6-hexanediamine (11.4%) -- None Immediate yellow precipitate " (9.8%) " (12.8%) PAM 0.6 White gel formed in 80 secondsGlutaraldehyde (2.7%) Polyamine (2.3%) -- None Brown precipitate in 9 minutes " (2.5%) " (2.3%) PAM 0.6 Clear brown gel in 90__________________________________________________________________________ seconds
EXAMPLE 5
A series of tests was conducted to determine the concentration of the various ingredients, and the ratios thereof, necessary to produce a stable gel. The procedures were generally the same as used in Examples 1-3. The data are listed in Table 2. All tests were conducted in a temperature range of 24.5° to 26.5° C. In the first series of data, only a precipitate resulted from the mixture of the three components. In the second series of data, the conditions produced a gel; however, syneresis (loss of water) was exhibited, usually within two days. No water loss after 30 days was noted for the gels in the third series of tests.
TABLE 2__________________________________________________________________________Matrix Forming Components Polymer Gel moles × moles × molemer × mole set matrix polymerA 1000 B 1000 C 1000 ratio time conc., % conc.,__________________________________________________________________________ %Glutaraldehyde 4.2 1,6-hexanediamine 7.0 PAM 1.4 0.55 ppt 3.1 0.26" 3.8 " 3.4 " 3.5 0.74 ppt 0.8 0.24" 3.8 " 2.4 " 3.5 0.92 ppt 0.6 0.24" 4.2 " 3.5 " 0.7 1.1 ppt 4.2 0.26" 8.4 " 7.0 " 0.7 1.1 ppt 7.9 0.26Glutaraldehyde 3.8 1,6-hexanediamine 2.4 PAM 3.5 0.92 40 sec 7.9 0.24" 2.1 " 1.7 " 0.7 1.0 45 sec 3.0 0.36" 8.8 " 6.8 " 3.5 1.0 40 sec 2.9 0.43" 5.3 " 3.4 " 3.5 1.0 30 sec 1.6 0.44" 3.0 " 1.1 " 3.5 1.1 22 sec 0.9 0.55" 7.6 " 4.8 " 3.5 1.2 20 sec 2.4 0.45Glutaraldehyde 3.0 1,6-hexanediamine 1.1 PAM 10.5 0.48 19 sec 0.9 1.64" 3.0 " 1.1 " 7.0 0.65 18 sec 0.9 1.09" 3.8 " 3.4 " 3.5 0.74 100 sec 1.4 0.44" 3.8 " 2.4 " 3.5 0.92 25 sec 2.5 0.96" 3.7 " 0.3 " 7.0 0.97 4 sec 2.6 3.17" 12.2 " 6.7 " 7.0 1.2 3 sec 1.1 2.71__________________________________________________________________________
EXAMPLE 6
Using a procedure generally the same as in Example 2, a series of tests was performed to study other aldehyde-amine combinations with PAM. The concentrations and ratios were chosen to produce stable gels. The data are shown in Table 3, where the effect of the constituents and proportions upon the gel time is illustrated. The deformation value, d. was generally below 10 for all of these gels.
TABLE 3__________________________________________________________________________Matrix Forming Components Polymer Gel moles × moles × molemer × set matrix polymerA 1000 B 1000 C 1000 time conc., % conc.,__________________________________________________________________________ %Formaldehyde 2.8 n-butylamine 2.2 PAM 3.5 7 hrs 1.1 1.7" 3.9 ethylenediamine 2.2 " " 60-132 hrs 1.1 1.7" 3.9 1,3-propanediamine 2.2 " " 7 hrs 1.3 1.7" 6.7 tetraethylenepentamine 2.2 " " 7 hrs 3.5 1.7" 12.7 polyamine 2.2 " " 53-67 hrs 5.5 1.7" 4.1 1,6-hexanediamine 2.8 " 1.4 39-80 hrs 3.8 0.8Glyoxal 6.3 1,6-hexanediamine 5.6 " 1.4 50 sec 5.5 0.5Glutaraldehyde 2.8 n-butylamine 2.2 " 1.4 110 sec 2.4 1.7" 3.9 ethylenediamine 2.2 " " 465 sec 2.9 1.7" 3.9 1,3-propanediamine 2.2 " " 1620 sec 3.1 1.7" 6.7 tetraethylenepentamine 2.2 " " 40 sec 6.6 1.7" 12.7 polyamine 2.2 " " 55 sec 11.5 1.7" 2.8 1,6-hexanediamine 1.1 " 10.5 25 sec 0.8 1.6" 2.1 ammonia 1.4 " 0.7 4-12 hrs 5.1 2.0__________________________________________________________________________
EXAMPLE 7
Experiments were conducted using three different copolymers instead of polyacrylamide. The first copolymer was of low molecular weight prepared by the persulfate-sulfite initiated polymerization of a solution containing 0.04 moles of dimethylamino-ethylmethacrylate and 0.26 moles of acrylamide. The other two copolymers contained 20:80 and 75:25 mole ratios of dimethyldiallyl ammonium chloride. They were obtained from the Calgon Corporation as WT-2575 and WT-2640, respectively. Five ml of the dimethylamino-ethylmethacrylate copolymer were dissolved in 10 ml of water containing 0.66 ml of 50% glutaraldehyde. This solution was then mixed with 10 ml of water containing 0.61 ml of hexamethylenediamine: a gel formed in 25 seconds. Similarly one ml of each of the other two copolymers, under otherwise identical conditions, produced gels in 55 sec.
EXAMPLE 8
The data in Table 4 were obtained using the general procedure described in Example 2. The data show that lower reaction temperatures increase the gel time. Also, the trend toward shorter gel times with increased polymer concentration may be observed from these data. All gels described in this table had d values ranging from 34 to 24, with the lower values associated with gels having higher polymer concentrations.
TABLE 4__________________________________________________________________________Matrix Forming Components Polymer Gel moles × moles × molemer × set Reaction mole matrix polymerA 1000 B 1000 C 1000 time Temp., °C. ratio conc, conc,__________________________________________________________________________ %Glutaraldehyde 3.0 1,6-hexanediamine 1.1 PAM 3.5 40 sec 18 1.1 0.9 0.55" " " " " " 22 sec 25 " " "Glutaraldehyde 3.0 1,6-hexanediamine 1.1 PAM 7.0 30 sec 18 0.65 0.9 1.09" " " " " " 18 sec 25 " " "Glutaraldehyde 3.0 1,6-hexanediamine 1.1 PAM 10.5 25 sec 18 0.48 0.9 1.64" " " " " " 19 sec 25 " " "__________________________________________________________________________
EXAMPLE 9
The data in Table 5 were obtained by following the procedure described in Example 2. These data show particularly that the lower molecular weight polymers decrease the set time, all other factors being the same. It may also be seen from the table that increasing polymer concentration results in decreased set time and stiffer gels. Although not included in the table, a test was conducted with PAM having a molecular weight of 5-6×10 6 ; however, little difference was noted when compared to PAM having a molecular weight of 520,000 to 600,000.
TABLE 5__________________________________________________________________________Matrix Forming Components Polymer Gel moles × moles × molemer × mole set matrix polymerA 1000 B 1000 C 1000 wt. time conc., % conc.,__________________________________________________________________________ %Glutaraldehyde 3.0 1,6-hexanediamine 1.1 PAM 3.5 520,000 22 sec 0.9 0.55" " " " " " 75,000 20 sec " "Glutaraldehyde 3.0 1,6-hexanediamine 1.1 PAM 7.0 520,000 18 sec 0.9 1.09" " " " " " 75,000 14 sec " "Glutaraldehyde 3.0 1,6-hexanediamine 1.1 PAM 10.5 520,000 19 sec 0.9 1.64" " " " " " 75,000 11 sec " "__________________________________________________________________________
EXAMPLE 10
Mixed amines were also utilized to produce gels according to the invention. Five ml of a 5% aqueous solution of polyacrylamide, having a molecular weight of 600,000, were mixed with 25 ml of tap water, 0.9 ml of polyamine and 0.2 ml of 1,6-hexanediamine (70%) and stirred well to accomplish complete dissolution. Thereafter, 0.98 ml of 50% aqueous solution of glutaraldehyde in 25 ml of additional tap water were quickly poured into the first solution with gentle agitation. The liquid turned to a brownish gel in 85 seconds. The initial temperature of both solutions was 25° C. There was no residual liquid, and no liquid was released over a period of two months in a sealed container. A similar test was made except four times the amount of glutaraldehyde was used. The gel time of the resultant gel was about the same (85 sec), and the deformation was 26 compared to 42 for the first test. Gels produced without the polyamine had gel times about one-half of these values.
EXAMPLE 11
A typical application of the gels formed according to the invention was tested. Two pieces of six inch vitrified clay sewer pipe were placed in a wooden box and surrounded with sand. The joint was sealed using a gel based upon hexanediamine and glutaraldehyde, using a conventional packer positioned within the pipes at the joint. Solutions from two small tanks were conducted through flow meters and valves into the packer through separate hoses. One tank contained 5 liters of a 4.3% solution of a branched polyacrylamide with 177 ml of 70% 1,6-hexanediamine; the other tank contained 5 liters of the same polyacrylamide solution and 554 ml of 50% glutaraldehyde. The valves were opened and the solutions allowed to flow into the pipe joint until no further flow occurred (approximately one minute). After waiting approximately 5 minutes, the packer equipment was removed and the outside of the pipe flooded with water. No leak was observed at the joint between the pipes. The joined pipes were exposed and separated; good adhesion of the gel to the pipe pieces was observed.
EXAMPLE 12
An experiment was conducted to determine the effect of a gel formed according to the invention upon the permeability of a construction-grade concrete block. An open-ended plastic tube (55 mm dia) was cemented to the 8 in thick block with a silicone rubber adhesive. The tube was filled with 150 ml water, and the time for drainage of the water through the block was determined to be 75 seconds.
A solution of 0.4% polyacrylamide and 4% tetraethylenepentamine was applied with a brush to the block inside the tube as well as adjacent to the exterior of the tube. After allowing 2-3 min for the first solution to be absorbed, a 25% solution of glutaraldehyde was sprayed upon the surface. After a time period of 15 minutes, the tube was refilled with 250 ml water. The time for all of the water to pass through the block increased to 286 seconds. A more concentrated second sealant coat was then applied to the block. This second coat was prepared by first applying a soluton containing 3.9% of branched polyacrylamide and 9% tetraethylenepentamine to the block followed by a spray of 25% glutaraldehyde. After a 15 min delay to ensure complete formation of a gel, the tube was refilled with 250 ml water. No measurable loss of water occurred in the following 4 hours.
In view of the foregoing examples of producing a stable water-insoluble gel, and uses thereof, one of ordinary skill in the art will recognize that constituents closely related to those specifically illustrated may be substituted in carrying out the invention. For a specific application, the particular components and ratios thereof may be chosen to provide the desired viscosity and gel time to accomplish the beneficial result of the invention.
The number of components for the practice of the invention is not limited to three. Example 10 was given as an illustration of using a mixture of two amines in the practice of the invention. Additional amines, or aldehydes, may be utilized to impart desired characteristics to the resultant gel. Similarly, a compatible mixture of polymers may be employed. Addition of other materials known in the art to impart strength and/or rigidity, may be incorporated into the gel. One such additive is diatomaceous earth as described in U.S. Pat. No. 4,094,150. Addition of materials, such as calcium chloride, to improve water retention may be used. Similarly, chemicals for inhibiting microbial growth or root growth, of the types known in the art, may be incorporated into the gels produced according to this invention.
Gels formed according to this invention may be utilized for purposes other than the above-described formation of a barrier to water permeation. For example, fibers may be formed using extrusion nozzle techniques. The components may be mixed either in the nozzle, or prior to introduction of a mixture into the nozzle, depending upon the gel time of the specific mixture. Fibers may also be produced from the gels using other techniques known in the art.
Films, membranes and other sheet material may be produced from the gels of this invention by conventional techniques. For example, the constituents for the gel are mixed and then applied to the surface of a relatively dense liquid that is nonreactive with the gel or its constituents. The quantity of material applied to the liquid surface is controlled to provide a desired thickness. Films are then produced by dehydration of the thin layers of the gels.
Other embodiments of the invention will be apparent to one skilled in the art from a consideration of this specification or practice of the invention disclosed herein. It is intended that the specification and examples be considered as exemplary only, with the true scope and spirit of the invention being indicated by the following claims. | Preparation of polymeric gels, filaments, and films prepared by producing a uniform dispersion of a water soluble acrylamide polymer or copolymer in the water insoluble reaction product of certain water soluble aldehydes and water soluble primary amines. The reaction is carried out in aqueous solution. Gel formation time may range from a few seconds to several minutes depending on selection of appropriate parameters. The gels have many desirable properties such as preparation from relatively nontoxic components, superior adhesion, toughness, and water impermeability. The gels have many uses such as adhesives, sealing cracks and joints in pipes, stabilizing earthen formations, waterproofing subgrade construction and as intermediates in the preparation of films, filaments, and membranes. Gels for these purposes may be treated with carbon dioxide to provide a color change and additional surface hardness. | 2 |
FIELD OF THE INVENTION
[0001] The present invention relates to imidazo[4,5-c]quinoline derivatives, processes for their preparation, pharmaceutical compositions containing them and their use in the treatment of diseases mediated by phosphatidylinositol-3-kinase (PI3K) and/or mammalian target of rapamycin (mTOR) and/or tumor necrosis factor-α (TNF-α) and/or interleukin-6 (IL-6), particularly in the treatment of cancer and inflammation.
BACKGROUND OF THE INVENTION
[0002] Cancer is an uncontrolled growth and spread of cells that may affect almost any tissue of the body. More than eleven million people are diagnosed with cancer every year. It is estimated that there will be sixteen million new cases every year by 2020. Cancer causes seven million deaths every year worldwide.
[0003] Cancer can be defined as abnormal growth of tissues characterized by a loss of cellular differentiation. It is caused due to a deregulation of the signaling pathways involved in cell survival, cell proliferation and cell death.
[0004] Current treatments for cancer have limited effectiveness and a number of side effects. Cancer therapy currently falls under the following categories including surgery, radiation therapy, chemotherapy, bone marrow transplantation, stem cell transplantation, hormonal therapy, immunotherapy, antiangiogenic therapy, targeted therapy, gene therapy and others.
[0005] Activation of phosphatidylinositol-3-kinase (PI3K) results in a disturbance of control of cell growth and survival, and hence this pathway is an attractive target for the development of novel anticancer agents (Nat. Rev. Drug Discov., 2005, 4, 988-1004). The mammalian target of rapamycin (mTOR) regulates cell growth and metabolism in response to environmental cues hence inhibitors of mTOR may be useful in the treatment of cancer and metabolic disorders (Cell, 2006, 124, 471-484).
[0006] PI3K mediated signaling pathway plays a very important role in cancer cell survival, cell proliferation, angiogenesis and metastasis. The PI3K pathway is activated by stimuli such as growth factors, hormones, cytokines, chemokines and hypoxic stress. Activation of PI3K results in the recruitment and activation of protein kinase B (AKT) onto the membrane, which gets phosphorylated at Serine 473 (Ser-473). Thus, phosphorylation of Ser-473 of AKT is a read-out/detector for the activation of the PI3K-mediated pathway. A cell-based ELISA technique can be used to study such activation.
[0007] AKT is known to positively regulate cell growth (accumulation of cell mass) by activating the mTOR serine threonine kinase. mTOR serves as a molecular sensor that regulates protein synthesis on the basis of nutrients. mTOR regulates biogenesis by phosphorylating and activating p70S6 kinase (S6K1), which in turn enhances translation of mRNAs that have polypyrimidine tracts. The phosphorylation status of S6K1 is a bonafide read-out of mTOR function.
[0008] Most tumors have an aberrant PI3K pathway (Nat. Rev. Drug Discov., 2005, 4, 988-1004). Since mTOR lies immediately downstream of PI3K, these tumors also have hyperactive mTOR function. Thus, most of the cancer types will potentially benefit from molecules that target PI3K and mTOR pathways.
[0009] The compounds that are PI3K and/or mTOR inhibitors, find use in the treatment of cancers. Compounds are used to reduce, inhibit, or diminish the proliferation of tumor cells, and thereby assist in reducing the size of a tumor. Representative cancers that may be treated by such compounds include but are not limited to bladder cancer, breast cancer, colorectal cancer, endometrial cancer, head & neck cancer, leukemia, lung cancer, lymphoma, melanoma, non-small-cell lung cancer, ovarian cancer, prostate cancer, testicular cancer, uterine cancer, cervical cancer, thyroid cancer, gastric cancer, brain stem glioma, cerebellar astrocytoma, cerebral astrocytoma, glioblastoma, ependymoma, Ewing's sarcoma family of tumors, germ cell tumor, extracranial cancer, Hodgkin's disease, acute lymphoblastic leukemia, acute myeloid leukemia, liver cancer, medulloblastoma, neuroblastoma, brain tumors, non-Hodgkin's lymphoma, mantle cell lymphoma, osteosarcoma, malignant fibrous histiocytoma of bone, retinoblastoma, rhabdomyosarcoma, soft tissue sarcomas, supratentorial primitive neuroectodermal and pineal tumors, visual pathway and hypothalamic glioma, Wilms' tumor, acute lymphocytic leukemia, adult acute myeloid leukemia, chronic lymphocytic leukemia, chronic myeloid leukemia, esophageal cancer, hairy cell leukemia, kidney cancer, multiple myeloma, oral cancer, pancreatic cancer, primary central nervous system lymphoma, skin cancer, small-cell lung cancer, among others.
[0010] SF 1126 (Semaphore, Inc.) is in phase I clinical trials. SF1126 is a covalent conjugate of LY294002 containing a peptide-based targeting group. In vivo, it gets converted spontaneously at physiologic pH to LY294002 which is a viable version, and as a prodrug, it is able to block PI3K without affecting the normal cells. GDC-0941 (Piramed Ltd. and Genentech, Inc.) is a PI3K inhibitor and is in phase I clinical trials. BEZ-235 (Novartis AG), which is currently in phase I/II clinical trials, inhibits all isoforms of PI3K and also inhibits the kinase activity of mTOR. XL-765 (Exelixis, Inc.) is also a dual inhibitor of mTOR and PI3K. The compound is in phase I clinical trials as an oral treatment for solid tumors.
[0011] Inflammation is the response of a tissue to injury that may be caused by a biological assault such as invading organisms and parasites, ischemia, antigen-antibody reactions or other forms of physical or chemical injury. It is characterized by increased blood flow to the tissue, causing pyrexia, erythema, induration and pain.
[0012] Several proinflammatory cytokines, especially TNF-α and interleukins (IL-1 β, IL-6, IL-8) play an important role in the inflammatory process. Both IL-1 and TNF-α are derived from mononuclear cells and macrophages and in turn induce the expression of a variety of genes that contribute to the inflammatory process. An increase in TNF-α synthesis/release is a common phenomenon during the inflammatory process. Inflammation is an inherent part of various disease states like rheumatoid arthritis, Crohn's disease, ulcerative colitis, septic shock syndrome, atherosclerosis, among other clinical conditions.
[0013] TNF-α has been implicated as a mediator in inflammatory bowel disease, inflammation, rheumatoid arthritis, juvenile rheumatoid arthritis, psoriatic arthritis, osteoarthritis, refractory rheumatoid arthritis, chronic non-rheumatoid arthritis, osteoporosis/bone resorption, Crohn's disease, septic shock, endotoxic shock, atherosclerosis, ischemia-reperfusion injury, coronary heart disease, vasculitis, amyloidosis, multiple sclerosis, sepsis, chronic recurrent uveitis, hepatitis C virus infection, malaria, ulcerative colitis, cachexia, psoriasis, plasmocytoma, endometriosis, Behcet's disease, Wegenrer's granulomatosis, AIDS, HIV infection, autoimmune disease, immune deficiency, common variable immunodeficiency (CVID), chronic graft-versus-host disease, trauma and transplant rejection, adult respiratory distress syndrome, pulmonary fibrosis, recurrent ovarian cancer, lymphoproliferative disease, refractory multiple myeloma, myeloproliferative disorder, diabetes, juvenile diabetes, meningitis, ankylosing spondylitis, skin delayed type hypersensitivity disorders, Alzheimer's disease, systemic lupus erythematosus and allergic asthma. Much research has been conducted to study the effect of TNF-α and anti-TNF-α therapies. Studies in the area of cancer have shown that with TNF-α therapy it is important to balance the cytotoxicity and systemic toxicity of the potential drug candidates.
[0014] Rheumatoid arthritis (RA)—an autoimmune disorder, is a chronic, systemic, articular inflammatory disease in which the normally thin synovial lining of joints is replaced by an inflammatory, highly vascularized, invasive fibrocollagenase tissue (pannus), which is destructive to both cartilage and bone. Areas that may be affected include the joints of the hands, wrists, neck, jaw, elbows, feet and ankles. Cartilage destruction in RA is linked to aberrant cytokines (e.g. TNF-α and IL-6) and growth factor expression in the affected joints.
[0015] The first line of treatment for inflammatory disorders involves the use of non-steroidal anti-inflammatory drugs (NSAIDs) e.g. ibuprofen, naproxen to alleviate symptoms such as pain. However, despite the widespread use of NSAIDs, many individuals cannot tolerate the doses necessary to treat the disorder over a prolonged period of time as NSAIDs are known to cause gastric erosions. Moreover, NSAIDs merely treat the symptoms of disorder and not the cause. When patients fail to respond to NSAIDs, other drugs such as methotrexate, gold salts, D-penicillamine and corticosteroids are used. These drugs also have significant toxic effects. Monoclonal antibody drugs such as Infliximab, Etanercept and Adalimumab are useful as anti-inflammatory agents, but have drawbacks such as route of administration (only parenteral), high cost, allergy induction, activation of latent tuberculosis, increased risk of cancer and congestive heart disease.
[0016] WO2005/054237 describes 1H-imidazoquinoline derivatives for use in the treatment of protein kinase dependent diseases such as benign or malignant tumor.
[0017] WO2006/122806 describes imidazoquinolines as lipid kinase inhibitors that are used alone or in combination with one or more other pharmaceutically active compounds for the treatment of an inflammatory or obstructive airway disease such as asthma or a proliferative disease such as a tumor disease.
[0018] WO 2003/097641 describes the use of imidazoquinolines in the treatment of protein kinase dependent diseases.
SUMMARY OF THE INVENTION
[0019] According to one aspect of the present invention there are provided compounds of formula (I) (as described herein below).
[0020] According to another aspect there are provided compounds of formula (I), which are inhibitors of PI3K and/or mTOR mediated signaling.
[0021] According to a further aspect, there are provided compounds formula (I) which are inhibitors of proinflammatory cytokines such as TNF-α and/or IL-6.
[0022] According to another aspect there are provided processes for producing compounds of formula (I).
[0023] According to a further aspect there is provided use of compounds of formula (I) or compositions containing compounds of formula (I) or compositions manufactured using compounds of formula (I) for the treatment of cancers such as breast cancer, leukemia, lung cancer and gastric cancer, prostate cancer, pancreatic cancer, glioblastoma, colon cancer, head and neck squamous cell carcinoma, multiple myeloma, cervical carcinoma and melanoma.
[0024] According to further aspect there is provided use of compounds of formula (I) or compositions containing compounds of formula (I) or compositions manufactured using compounds of formula (I) for the treatment of inflammation, including diseases such as rheumatoid arthritis, Crohn's disease, ulcerative colitis, septic shock syndrome, psoriasis and atherosclerosis.
[0025] According to another aspect of the present invention there is provided a method for treatment of cancer comprising administering to a mammal in need thereof a therapeutically effective amount of compounds of formula (I).
[0026] According to another aspect of the present invention there is provided a method for treatment of inflammation comprising administering to a mammal in need thereof a therapeutically effective amount of compounds of formula (I).
[0027] These and other objectives and advantages of the present invention will be apparent to those skilled in the art from the following description.
DETAILED DESCRIPTION OF THE INVENTION
[0028] The present invention provides the compounds of formula (I):
[0000]
[0000] in all their stereoisomeric and tautomeric forms and mixtures thereof in all ratios, their pharmaceutically acceptable salts and pharmaceutically acceptable solvates,
wherein,
R 1 is aryl, which is unsubstituted or substituted with an alkyl group, wherein the alkyl group is unsubstituted or substituted with one or more of the same or different groups selected from nitro, cyano, —CONH 2 , amino, halogen, hydroxy, haloalkyl and alkoxy;
R 2 is alkyl, alkenyl, alkynyl, cycloalkyl, aryl, heterocyclyl, heteroaryl, amino, —NHR 8 or —NR 8 R 8 ;
R 3 , R 4 , R 5 and R 7 are each independently selected from hydrogen, alkyl, alkenyl, alkynyl, cycloalkyl, aralkyl, halogen, acyl, hydroxy, alkoxy, amino, cyano and nitro;
R 6 is hydrogen, alkyl, alkenyl, alkynyl, cycloalkyl, aralkyl, halogen, acyl, hydroxy, amino, cyano, nitro, thiol, —COOH, —CONH 2 , —OR 8 , —NHR 8 , —SR 8 or —B(OH) 2 ;
each R 8 is independently selected from alkyl, alkenyl, alkynyl, cycloalkyl, aralkyl, aryl, heteroaryl or heterocyclyl; and
Y is —C(O), —C(S) or —S(O) n , wherein n is 0, 1 or 2;
[0029] wherein alkyl is unsubstituted or substituted by one or more of the same or different groups such as halogen, nitro, cyano, imino, amino, hydroxy, carbonyl, carboxy, ester, ether, alkyl, alkoxy, cycloalkyl, alkylthio, thioester, sulfonyl, aralkyl, acyl, acyloxy, —CONH 2 , heterocyclyl, aryl and heteroaryl;
[0030] alkenyl is unsubstituted or substituted by one or more of the same or different groups such as halogen, hydroxy, carboxy, acetoxy, amino, cyano, nitro, acyl, alkyl, haloalkyl, cycloalkyl, alkoxy, aryloxy, aryl, aralkyl and heterocyclyl;
[0031] alkynyl is unsubstituted or substituted by one or more of the same or different groups such as alkyl, halogen, hydroxy, carboxy, acetoxy, amino, cyano, nitro, acyl, haloalkyl, cycloalkyl, alkoxy, aryloxy, aryl, aralkyl and heterocyclyl;
[0032] cycloalkyl is unsubstituted or substituted by one or more of the same or different groups such as halogen, nitro, cyano, imino, amino, hydroxy, carbonyl, carboxy, ester, ether, alkyl, alkoxy, cycloalkyl, alkylthio, thioester, sulfonyl, haloalkyl, aralkyl, acyl, acyloxy, —CONH 2 , lower alkyl, heterocyclyl, aryl and heteroaryl;
[0033] aryl is unsubstituted or substituted by one or more of the same or different groups such as halogen, hydroxy, alkyl, amino, cyano, nitro, thiol, —CONH 2 , carbonyl, sulfonyl, haloalkyl, acyl, alkoxy, haloalkoxy, trifluoromethoxy, aryloxy and aryl;
[0034] heteroaryl is unsubstituted or substituted by one or two of the same or different groups such as cyano, nitro, halogen, alkyl, haloalkyl, hydroxy, alkoxy, amino, —CONH 2 , cycloalkyl, carboxy, acyl and aryl;
[0035] heterocyclyl is unsubstituted or substituted by one or more of the same or different groups such as alkyl, alkoxy, trifluoromethoxy, halogen, hydroxy, hydroxyalkyl, haloalkyl, aryloxy, amino, cyano, nitro, thiol, carbonyl, sulfonyl, carboxy, acyl, heterocyclyl, aryl, —CONH 2 and —NHR 8 .
[0036] The present invention also relates to a process for the preparation of the compounds of formula (I), their pharmaceutically acceptable salts, their pharmaceutically acceptable solvates, pharmaceutically acceptable polymorphs and pharmaceutical compositions containing them.
DEFINITIONS
[0037] Listed below are definitions, which apply to the terms as they are used throughout the specification and the appended claims (unless they are otherwise limited in specific instances), either individually or as part of a larger group. It will be understood that “substitution” or “substituted by” or “substituted with” includes the implicit proviso that such substitution is in accordance with the permitted valence of the substituted atom and the substituent, as well as represents a stable compound, which does not readily undergo transformation such as by rearrangement, cyclization, elimination, etc.
[0038] The term “alkyl” whether used alone or as part of a substituent group, refers to the radical of saturated aliphatic groups, including straight or branched-chain containing from 1 to 10 carbon atoms. Furthermore, unless stated otherwise, the term “alkyl” includes unsubstituted as well as substituted alkyl. Suitable alkyl residues contain from 1 to 6 carbon atoms, for example, from 1 to 4 carbon atoms, such as methyl, ethyl, propyl, isopropyl, n-butyl, isobutyl and t-butyl.
[0039] The term “lower alkyl” whether used alone or as part of a substituent group, refers to the radical of saturated aliphatic groups, including straight or branched-chain containing from one to six carbon atoms, such as methyl, ethyl, n-propyl, isopropyl, n-butyl, sec-butyl, isobutyl, tert-butyl, n-pentyl and n-hexyl. Unless stated otherwise, alkyl groups can be unsubstituted or substituted by one or more identical or different substituents. Any kind of substituent present in substituted alkyl residues can be present in any desired position provided that the substitution does not lead to an unstable molecule. A substituted alkyl refers to an alkyl residue in which one or more hydrogen atoms are replaced with substituents, for example, halogen, hydroxy, carbonyl, carboxy, alkoxy, cycloalkyl, ester, ether, cyano, amino, —CONH 2 , imino, alkylthio, thioester, sulfonyl, nitro, haloalkyl, aralkyl, acyl, acyloxy, aryl, heterocyclyl, heteroaryl, —NR x COR y , —NR x SOR y , —NR x SO 2 R y , —S(O) n R x , —S(O) m NR x R y , wherein R x and R y are independently selected from hydrogen, hydroxy, alkyl, alkoxy, alkenyl, alkynyl, cycloalkyl, aryl, aralkyl and heterocyclyl; n is 0, 1 or 2 and m is 1 or 2.
[0040] The term “alkenyl” refers to an unsaturated, branched, straight chain or cyclic alkyl group having from 2 to 6 carbon atoms and at least one carbon-carbon double bond (two adjacent sp 2 carbon atoms). Depending on the placement of double bond and substituents if any, the geometry of the double bond may be entgegen (E), or zusammen (Z), cis or trans. Examples of alkenyl include, but are not limited to vinyl, allyl and 2-propenyl. Unless stated otherwise, the alkenyl groups can be unsubstituted or substituted by one or more of the same or different groups such as halogen, amino, cyano, nitro, hydroxy, carboxy, acyl, acetoxy, alkyl, haloalkyl, alkoxy, cycloalkyl, aryloxy, aryl, aralkyl or heterocyclyl.
[0041] The term “alkynyl” refers to an unsaturated, branched or straight chain having from 2 to 6 carbon atoms and at least one carbon-carbon triple bond (two adjacent sp carbon atoms). Examples of alkynyl include, but are not limited to, ethynyl, 1-propynyl, 3-propynyl and 3-butynyl. Unless stated otherwise, the alkynyl groups can be unsubstituted or substituted with one or more groups, such as halogen, hydroxy, carboxy, amino, cyano, nitro, acyl, acetoxy, alkyl, haloalkyl, cycloalkyl, alkoxy, aryloxy, aryl, aralkyl or heterocyclyl.
[0042] The term “cycloalkyl” refers to a saturated or partially unsaturated cyclic hydrocarbon group including 1, 2 or 3 rings and including a total of 3 to 14 carbons forming the rings. Suitable examples of cycloalkyl include cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl and cyclooctyl. Unless stated otherwise, the cycloalkyl groups can be unsubstituted or substituted with one or more of the same or different groups, such as halogen, hydroxy, alkoxy, oxo, alkyl, cycloalkyl, carboxy, acyl, acyloxy, amino, cyano, nitro, carbonyl, ester, ether, —CONH 2 , imino, alkylthio, aryl or heterocyclyl.
[0043] The term “alkoxy” refers to the alkyl-O— wherein the term alkyl is as defined above. Examples of alkoxy include, but are not limited to methoxy and ethoxy.
[0044] The term “haloalkyl” as used herein refers to radicals wherein any one or more of the alkyl carbon atoms are substituted with one or more halogen. Examples of haloalkyl include, but are not limited to trifluoromethyl and trichloromethyl. Specifically embraced are monohaloalkyl, dihaloalkyl and polyhaloalkyl radicals including perhaloalkyl. A monohaloalkyl radical, for one example, may have an iodo, bromo, chloro or fluoro atom within the radical. Dihalo and polyhaloalkyl radicals may have two or more of the same halo atoms or a combination of different halo radicals. Examples of haloalkyl radicals include fluoromethyl, difluoromethyl, trifluoromethyl, chloromethyl, dichloromethyl, trichloromethyl, pentafluoroethyl, heptafluoropropyl, difluorochloromethyl, dichlorofluoromethyl, difluoroethyl, difluoropropyl, dichloroethyl and dichloropropyl. The term “perfluoroalkyl” means alkyl radicals having all hydrogen atoms replaced with fluoro atoms. Examples include trifluoromethyl and pentafluoroethyl.
[0045] The term “haloalkoxy” as used herein refers to a haloalkyl group attached to the parent molecular moiety through an oxygen atom.
[0046] The term “acyl” refers to the group —C(O)R a , wherein R a is alkyl, cycloalkyl, aryl, aralkyl, heteroaryl and heteroaralkyl. The groups alkyl, cycloalkyl, aryl, aralkyl, heteroaryl and heteroaralkyl can be unsubstituted or substituted with halogen, hydroxy, carboxy, alkoxy, cycloalkyl, ester, ether, cyano, amino, —CONH 2 , alkylthio, thioester, sulfonyl, nitro, haloalkyl, —NR x COR y , —NR x SOR y , —NR x SO 2 R y , —S(O) n R x , —S(O) m NR x R y , wherein R x and R y are independently selected from hydrogen, hydroxy, alkyl, alkoxy, alkenyl, alkynyl, cycloalkyl, aryl, aralkyl and heterocyclyl; n is as an integer from 0-2 and m is an integer from 1 to 2.
[0047] The term “ester” refers to a group of the form —COOR a , wherein R a is alkyl and aralkyl as defined above. Examples include the physiologically hydrolysable esters such as the methyl, ethyl, n- and iso-propyl, n-, sec- and tert-butyl and benzyl esters.
[0048] The term “ether” refers to a group of formula —R a OR a , wherein R a is independently selected from alkyl, cycloalkyl, aryl, aralkyl, heteroaryl and heterocyclyl as defined above.
[0049] The term “aryl” refers to a monocyclic or polycyclic hydrocarbon group having up to 10 ring carbon atoms, in which at least one carbocyclic ring is present that has a conjugated π electron system. Examples of aryl residues include phenyl and naphthyl. Unless stated otherwise, aryl residues, for example phenyl or naphthyl, can be unsubstituted or substituted by one or more substituents, for example, up to five identical or different substituents selected from the group consisting of alkyl, haloalkyl, acyl, halogen, hydroxy, alkoxy, haloalkoxy, trifluoromethoxy, aryloxy, amino, cyano, nitro, thiol, —CONH 2 , carbonyl, sulfonyl and aryl.
[0050] Aryl residues can be bonded via any desired position, and in substituted aryl residues, the substituents can be located in any desired position. For example, in monosubstituted phenyl residues the substituent can be located in the 2-position, the 3-position, the 4-position, the 5-position, or the 6-position. If the phenyl group carries two substituents, they can be located in 2,3-position, 2,4-position, 2,5-position, 2,6-position, 3,4-position or 3,5-position.
[0051] The term “aryloxy” refers to the aryl-O— wherein the term aryl is as defined above. Exemplary aryloxy groups include, but are not limited to, phenoxy and naphthoxy.
[0052] The terms “heterocyclyl” and “heterocyclic” refer to a saturated, partially unsaturated or aromatic monocyclic or polycyclic ring system containing 3-14 ring atoms of which 1, 2, 3 or 4 are identical or different heteroatoms selected from nitrogen, oxygen and sulfur. The heterocyclyl group may, for example, have at least one heteroatom selected from 0 to 2 oxygen atoms, 0 to 2 sulfur atoms and 0 to 4 nitrogen atoms in the ring. Monocyclic heterocyclyl groups include 3-membered, 4-membered, 5-membered, 6-membered and 7-membered rings. Suitable examples of heterocyclyl include, but are not limited to, pyrrolyl, imidazolyl, thiophenyl, pyrrolidinyl, pyridinyl, pyrazinyl, pyridazinyl, pyrimidinyl, pyrazolyl, triazolyl, tetrazolyl, piperidinyl, piperazinyl and morpholinyl. Polycyclic heterocyclyl groups can include two fused rings (bicyclic) or three fused rings (tricyclic), one of which is a 5-, 6- or 7-membered heterocyclic ring and the other is a 5-, 6- or 7-membered carbocyclic or heterocyclic ring. Exemplary bicyclic heterocyclic groups include benzoxazolyl, quinolinyl, isoquinolyl, indolyl, isoindolyl, and benzofurazanyl. Exemplary tricyclic heterocyclic groups include, but not limited to, substituted or unsubstituted naphthofuranyl, benzoindole, pyrroloquinoline and furoquinoline. Heterocyclyl includes saturated heterocyclic ring systems, which do not contain any double bonds within the rings, as well as unsaturated heterocyclic ring systems, which contain one or more, up to 5 double bonds within the rings provided that the resulting system is stable. Unsaturated rings may be non-aromatic or aromatic.
[0053] Aromatic heterocyclyl groups may also be referred to by the customary term “heteroaryl” for which all the definitions and explanations above and below relating to heterocyclyl apply. Unless stated otherwise, the heteroaryl and heterocyclyl group can be unsubstituted or substituted with one or more (e.g., up to 5), identical or different, substituents. Examples of substituents for the ring carbon and ring nitrogen atoms are alkyl, acyl, alkoxy, trifluoromethoxy, halogen, hydroxy, hydroxyalkyl, haloalkyl, aryloxy, amino, cyano, nitro, thiol, —CONH 2 , carbonyl, carboxy, sulfonyl, cycloalkyl, heterocyclyl, aryl and —NHR 8 , wherein R 8 is alkyl, alkenyl, alkynyl, cycloalkyl, aralkyl, aryl, heteroaryl or heterocyclyl. The substituents can be present at one or more positions provided that it results into a stable molecule.
[0054] The term “aralkyl” refers to an alkyl group substituted with an aryl or heteroaryl group, wherein the terms alkyl, aryl and heteroaryl are as defined above. Exemplary aralkyl groups include —(CH 2 ) p -phenyl, —(CH 2 ) p -pyridyl, wherein p is an integer from 1 to 6. The alkyl, aryl and heteroaryl in the said aralkyl group are as defined above.
[0055] The term “heteroatom” refers to nitrogen, oxygen and sulfur. It should be noted that any heteroatom with unsatisfied valences is assumed to have a hydrogen atom to satisfy the valences. The ring heteroatoms can be present in any desired number and in any position with respect to each other provided that the resulting heterocyclic system is stable and suitable as a subgroup in a drug substance.
[0056] The term “halo” or “halogen” unless otherwise stated refers to fluorine, chlorine, bromine, or iodine atom.
[0057] The term “amino” refers to the group —NH 2 which may be optionally substituted with alkyl, alkenyl, alkynyl, aryl, heterocyclyl, or cycloalkyl wherein the terms alkyl, alkenyl, alkynyl, aryl, heterocyclyl and cycloalkyl are as defined herein above.
[0058] As used herein, the terms “treat” and “therapy” and the like refer to alleviate, slow the progression, prophylaxis, modulation, attenuation or cure of existing disease (e.g., cancer or inflammation).
Embodiments
[0059] In an embodiment, the present invention provides compounds of formula (I), wherein,
[0000] R 1 is phenyl, which is unsubstituted or substituted with an alkyl group, wherein the alkyl group is unsubstituted or substituted with one or more of the same or different groups selected from nitro, cyano, —CONH 2 , amino, halogen, hydroxy, haloalkyl and alkoxy;
R 2 is alkyl, alkenyl, alkynyl, cycloalkyl, aryl, heteroaryl, heterocyclyl, amino, —NHR 8 or NR 8 R 8 ;
R 3 , R 4 , R 5 and R 7 are each independently hydrogen, alkyl, alkenyl, alkynyl, cycloalkyl, aralkyl, halogen, acyl, hydroxy, alkoxy, amino, cyano and nitro;
R 6 is hydrogen, alkyl, alkenyl, alkynyl, cycloalkyl, aralkyl, halogen, acyl, hydroxy, amino, cyano, nitro, thiol, —COOH, —CONH 2 , —OR 8 , —NHR 8 , —SR 8 or —B(OH) 2 ;
each R 8 is independently selected from alkyl, alkenyl, alkynyl, cycloalkyl, aralkyl, aryl, heteroaryl or heterocyclyl; and
Y is —C(O), —C(S) or —S(O) n ; wherein n is 0, for 2;
[0060] wherein alkyl is unsubstituted or substituted with one or more of the same or different groups such as cyano, nitro, halogen, hydroxy, amino, —CONH 2 , alkoxy, acyl and aryl;
[0061] alkenyl is unsubstituted or substituted by one or more of the same or different groups such as cyano, nitro, halogen, lower alkyl, haloalkyl, hydroxy, alkoxy, acyl and aryl;
[0062] alkynyl is unsubstituted or substituted with one or more of the same or different groups selected from cyano, nitro, halogen, lower alkyl, haloalkyl, hydroxy, alkoxy, acyl and aryl;
[0063] cycloalkyl is unsubstituted or substituted with one or more of the same or different groups such as cyano, nitro, halogen, hydroxy, amino, —CONH 2 , lower alkyl, haloalkyl, alkoxy, acyl and aryl;
[0064] aryl is unsubstituted or substituted with one or more of the same or different groups selected from cyano, nitro, halogen, lower alkyl, haloalkyl, hydroxy, alkoxy and acyl;
[0065] heteroaryl is unsubstituted or substituted with one or more of the same or different groups selected from cyano, nitro, lower alkyl, haloalkyl, alkoxy, hydroxy, halogen, amino, —CONH 2 , carboxy and acyl;
[0066] heterocyclyl is unsubstituted or substituted with one or more of the same or different groups selected from cyano, nitro, halogen, lower alkyl, haloalkyl, hydroxy, alkoxy, amino, —CONH 2 , carboxy, acyl and aryl;
[0000] in all their stereoisomeric and tautomeric forms and mixtures thereof in all ratios, their pharmaceutically acceptable salts and pharmaceutically acceptable solvates.
[0067] In another embodiment, the present invention provides compounds of formula (I), wherein,
[0000] R 1 is phenyl substituted with —C(CH 3 ) 2 CN;
R 2 is alkyl, alkenyl, alkynyl, cycloalkyl, aryl, heteroaryl, heterocyclyl, amino, —NHR 8 or —NR 8 R 8 ;
R 3 , R 4 , R 5 and R 7 are each independently selected from hydrogen, alkyl, alkenyl, alkynyl, cycloalkyl, aralkyl, halogen, acyl, hydroxy, alkoxy, amino, cyano and nitro;
R 6 is hydrogen, alkyl, alkenyl, alkynyl, cycloalkyl, aralkyl, halogen, acyl, hydroxy, amino, cyano, nitro, thiol, —COOH, —CONH 2 , —OR 8 , —NHR 8 , —SR 8 or —B(OH) 2 ;
each R 8 is independently selected from alkyl, alkenyl, alkynyl, cycloalkyl, aralkyl, aryl, heteroaryl or heterocyclyl; and
Y is —C(O), —C(S) or —S(O) n , wherein n is 0, 1 or 2;
[0068] wherein, alkyl is unsubstituted or substituted with one or more of the same or different groups selected from cyano, nitro, halogen, amino, —CONH 2 , hydroxy, alkoxy, acyl and aryl;
[0069] alkenyl is unsubstituted or substituted with one or more of the same or different groups selected from cyano, nitro, halogen, lower alkyl, haloalkyl, hydroxy, alkoxy, acyl and aryl;
[0070] alkynyl is unsubstituted or substituted by one or more of the same or different groups selected from cyano, nitro, halogen, lower alkyl, haloalkyl, hydroxy, alkoxy, acyl and aryl;
[0071] cycloalkyl is unsubstituted or substituted with one or more of the same or different groups selected from cyano, nitro, halogen, amino, —CONH 2 , hydroxy, lower alkyl, haloalkyl, alkoxy, acyl and aryl;
[0072] aryl is unsubstituted or substituted with one or more of the same or different groups selected from cyano, nitro, halogen, lower alkyl, haloalkyl, hydroxy, alkoxy, haloalkoxy, acyl and aryl;
[0073] heteroaryl is unsubstituted or substituted with one or more of the same or different groups selected from cyano, nitro, halogen, lower alkyl, haloalkyl, hydroxy, alkoxy, amino, —CONH 2 , carboxy, acyl and aryl;
[0074] heterocyclyl is unsubstituted or substituted with one or more of the same or different groups selected from cyano, nitro, halogen, lower alkyl, haloalkyl, hydroxy, alkoxy, amino, —CONH 2 , carboxy, acyl and aryl;
[0000] in all their stereoisomeric and tautomeric forms and mixtures thereof in all ratios, their pharmaceutically acceptable salts and pharmaceutically acceptable solvates.
[0075] In another embodiment, the present invention provides compounds of formula (I), wherein,
[0000] R 1 is phenyl substituted with —C(CH 3 ) 2 CN;
R 2 is alkyl, alkenyl, alkynyl, cycloalkyl, aryl, heteroaryl, heterocyclyl, amino, —NHR 8 or —NR 8 R 8 ;
R 3 , R 4 , R 5 and R 7 are each independently selected from hydrogen, alkyl, alkenyl, alkynyl, cycloalkyl, aralkyl, halogen, acyl, hydroxy, alkoxy, amino, cyano and nitro;
R 6 is halogen or lower alkyl;
each R 8 is independently selected from alkyl, alkenyl, alkynyl, cycloalkyl, aralkyl, aryl, heteroaryl or heterocyclyl; and
Y is —C(O), —C(S) or —S(O) 2 ;
[0076] wherein, alkyl is unsubstituted or substituted with one or more of the same or different groups selected from cyano, nitro, halogen, amino, —CONH 2 , hydroxy, alkoxy, acyl and aryl;
[0077] alkenyl is unsubstituted or substituted with one or more of the same or different groups selected from cyano, nitro, halogen, lower alkyl, haloalkyl, hydroxy, alkoxy, acyl and aryl;
[0078] alkynyl is unsubstituted or substituted by one or more of the same or different groups selected from cyano, nitro, halogen, lower alkyl, haloalkyl, hydroxy, alkoxy, acyl and aryl;
[0079] cycloalkyl is unsubstituted or substituted with one or more of the same or different groups selected from cyano, nitro, halogen, amino, —CONH 2 , hydroxy, lower alkyl, haloalkyl, alkoxy, acyl and aryl;
[0080] aryl is unsubstituted or substituted with one or more of the same or different groups selected from cyano, nitro, halogen, lower alkyl, haloalkyl, hydroxy, alkoxy, haloalkoxy, acyl and aryl;
[0081] heteroaryl is unsubstituted or substituted with one or more of the same or different groups selected from cyano, nitro, halogen, lower alkyl, haloalkyl, hydroxy, alkoxy, amino, —CONH 2 , carboxy, acyl and aryl;
[0082] heterocyclyl is unsubstituted or substituted with one or more of the same or different groups selected from cyano, nitro, halogen, lower alkyl, haloalkyl, hydroxy, alkoxy, amino, —CONH 2 , carboxy, acyl and aryl;
[0000] in all their stereoisomeric and tautomeric forms and mixtures thereof in all ratios, their pharmaceutically acceptable salts and pharmaceutically acceptable solvates.
[0083] In another embodiment, the present invention provides compounds of formula (I), wherein,
[0000] R 1 is phenyl substituted with —C(CH 3 ) 2 CN;
R 2 is alkyl, alkenyl, alkynyl, cycloalkyl, aryl, heteroaryl, heterocyclyl, amino, —NHR 8 or —NR 8 R 8 ;
R 3 , R 4 , R 5 and R 7 are hydrogen;
R 6 is halogen or lower alkyl;
each R 8 is independently selected from alkyl, alkenyl, alkynyl, cycloalkyl, aralkyl, aryl, heteroaryl or heterocyclyl; and
Y is —C(O), —C(S) or —S(O) 2 ;
[0084] wherein, alkyl is unsubstituted or substituted with one or more of the same or different groups selected from cyano, nitro, amino, —CONH 2 , hydroxy, alkoxy, halogen, acyl and aryl;
[0085] alkenyl is unsubstituted or substituted with one or more of the same or different groups selected from cyano, nitro, halogen, lower alkyl, haloalkyl, hydroxy, alkoxy, acyl and aryl;
[0086] alkynyl is unsubstituted or substituted by one or more of the same or different groups selected from cyano, nitro, halogen, lower alkyl, haloalkyl, hydroxy, alkoxy, acyl and aryl;
[0087] cycloalkyl is unsubstituted or substituted with one or more of the same or different groups selected from cyano, nitro, amino, —CONH 2 , hydroxy, alkoxy, halogen, lower alkyl, haloalkyl, acyl and aryl;
[0088] aryl is unsubstituted or substituted with one or more of the same or different groups selected from cyano, nitro, halogen, lower alkyl, haloalkyl, hydroxy, alkoxy, haloalkoxy, acyl and aryl;
[0089] heteroaryl is unsubstituted or substituted with one or more of the same or different groups selected from cyano, nitro, halogen, lower alkyl, haloalkyl, hydroxy, alkoxy, amino, —CONH 2 , carboxy, acyl and aryl;
[0090] heterocyclyl is unsubstituted or substituted with one or more of the same or different groups selected from cyano, nitro, halogen, lower alkyl, haloalkyl, hydroxy, alkoxy, amino, —CONH 2 , carboxy, acyl and aryl;
[0000] in all their stereoisomeric and tautomeric forms and mixtures thereof in all ratios, their pharmaceutically acceptable salts and pharmaceutically acceptable solvates.
[0091] In another embodiment, the present invention provides compounds of formula (I), wherein,
[0000] R 1 is phenyl substituted with —C(CH 3 ) 2 CN;
R 2 is alkyl, alkenyl, alkynyl, cycloalkyl, aryl, heteroaryl, heterocyclyl, amino, —NHR 8 or —NR 8 R 8 ;
R 3 , R 4 , R 5 and R 7 are each independently hydrogen;
R 6 is halogen or lower alkyl;
each R 8 is independently selected from alkyl, alkenyl, alkynyl, cycloalkyl, aralkyl, aryl, heteroaryl or heterocyclyl; and
Y is —S(O) 2 ;
[0092] wherein, alkyl is unsubstituted or substituted with one or more of the same or different groups selected from cyano, nitro, halogen, amino, —CONH 2 , hydroxy, alkoxy, acyl and aryl;
[0093] alkenyl is unsubstituted or substituted with one or more of the same or different groups selected from cyano, nitro, halogen, lower alkyl, haloalkyl, hydroxy, alkoxy, acyl and aryl;
[0094] alkynyl is unsubstituted or substituted by one or more of the same or different groups selected from cyano, nitro, halogen, lower alkyl, haloalkyl, hydroxy, alkoxy, acyl and aryl;
[0095] cycloalkyl is unsubstituted or substituted with one or more of the same or different groups selected from cyano, nitro, halogen, amino, —CONH 2 , hydroxy, lower alkyl, haloalkyl, alkoxy, acyl and aryl;
[0096] aryl is unsubstituted or substituted with one or more of the same or different groups selected from cyano, nitro, halogen, lower alkyl, haloalkyl, hydroxy, alkoxy, haloalkoxy, acyl and aryl;
[0097] heteroaryl is unsubstituted or substituted with one or more of the same or different groups selected from cyano, nitro, halogen, lower alkyl, haloalkyl, hydroxy, alkoxy, amino, —CONH 2 , carboxy, acyl and aryl;
[0098] heterocyclyl is unsubstituted or substituted with one or more of the same or different groups selected from cyano, nitro, halogen, lower alkyl, haloalkyl, hydroxy, alkoxy, amino, —CONH 2 , carboxy, acyl and aryl;
[0000] in all their stereoisomeric and tautomeric forms and mixtures thereof in all ratios, their pharmaceutically acceptable salts and pharmaceutically acceptable solvates.
[0099] In another embodiment, the present invention provides compounds of formula (I), wherein,
[0000] R 1 is phenyl substituted with —C(CH 3 ) 2 CN;
R 2 is alkyl, aryl, or heteroaryl;
R 3 , R 4 , R 5 and R 7 are each independently hydrogen;
R 6 is halogen or lower alkyl; and
Y is —S(O) 2 ;
[0100] wherein, alkyl is unsubstituted or substituted with one or more of the same or different groups selected from cyano, nitro, halogen, amino, —CONH 2 , hydroxy, alkoxy, acyl and aryl;
[0101] aryl is unsubstituted or substituted with one or more of the same or different groups selected from cyano, nitro, halogen, lower alkyl, haloalkyl, hydroxy, alkoxy, haloalkoxy, acyl and aryl;
[0102] heteroaryl is unsubstituted or substituted with one or more of the same or different groups selected from cyano, nitro, halogen, lower alkyl, haloalkyl, hydroxy, alkoxy, amino, —CONH 2 , carboxy, acyl and aryl;
[0000] in all their stereoisomeric and tautomeric forms and mixtures thereof in all ratios, their pharmaceutically acceptable salts and pharmaceutically acceptable solvates.
[0103] In another embodiment, the present invention provides compounds of formula (I), wherein,
[0000] R 1 is phenyl substituted with —C(CH 3 ) 2 CN;
R 2 is alkyl, alkenyl, alkynyl, cycloalkyl, aryl, heteroaryl, heterocyclyl, amino, —NHR 8 or —NR 8 R 8 ;
R 3 , R 4 , R 5 and R 7 are each independently hydrogen;
R 6 is halogen or lower alkyl;
each R 8 is independently selected from alkyl, alkenyl, alkynyl, cycloalkyl, aralkyl, aryl, heteroaryl or heterocyclyl; and
Y is —C(O);
[0104] wherein, alkyl is unsubstituted or substituted with one or more of the same or different groups selected from cyano, nitro, amino, —CONH 2 , hydroxy, alkoxy, halogen, acyl and aryl;
[0105] alkenyl is unsubstituted or substituted with one or more of the same or different groups selected from cyano, nitro, halogen, lower alkyl, haloalkyl, hydroxy, alkoxy, acyl and aryl;
[0106] alkynyl is unsubstituted or substituted by one or more of the same or different groups selected from cyano, nitro, halogen, lower alkyl, haloalkyl, hydroxy, alkoxy, acyl and aryl;
[0107] cycloalkyl is unsubstituted or substituted with one or more of the same or different groups selected from cyano, nitro, amino, —CONH 2 , hydroxy, alkoxy, halogen, lower alkyl, haloalkyl, acyl and aryl;
[0108] aryl is unsubstituted or substituted with one or more of the same or different groups selected from cyano, nitro, halogen, lower alkyl, haloalkyl, hydroxy, alkoxy, haloalkoxy, acyl and aryl;
[0109] heteroaryl is unsubstituted or substituted with one or more of the same or different groups selected from cyano, nitro, halogen, lower alkyl, haloalkyl, hydroxy, alkoxy, amino, —CONH 2 , carboxy, acyl and aryl;
[0110] heterocyclyl is unsubstituted or substituted with one or more of the same or different groups selected from cyano, nitro, halogen, lower alkyl, haloalkyl, hydroxy, alkoxy, amino, —CONH 2 , carboxy, acyl and aryl;
[0000] in all their stereoisomeric and tautomeric forms and mixtures thereof in all ratios, their pharmaceutically acceptable salts and pharmaceutically acceptable solvates.
[0111] In another embodiment, the present invention provides compounds of formula (I), wherein,
[0000] R 1 is phenyl substituted with —C(CH 3 ) 2 CN;
R 2 is alkyl, alkenyl, aryl, heterocyclyl or —NHR 8 ;
R 3 , R 4 , R 5 and R 7 are each independently hydrogen;
R 6 is halogen or lower alkyl;
R 8 is alkyl, alkenyl, alkynyl, cycloalkyl, aralkyl, aryl, heteroaryl or heterocyclyl; and
Y is —C(O);
[0112] wherein, alkyl is unsubstituted or substituted with one or more of the same or different groups selected from cyano, nitro, amino, —CONH 2 , hydroxy, alkoxy, halogen, acyl and aryl;
[0113] alkenyl is unsubstituted or substituted with one or more of the same or different groups selected from cyano, nitro, halogen, lower alkyl, haloalkyl, hydroxy, alkoxy, acyl and aryl;
[0114] alkynyl is unsubstituted or substituted by one or more of the same or different groups selected from cyano, nitro, halogen, lower alkyl, haloalkyl, hydroxy, alkoxy, acyl and aryl;
[0115] cycloalkyl is unsubstituted or substituted with one or more of the same or different groups selected from cyano, nitro, amino, —CONH 2 , hydroxy, alkoxy, halogen, lower alkyl, haloalkyl, acyl and aryl;
[0116] aryl is unsubstituted or substituted with one or more of the same or different groups selected from cyano, nitro, halogen, lower alkyl, haloalkyl, hydroxy, alkoxy, haloalkoxy, acyl and aryl;
[0117] heteroaryl is unsubstituted or substituted with one or more of the same or different groups selected from cyano, nitro, halogen, lower alkyl, haloalkyl, hydroxy, alkoxy, amino, —CONH 2 , carboxy, acyl and aryl;
[0118] heterocyclyl is unsubstituted or substituted with one or more of the same or different groups selected from cyano, nitro, halogen, lower alkyl, haloalkyl, hydroxy, alkoxy, amino, —CONH 2 , carboxy, acyl and aryl;
[0000] in all their stereoisomeric and tautomeric forms and mixtures thereof in all ratios, their pharmaceutically acceptable salts and pharmaceutically acceptable solvates.
[0119] In another embodiment, the present invention provides compounds of formula (I), wherein,
[0000] R 1 is phenyl substituted with —C(CH 3 ) 2 CN;
R 2 is alkyl, alkenyl, aryl, heterocyclyl or —NHR 8 ;
R 3 , R 4 , R 5 and R 7 are each independently hydrogen;
R 6 is halogen or lower alkyl;
R 8 is alkyl, alkenyl, aralkyl or aryl; and
Y is —C(O);
[0120] wherein, alkyl is unsubstituted or substituted with one or more of the same or different groups selected from cyano, nitro, amino, —CONH 2 , hydroxy, alkoxy, halogen, acyl and aryl;
[0121] alkenyl is unsubstituted or substituted with one or more of the same or different groups selected from cyano, nitro, halogen, lower alkyl, haloalkyl, hydroxy, alkoxy, acyl and aryl;
[0122] aryl is unsubstituted or substituted with one or more of the same or different groups selected from cyano, nitro, halogen, lower alkyl, haloalkyl, hydroxy, alkoxy, haloalkoxy, acyl and aryl;
[0123] heterocyclyl is unsubstituted or substituted with one or more of the same or different groups selected from cyano, nitro, halogen, lower alkyl, haloalkyl, hydroxy, alkoxy, amino, —CONH 2 , carboxy, acyl and aryl;
[0000] in all their stereoisomeric and tautomeric forms and mixtures thereof in all ratios, their pharmaceutically acceptable salts and pharmaceutically acceptable solvates.
[0124] In another embodiment, the present invention provides compounds of formula (I), wherein,
[0000] R 1 is phenyl substituted with —C(CH 3 ) 2 CN;
R 2 is —NHR 8 ;
[0125] R 3 , R 4 , R 5 and R 7 are each independently hydrogen;
R 6 is halogen or lower alkyl;
R 8 is alkyl, alkenyl, alkynyl, cycloalkyl, aralkyl, aryl, heteroaryl or heterocyclyl; and
Y is —C(S);
[0126] wherein, alkyl is unsubstituted or substituted with one or more of the same or different groups selected from cyano, nitro, amino, —CONH 2 , hydroxy, alkoxy, halogen, acyl and aryl;
[0127] alkenyl is unsubstituted or substituted with one or more of the same or different groups selected from cyano, nitro, halogen, lower alkyl, haloalkyl, hydroxy, alkoxy, acyl and aryl;
[0128] alkynyl is unsubstituted or substituted by one or more of the same or different groups selected from cyano, nitro, halogen, lower alkyl, haloalkyl, hydroxy, alkoxy, acyl and aryl;
[0129] cycloalkyl is unsubstituted or substituted with one or more of the same or different groups selected from cyano, nitro, amino, —CONH 2 , hydroxy, alkoxy, halogen, lower alkyl, haloalkyl, acyl and aryl;
[0130] aryl is unsubstituted or substituted with one or more of the same or different groups selected from cyano, nitro, halogen, lower alkyl, haloalkyl, hydroxy, alkoxy, haloalkoxy, acyl and aryl;
[0131] heteroaryl is unsubstituted or substituted with one or more of the same or different groups selected from cyano, nitro, halogen, lower alkyl, haloalkyl, hydroxy, alkoxy, amino, —CONH 2 , carboxy, acyl and aryl;
[0132] heterocyclyl is unsubstituted or substituted with one or more of the same or different groups selected from cyano, nitro, halogen, lower alkyl, haloalkyl, hydroxy, alkoxy, amino, —CONH 2 , carboxy, acyl and aryl;
[0000] in all their stereoisomeric and tautomeric forms and mixtures thereof in all ratios, their pharmaceutically acceptable salts and pharmaceutically acceptable solvates.
[0133] Representative compounds, encompassed in accordance with the present invention include:
2-(4-(8-bromo-2-oxo-3-(4-(trifluoromethoxy)phenylsulfonyl)-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)-2-methylpropanenitrile; 2-(8-bromo-1-(4-(2-cyanopropan-2-yl)phenyl)-2-oxo-1H-imidazo[4,5-c]quinolin-3 (2H)-ylsulfonyl)benzonitrile; 2-(4-(8-bromo-2-oxo-3-(m-tolylsulfonyl)-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)-2-methylpropanenitrile; 2-(4-(8-bromo-3-(2-methyl-4-nitrophenylsulfonyl)-2-oxo-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)-2-methylpropanenitrile; 2-(4-(8-bromo-3-(3-fluoro-4-methylphenylsulfonyl)-2-oxo-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)-2-methylpropanenitrile; 2-(4-(8-bromo-3-(3,5-dimethylphenylsulfonyl)-2-oxo-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)-2-methylpropanenitrile; 2-(4-(8-bromo-2-oxo-3-(phenylsulfonyl)-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)-2-methylpropanenitrile; 2-(4-(8-bromo-2-oxo-3-tosyl-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)-2-methylpropanenitrile; 2-(4-(8-bromo-2-oxo-3-(thiophen-2-ylsulfonyl)-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)-2-methylpropanenitrile; 2-(4-(8-bromo-3-(3-fluorophenylsulfonyl)-2-oxo-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)-2-methylpropanenitrile; 2-(4-(8-bromo-2-oxo-3-(quinolin-8-ylsulfonyl)-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)-2-methylpropanenitrile; 2-(4-(3-(4-acetylphenylsulfonyl)-8-bromo-2-oxo-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)-2-methylpropanenitrile; 2-(4-(8-bromo-2-oxo-3-(3-(trifluoromethyl)phenylsulfonyl)-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)-2-methylpropanenitrile; 2-(4-(8-bromo-3-(3-methoxyphenylsulfonyl)-2-oxo-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)-2-methylpropanenitrile; 2-(4-(8-bromo-3-(3-bromophenylsulfonyl)-2-oxo-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)-2-methylpropanenitrile; 2-(4-(8-bromo-3-(3,5-difluorophenylsulfonyl)-2-oxo-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)-2-methylpropanenitrile; 2-(4-(8-bromo-3-(2,4-difluorophenylsulfonyl)-2-oxo-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)-2-methylpropanenitrile; 2-(4-(8-bromo-3-(methylsulfonyl)-2-oxo-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)-2-methylpropanenitrile; 2-(4-(8-chloro-2-oxo-3-(m-tolylsulfonyl)-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)-2-methylpropanenitrile; 2-(8-chloro-1-(4-(2-cyanopropan-2-yl)phenyl)-2-oxo-1H-imidazo[4,5-c]quinolin-3(2H)-ylsulfonyl)benzonitrile; 2-methyl-2-(4-(8-methyl-2-oxo-3-(m-tolylsulfonyl)-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)propanenitrile; 2-(4-(3-(3-fluorophenylsulfonyl)-8-methyl-2-oxo-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)-2-methylpropanenitrile; 2-methyl-2-(4-(8-methyl-3-(2-methyl-5-nitrophenylsulfonyl)-2-oxo-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)propanenitrile; 2-methyl-2-(4-(8-methyl-2-oxo-3-(quinolin-8-ylsulfonyl)-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)propanenitrile; 2-(4-(3-(4-acetylphenylsulfonyl)-8-methyl-2-oxo-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)-2-methylpropanenitrile; 2-(4-(8-bromo-3-(morpholine-4-carbonyl)-2-oxo-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)-2-methylpropanenitrile; (E)-2-(4-(8-bromo-3-but-2-enoyl-2-oxo-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)-2-methylpropanenitrile; 2-(4-(8-bromo-2-oxo-3-(2-propylpentanoyl)-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)-2-methylpropanenitrile; (E)-2-(4-(8-bromo-3-cinnamoyl-2-oxo-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)-2-methylpropanenitrile; 2-(4-(3-benzoyl-8-bromo-2-oxo-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)-2-methylpropanenitrile; 8-bromo-1-(4-(2-cyanopropan-2-yl)phenyl)-N-(4-methoxyphenyl)-2-oxo-1H-imidazo[4,5-c]quinoline-3(2H)-carboxamide; N-benzyl-8-bromo-1-(4-(2-cyanopropan-2-yl)phenyl)-2-oxo-1H-imidazo[4,5-c]quinoline-3(2H)-carboxamide; 8-Bromo-N-(2-bromophenyl)-1-(4-(2-cyanopropan-2-yl)phenyl)-2-oxo-1H-imidazo[4,5-c]quinoline-3(2H)-carboxamide; 8-bromo-N-(2-chloroethyl)-1-(4-(2-cyanopropan-2-yl)phenyl)-2-oxo-1H-imidazo[4,5-c]quinoline-3(2H)-carboxamide; N-allyl-8-bromo-1-(4-(2-cyanopropan-2-yl)phenyl)-2-oxo-1H-imidazo[4,5-c]quinoline-3(2H)-carboxamide; 2-(4-(3-acetyl-8-chloro-2-oxo-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)-2-methylpropanenitrile; 2-(4-(3-benzoyl-8-chloro-2-oxo-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)-2-methylpropanenitrile; (E)-2-(4-(3-but-2-enoyl-8-chloro-2-oxo-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)-2-methylpropanenitrile; (E)-2-(4-(3-but-2-enoyl-8-methyl-2-oxo-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)-2-methylpropanenitrile; 8-bromo-N-(2-chloroethyl)-1-(4-(2-cyanopropan-2-yl)phenyl)-2-oxo-1H-imidazo[4,5-c]quinoline-3(2H)-carbothioamide;
and their pharmaceutically acceptable salts and solvates.
[0174] According to a further feature of the present invention there is provided a process for the preparation of the compounds of the present invention as given in the following scheme.
[0175] According to a further aspect of the present invention, there is provided a process for the preparation of a compound of formula (A 8),
[0000]
[0000] wherein, R 2 is alkyl, alkenyl, alkynyl, cycloalkyl, aryl, heterocyclyl or heteroaryl; R 3 is hydrogen; R 1 , R 4 , R 5 , R 6 and R 7 are as defined for formula (I), which comprises,
reacting a compound of formula (A 7)
[0000]
[0000] with compound of formula R 2 COCl, wherein R 2 is alkyl, alkenyl, alkynyl, cycloalkyl, aryl, heterocyclyl or heteroaryl; R 3 is hydrogen; R 1 , R 4 , R 5 , R 6 and R 7 are as defined for formula (I), in the presence of a base such as sodium hydride and solvent such as DMF; and optionally converting the resulting compound into a pharmaceutically acceptable salt.
[0176] According to a further aspect of the present invention, there is provided a process for the preparation of a compound of formula (A 9),
[0000]
[0000] wherein, R 3 is hydrogen; R 1 , R 2 , R 4 , R 5 , R 6 and R 7 are as defined for formula (I), which comprises, reacting a compound of formula (A 7)
[0000]
[0000] with compound of formula R 2 SO 2 Cl, wherein R 3 is hydrogen; R 1 , R 2 , R 4 , R 5 , R 6 and R 7 are as defined for formula (I), in the presence of a base such as triethylamine; and
optionally converting the resulting compound into a pharmaceutically acceptable salt.
[0177] According to a further aspect of the present invention, there is provided a process for the preparation of a compound of formula (A 10),
[0000]
[0000] wherein, R 3 is hydrogen; R 1 , R 4 , R 5 , R 6 , R 7 and R 8 are as defined for formula (I),
which comprises, reacting a compound of formula (A 7)
[0000]
[0000] with compound of formula R 8 N═C═O, wherein R 3 is hydrogen; R 1 , R 4 , R 5 , R 6 , R 7 and R 8 are as defined for formula (I), in the presence of a solvent such as benzene or DCM;
optionally converting the resulting compound into a pharmaceutically acceptable salt.
[0178] According to a further aspect of the present invention, there is provided a process for the preparation of a compound of formula (A 11),
[0000]
[0000] wherein, R 3 is hydrogen; R 1 , R 4 , R 5 , R 6 , R 7 and R 8 are as defined for formula (I),
which comprises, reacting a compound of formula (A 7)
[0000]
[0000] with compound of formula R 8 N═C═S, wherein R 3 is hydrogen; R 1 , R 4 , R 5 , R 6 , R 7 and R 8 are as defined for formula (I), in the presence of a solvent such as DCM; and
optionally converting the resulting compound into a pharmaceutically acceptable salt.
Schemes
[0179] The compounds of the present invention also include all stereoisomeric forms and mixtures thereof in all ratios and their pharmaceutically acceptable salts, solvates and polymorphs. Furthermore, all the compounds of the present invention are a subject of the present invention in the form of their prodrugs and other derivatives.
[0180] According to another aspect of the present invention, the compounds of formula (I) can be prepared in a number of ways using methods well known to the person skilled in the art. Examples of methods to prepare the present compounds are described below and illustrated in Scheme 1 but not limited thereto. It will be appreciated by persons skilled in the art that within certain of the processes described herein, the order of the synthetic steps employed may be varied and will depend inter alia on factors such as the nature of functional groups present in a particular substrate and the protecting group strategy (if any) to be adopted clearly, such factors will also influence the choice of reagent to be used in the synthetic steps.
[0181] The reagents, reactants and intermediates used in the following processes are either commercially available or can be prepared according to standard literature procedures known in the art. The starting compounds and the intermediates used for the synthesis of compounds of the present invention, are referred to with general formulae namely (A 1), (A 2), (A 3), (A 4), (A 5), (A 6) and (A 7). The compounds of the present invention are referred to with general formulae namely (A 8), (A 9), (A 10) and (A 11).
[0000] The process used in scheme 1 of the present invention, is referred to with general symbols namely 1a, 1b, 1c, 1d, 1e, 1f, 1g, 1 h, 1i and 1j.
[0182] Process for the preparation of compounds of the present invention is set forth in the following scheme:
[0000]
[0000] wherein R 3 is hydrogen; R 1 , R 2 , R 4 , R 5 , R 6 , R 7 and R 8 are as defined for formula (I).
Reaction Conditions
[0000]
1a: conc. HCl, water, NaOH, ice, CH 3 NO 2 ;
1b: Acetic anhydride, potassium acetate, 125° C.;
1c: POCl 3 , 125° C.;
1d: R 1 —NH 2 , acetic acid, room temperature;
1e: 10% Pd/C or Raney Ni; H 2 ; MeOH or MeOH:THF (1:1), room temperature;
1f: Triphosgene, dichloromethane, triethylamine, 0° C.;
1g: NaH or sodium acetate or triethylamine, dichloromethane or dry dimethylformamide, R 2 —COCl or R 2 —C(O)OC(O)R 2 ;
1h: Triethylamine, dichloromethane, R 2 —SO 2 Cl;
1i: Dry benzene or dichloromethane, triethylamine, potassium fluoride, R 8 —NCO;
1j: Dichloromethane, triethylamine, R 8 —NCS.
[0193] The compound of formula (A2) can be prepared by reacting nitromethane in presence of alkali metal hydroxide such as NaOH at 0° C. to room temperature; then pouring the product into conc. HCl at 0-10° C. and adding the compound of the formula (A1) in aqueous acid such as water-HCl mixture, and stirring at 0° C. to room temperature.
[0194] The compound of formula (A2) can be reacted with an acid anhydride such as acetic anhydride in presence of alkali metal salt such as potassium acetate or sodium acetate at 80-140° C. to obtain compound of formula (A3).
[0195] The compound of formula (A4) can be prepared by reacting compound of formula (A3) with a halogenating agent, for example with chlorinating agent such as POCl 3 at 80-140° C.
[0196] The compound of formula (A5) can be prepared by treating compound of formula (A4) with an amine of formula R 1 —NH 2 , in presence of acetic acid, wherein R 1 is as defined for formula (I) at 0-40° C.
[0197] An amine of formula (A6) can be prepared by reducing compound of formula (A5) in presence of a catalyst such as palladium on carbon or Raney Nickel with hydrogen in an appropriate solvent, such as ethanol, methanol, tetrahydrofuran or mixture thereof.
[0198] The tricyclic compound of formula (A7) can be prepared by treating compound of formula (A6) with trichloromethylchloroformate or triphosgene in presence of a base such as triethylamine or trimethylamine in an appropriate solvent such as dichloromethane or chloroform.
[0199] The tricyclic compound of formula (A7) can be treated with compound of formula R 2 COCl or R 2 —C(O)OC(O)R 2 in an appropriate solvent, such as dimethylformamide, dichloromethane, tetrahydrofuran, dimethylsulfoxide, acetonitrile or mixture thereof, in presence of base such as sodium hydride, potassium hydride, sodium acetate, potassium acetate, triethylamine or mixture thereof to obtain compound of formula (A8).
[0200] The tricyclic compound of formula (A7) can be treated with compound of formula R 2 SO 2 Cl, in presence of a base such as triethylamine, sodium carbonate, potassium carbonate or mixture thereof to obtain compound of formula (A9) wherein R 2 is as defined for formula (I).
[0201] The tricyclic compound of formula (A7) can be treated with compound of formula R 8 N═C═O, in a solvent such as dichloromethane, benzene, terahydrofuran or mixture thereof, in presence of a base such as potassium fluoride, sodium hydride, potassium hydride, lithium diisopropylamide or mixture thereof to obtain compound of formula (A10), wherein R 8 is as defined for formula (I).
[0202] The tricyclic compound of formula (A7) can be treated with compound of formula R 8 N═C═S, in a solvent such as dichloromethane, dimethylformamide, tetrahydrofuran or mixture thereof to obtain compound of formula (A11), wherein R 8 is as defined for formula (I).
[0203] When the compounds of the present invention represented by the general formula (I) contain one or more basic groups, i.e. groups which can be protonated, they can form an addition salt with an inorganic or organic acid. Examples of suitable inorganic acids include, boric acid, perchloric acid, hydrochloric acid, hydrobromic acid, hydrofluoric acid, sulfuric acid, sulfamic acid, phosphoric acid, nitric acid and other inorganic acids known to the person skilled in the art. Examples of suitable organic acids include: acetic acid, propionic acid, succinic acid, glycolic acid, stearic acid, lactic acid, malic acid, tartaric acid, citric acid, ascorbic acid, pamoic acid, maleic acid, hydroxymaleic acid, fumaric acid, phenylacetic acid, glutamic acid, benzoic acid, salicylic acid, sulfanilic acid, 2-acetoxybenzoic acid, toluenesulfonic acid, methanesulfonic acid, benzenesulfonic acid, ethane disulfonic acid, oxalic acid, isethionic acid, ketoglutaric acid, glycerophosphoric acid, aspartic acid, picric acid, lauric acid, palmitic acid, cholic acid, pantothenic acid, alginic acid, naphthoic acid, mandelic acid, tannic acid, camphoric acid and other organic acids known to the person skilled in the art.
[0204] Thus, when the compounds of the present invention represented by the general formula (I) contain an acidic group they can form an addition salt with a suitable base. For example, such salts of the compounds of the present invention may include their alkali metal salts such as Li, Na, and K salts, or alkaline earth metal salts like Ca, Mg salts, or aluminium salts, or salts with ammonia or salts of organic bases such as lysine, arginine, guanidine, diethanolamine, choline and tromethamine [tris(hydroxymethyl)aminomethane].
[0205] The pharmaceutically acceptable salts of the present invention can be synthesized from the subject compound, which contains a basic or an acidic moiety, by conventional chemical methods. Generally the salts are prepared by contacting the free base or acid with desired salt-forming inorganic or organic acid or base in a suitable solvent or dispersant or from another salt by cation or anion exchange. Suitable solvents are, for example, ethyl acetate, ether, alcohols, acetone, tetrahydrofuran (THF), dioxane or mixtures of these solvents.
[0206] The present invention furthermore includes all solvates of the compounds of the formula (I), for example hydrates, and the solvates formed with other solvents of crystallization, such as alcohols, ethers, ethyl acetate, dioxane, dimethylformamide (DMF), or a lower alkyl ketone, such as acetone, or mixtures thereof.
Methods of Treatment
[0207] The compounds of the present invention are PI3K and/or mTOR and/or TNFα and/or IL-6 inhibitors and find use in the treatment of benign or malignant tumors and/or inflammation.
[0208] Compounds of the present invention can be used to reduce, inhibit, or diminish the proliferation of tumor cells, and thereby assist in reducing the size of a tumor. Benign or malignant tumors that can be treated by compounds of formula (I) include, but are not limited to bladder cancer, breast cancer, colorectal cancer, endometrial cancer, head & neck cancer, leukemia, lung cancer, lymphoma, melanoma, non-small-cell lung cancer, ovarian cancer, prostate cancer, testicular cancer, uterine cancer, cervical cancer, thyroid cancer, gastric cancer, brain stem glioma, cerebellar astrocytoma, cerebral astrocytoma, glioblastoma, ependymoma, Ewing's sarcoma family of tumors, germ cell tumor, extracranial cancer, Hodgkin's disease, acute lymphoblastic leukemia, acute myeloid leukemia, liver cancer, medulloblastoma, neuroblastoma, brain tumors, non-Hodgkin's lymphoma, mantle cell lymphoma, osteosarcoma, malignant fibrous histiocytoma of bone, retinoblastoma, rhabdomyosarcoma, soft tissue sarcomas, supratentorial primitive neuroectodermal and pineal tumors, visual pathway and hypothalamic glioma, Wilms' tumor, acute lymphocytic leukemia, adult acute myeloid leukemia, chronic lymphocytic leukemia, chronic myeloid leukemia, esophageal cancer, hairy cell leukemia, kidney cancer, multiple myeloma, oral cancer, pancreatic cancer, primary central nervous system lymphoma, skin cancer and small-cell lung cancer. Compounds of the formula (I) are also of use in the treatment of inflammatory diseases, for example psoriasis, contact dermatitis, atopic dermatitis, alopecia areata, erythema multiforme, dermatitis herpetiformis, scleroderma, vitiligo, hypersensitivity angiitis, urticaria, bullous pemphigoid, lupus erythematosus, pemphigus, epidermolysis bullosa acquisita, and other inflammatory or allergic conditions of the skin.
[0209] Compounds of the present invention may also be used for the treatment of other diseases or conditions, such as psoriasis, contact dermatitis, atopic dermatitis, alopecia areata, erythema multiforme, dermatitis herpetiformis, scleroderma, vitiligo, hypersensitivity angiitis, urticaria, bullous pemphigoid, lupus erythematosus, pemphigus, epidermolysis bullosa acquisita, inflammatory bowel disease, inflammation, rheumatoid arthritis, juvenile rheumatoid arthritis, psoriatic arthritis, osteoarthritis, refractory rheumatoid arthritis, chronic non-rheumatoid arthritis, osteoporosis/bone resorption, Crohn's disease, septic shock, endotoxic shock, atherosclerosis, ischaemia-reperfusion injury, coronary heart disease, vasculitis, amyloidosis, multiple sclerosis, sepsis, chronic recurrent uveitis, hepatitis C virus infection, malaria, ulcerative colitis, cachexia, plasmocytoma, endometriosis, Behcet's disease, Wegenrer's granulomatosis, AIDS, HIV infection, autoimmune disease, immune deficiency, common variable immunodeficiency (CVID), chronic graft-versus-host disease, trauma and transplant rejection, adult respiratory distress syndrome, pulmonary fibrosis, recurrent ovarian cancer, lymphoproliferative disease, refractory multiple myeloma, myeloproliferative disorder, diabetes, juvenile diabetes, meningitis, ankylosing spondylitis, skin delayed type hypersensitivity disorders, Alzheimer's disease, systemic lupus erythematosus and allergic asthma.
[0210] According to another aspect of the present invention, there is provided a method for the treatment of diseases mediated by PI3K or mTOR, comprising administering to a mammal in need thereof a therapeutically effective amount of a compound of formula I or a pharmaceutically acceptable salt or a pharmaceutically acceptable solvate thereof.
[0211] According to another aspect of the present invention, there is provided a method for the treatment of cancer, wherein the cancer is selected from the group comprising of bladder cancer, breast cancer, colorectal cancer, endometrial cancer, head and neck cancer, leukemia, lung cancer, lymphoma, melanoma, non-small-cell lung cancer, ovarian cancer, prostate cancer, testicular cancer, uterine cancer, cervical cancer, thyroid cancer, gastric cancer, brain stem glioma, cerebellar astrocytoma, cerebral astrocytoma, glioblastoma, ependymoma, Ewing's sarcoma family of tumors, germ cell tumor, extracranial cancer, Hodgkin's disease, acute lymphoblastic leukemia, acute myeloid leukemia, liver cancer, medulloblastoma, neuroblastoma, brain tumors, non-Hodgkin's lymphoma, mantle cell lymphoma, osteosarcoma, malignant fibrous histiocytoma of bone, retinoblastoma, rhabdomyosarcoma, soft tissue sarcomas, supratentorial primitive neuroectodermal and pineal tumors, visual pathway and hypothalamic glioma, Wilms' tumor, acute lymphocytic leukemia, adult acute myeloid leukemia, chronic lymphocytic leukemia, chronic myeloid leukemia, esophageal cancer, hairy cell leukemia, kidney cancer, multiple myeloma, oral cancer, pancreatic cancer, primary central nervous system lymphoma, skin cancer and small-cell lung cancer comprising administering to a mammal in need thereof a therapeutically effective amount of a compound of formula I or a pharmaceutically acceptable salt or a pharmaceutically acceptable solvate thereof.
[0212] According to another aspect of the present invention, there is provided a method for the treatment of cancer, including lung cancer, non-small-cell lung cancer, prostate cancer, ovarian cancer, colorectal cancer, pancreatic cancer, breast cancer and glioblastoma comprising administering to a mammal in need thereof a therapeutically effective amount of a compound of formula I or a pharmaceutically acceptable salt or a pharmaceutically acceptable solvate thereof.
[0213] According to further aspect of the present invention, there is provided a method for the treatment of diseases mediated by TNF-α or IL-6, comprising administering to a mammal in need thereof a therapeutically effective amount of a compound of formula (I) or a pharmaceutically acceptable salt or a pharmaceutically acceptable solvate thereof.
[0214] According to another aspect of the present invention, there is provided a method for the treatment of TNF-α or IL-6 related disorder selected from the group comprising of psoriasis, contact dermatitis, atopic dermatitis, alopecia areata, erythema multiforme, dermatitis herpetiformis, scleroderma, vitiligo, hypersensitivity angiitis, urticaria, bullous pemphigoid, lupus erythematosus, pemphigus, epidermolysis bullosa acquisita, inflammatory bowel disease, inflammation, rheumatoid arthritis, juvenile rheumatoid arthritis, psoriatic arthritis, osteoarthritis, refractory rheumatoid arthritis, chronic non-rheumatoid arthritis, osteoporosis/bone resorption, Crohn's disease, septic shock, endotoxic shock, atherosclerosis, ischaemia-reperfusion injury, coronary heart disease, vasculitis, amyloidosis, multiple sclerosis, sepsis, chronic recurrent uveitis, hepatitis C virus infection, malaria, ulcerative colitis, cachexia, plasmocytoma, endometriosis, Behcet's disease, Wegenrer's granulomatosis, AIDS, HIV infection, autoimmune disease, immune deficiency, common variable immunodeficiency (CVID), chronic graft-versus-host disease, trauma and transplant rejection, adult respiratory distress syndrome, pulmonary fibrosis, recurrent ovarian cancer, lymphoproliferative disease, refractory multiple myeloma, myeloproliferative disorder, diabetes, juvenile diabetes, meningitis, ankylosing spondylitis, skin delayed type hypersensitivity disorders, Alzheimer's disease, systemic lupus erythematosus and allergic asthma, comprising administering to a mammal in need thereof a therapeutically effective amount of a compound of formula (I) or a pharmaceutically acceptable salt or a pharmaceutically acceptable solvate thereof.
[0215] According to another aspect of the present invention, there is provided a method for the treatment of diseases mediated by TNF-α or IL-6 selected from the group comprising of rheumatoid arthritis, Crohn's disease, ulcerative colitis, septic shock, psoriasis and atherosclerosis, comprising administering to a mammal in need thereof a therapeutically effective amount of a compound of formula (I) or a pharmaceutically acceptable salt or a pharmaceutically acceptable solvate thereof.
[0216] According to another aspect of the present invention, there is provided the use of a compound of formula (I) in the treatment of diseases mediated by PI3K and/or mTOR.
[0217] According to another aspect of the present invention, there is provided the use of a compound of formula (I) in the treatment of cancers wherein the cancer is selected from the group comprising of bladder cancer, breast cancer, colorectal cancer, endometrial cancer, head and neck cancer, leukemia, lung cancer, lymphoma, melanoma, non-small-cell lung cancer, ovarian cancer, prostate cancer, testicular cancer, uterine cancer, cervical cancer, thyroid cancer, gastric cancer, brain stem glioma, cerebellar astrocytoma, cerebral astrocytoma, glioblastoma, ependymoma, Ewing's sarcoma family of tumors, germ cell tumor, extracranial cancer, Hodgkin's disease, acute lymphoblastic leukemia, acute myeloid leukemia, liver cancer, medulloblastoma, neuroblastoma, brain tumors, non-Hodgkin's lymphoma, mantle cell lymphoma, osteosarcoma, malignant fibrous histiocytoma of bone, retinoblastoma, rhabdomyosarcoma, soft tissue sarcomas, supratentorial primitive neuroectodermal and pineal tumors, visual pathway and hypothalamic glioma, Wilms' tumor, acute lymphocytic leukemia, adult acute myeloid leukemia, chronic lymphocytic leukemia, chronic myeloid leukemia, esophageal cancer, hairy cell leukemia, kidney cancer, multiple myeloma, oral cancer, pancreatic cancer, primary central nervous system lymphoma, skin cancer and small-cell lung cancer.
[0218] According to another aspect of the present invention, there is provided the use of a compound of formula (I) in the treatment of cancers such as lung cancer, non-small-cell lung cancer, prostate cancer, ovarian cancer, colorectal cancer, breast cancer, pancreatic cancer and glioblastoma.
[0219] According to another aspect of the present invention there is provided the use of compound of formula (I) in the treatment of diseases mediated by TNF-α and/or IL-6.
[0220] According to another aspect of the present invention there is provided the use of compound of formula (I) in the treatment of diseases selected from the group comprising of psoriasis, contact dermatitis, atopic dermatitis, alopecia areata, erythema multiforme, dermatitis herpetiformis, scleroderma, vitiligo, hypersensitivity angiitis, urticaria, bullous pemphigoid, lupus erythematosus, pemphigus, epidermolysis bullosa acquisita, inflammatory bowel disease, inflammation, rheumatoid arthritis, juvenile rheumatoid arthritis, psoriatic arthritis, osteoarthritis, refractory rheumatoid arthritis, chronic non-rheumatoid arthritis, osteoporosis/bone resorption, Crohn's disease, septic shock, endotoxic shock, atherosclerosis, ischaemia-reperfusion injury, coronary heart disease, vasculitis, amyloidosis, multiple sclerosis, sepsis, chronic recurrent uveitis, hepatitis C virus infection, malaria, ulcerative colitis, cachexia, plasmocytoma, endometriosis, Behcet's disease, Wegenrer's granulomatosis, AIDS, HIV infection, autoimmune disease, immune deficiency, common variable immunodeficiency (CVID), chronic graft-versus-host disease, trauma and transplant rejection, adult respiratory distress syndrome, pulmonary fibrosis, recurrent ovarian cancer, lymphoproliferative disease, refractory multiple myeloma, myeloproliferative disorder, diabetes, juvenile diabetes, meningitis, ankylosing spondylitis, skin delayed type hypersensitivity disorders, Alzheimer's disease, systemic lupus erythematosus and allergic asthma.
[0221] According to another aspect of the present invention, there is provided the use of a compound of formula (I) in the treatment of inflammation such as rheumatoid arthritis, Crohn's disease, ulcerative colitis, septic shock syndrome, psoriasis and atherosclerosis.
[0222] According to another aspect of the present invention there are provided methods for manufacture of medicaments comprising compounds of formula (I), which are useful for the treatment of cancers such as breast cancer, leukemia, lung cancer, gastric cancer, prostate cancer, pancreatic cancer, glioblastoma, colon cancer, head and neck squamous cell carcinoma, multiple myeloma, cervical carcinoma and melanoma.
[0223] According to another aspect of the present invention there are provided methods for manufacture of medicaments comprising compounds of formula (I), which are useful for the treatment of inflammation, including diseases such as rheumatoid arthritis, Crohn's disease, ulcerative colitis, septic shock syndrome and atherosclerosis.
Pharmaceutical Compositions and Methods
[0224] According to another aspect of the present invention there is provided a pharmaceutical composition, comprising a therapeutically effective amount of a compound of formula (I) or a pharmaceutically acceptable salt or a pharmaceutically acceptable solvate thereof and a pharmaceutically acceptable excipient or carrier.
[0225] The pharmaceutical preparations according to the invention are prepared in a manner known per se and familiar to one skilled in the art. Pharmaceutically acceptable inert inorganic and/or organic carriers and/or additives can be used in addition to the compounds of formula (I), and/or their physiologically tolerable salts. For the production of pills, tablets, coated tablets and hard gelatin capsules it is possible to use, for example, lactose, corn starch or derivatives thereof, gum arabica, magnesia or glucose, etc. Carriers for soft gelatin capsules and suppositories are, for example, fats, waxes, natural or hardened oils, etc. Suitable carriers for the production of solutions, for example injection solutions, or of emulsions or syrups are, for example, water, physiological sodium chloride solution or alcohols, for example, ethanol, propanol or glycerol, sugar solutions, such as glucose solutions or mannitol solutions, or a mixture of the various solvents which have been mentioned.
[0226] The pharmaceutical preparations normally contain about 1 to 99%, for example, about 5 to 70%, or from about 5 to about 30% by weight of the compound of the formula (I) and/or its physiologically tolerable salt. The amount of the active ingredient of the formula (I) and/or its physiologically tolerable salt in the pharmaceutical preparations normally is from about 1 to 1000 mg.
[0227] The dose of the compounds of this invention, which is to be administered, can cover a wide range. The dose to be administered daily is to be selected to suit the desired effect. A suitable dosage is about 0.001 to 100 mg/kg/day of the compound of formula (I) and/or their physiologically tolerable salt, for example, about 0.01 to 50 mg/kg/day of a compound of formula (I) or a pharmaceutically acceptable salt of the compound. If required, higher or lower daily doses can also be administered. Actual dosage levels of the active ingredients in the pharmaceutical compositions of this invention may be varied so as to obtain an amount of the active ingredient, which is effective to achieve the desired therapeutic response for a particular patient, composition, and mode of administration without being toxic or resulting in unacceptable side effects to the patient.
[0228] The pharmaceuticals can be administered orally, for example in the form of pills, tablets, coated tablets, lozenges, capsules, dispersible powders or granules, suspensions, emulsions, syrups or elixirs. Administration, however, can also be carried out rectally, for example in the form of suppositories, or parenterally, for example intravenously, intramuscularly or subcutaneously, in the form of injectable sterile solutions or suspensions, or topically, for example in the form of solutions or transdermal patches, or in other ways, for example in the form of aerosols or nasal sprays.
[0229] The selected dosage level will depend upon a variety of factors including the activity of the particular compound of the present invention employed, the route of administration, the time of administration, the rate of excretion of the particular compound being employed, the duration of the treatment, other drugs, compounds and/or materials used in combination with the particular compounds employed, the age, sex, weight, condition, general health and prior medical history of the patient being treated, and like factors well known in the medical arts.
[0230] In addition to the active ingredient of the general formula (I) and/or its physiologically acceptable salt and carrier substances, the pharmaceutical preparations can contain additives such as, for example, fillers, antioxidants, dispersants, emulsifiers, defoamers, flavors, preservatives, solubilizers or colorants. They can also contain two or more compounds of the general formula (I) and/or their physiologically tolerable salts. Furthermore, in addition to at least one compound of the general formula (I) and/or its physiologically tolerable salt, the pharmaceutical preparations can also contain one or more other therapeutically or prophylactically active ingredients.
[0231] By “pharmaceutically acceptable” it is meant the carrier, diluent, excipients, and/or salt must be compatible with the other ingredients of the formulation, and not deleterious to the recipient thereof.
[0232] According to another aspect of the present invention there is provided a pharmaceutical composition, comprising a therapeutically effective amount of a compound of formula (I) or a pharmaceutically acceptable salt or a pharmaceutically acceptable solvate thereof and at least one further pharmaceutically active compound, together with a pharmaceutically acceptable excipient or carrier. Pharmaceutically active compound in combination with one or more compound of formula (I) for treatment of cancer can be selected from, but not limited to, one or more of the following groups: (i) Kinase inhibitors such as gefitinib, imatinib, erlotinib, lapatinib, bevacizumab, avastin, sorafenib, Bcr-Abl kinase inhibitors or LY-317615 (ii) Alkylating agent such as, mitomycin C, busulfan, oxaliplatin, cisplatin, procarbazine or dacarbazine (iii) Antimetabolites such as, methotrexate, mercaptopurine, thioguanine, fludarabine phosphate, fluorouracil, vinblastine, vincristine or paclitaxel (iii) Antibiotics such as, anthracyclines, dactinomycin or bleomycin (iv) Hormonal agents such as, tamoxifen, flutamide, GnRH (Gonadotropin-Releasing Hormone) agonists or aromatase inhibitors or (v) Cancer vaccines such as, avicine, oregovomab or theratope.
[0233] Pharmaceutically active compound in combination with one or more compound of formula (I) for treatment of inflammatory disorder can be selected from, but not limited to, one or more of the following groups:
[0234] It is understood that modifications that do not substantially affect the activity of the various embodiments of this invention are included within the invention disclosed herein. Accordingly, the following examples are intended to illustrate but not to limit the present invention.
Experimental
[0235] The invention is further understood by reference to the following examples, which are intended to be purely exemplary of the invention. The present invention is not limited in scope by the exemplified embodiments, which are intended as illustrations of single aspects of the invention only. Any methods that are functionally equivalent are within the scope of the invention. Various modifications of the invention in addition to those described herein will become apparent to those skilled in the art from the foregoing description. Such modifications fall within the scope of the appended claims.
[0000] Nomenclature of the compounds exemplified in the present invention was derived from Chemdraw Ultra version 9.0.1 CambridgeSoft Corporation, Cambridge.
Unless otherwise stated all temperatures are in degree Celsius. Also, in these examples and elsewhere, abbreviations have the following meanings:
[0000]
List of abbreviations
mmol
Millimolar
DMF
Dimethyl formamide
mL
Milliliter
THF
Tetrahydrofuran
g
Gram
MeOH
Methanol
H 2
Hydrogen
POCl 3
Phosphorus oxychloride
CO 2
Carbon dioxide
MgCl 2
Magnesium chloride
NaOH
Sodium hydroxide
DMSO
Dimethyl sulfoxide
NaHCO 3
Sodium bicarbonate
Pet ether
Petroleum ether
Na 2 CO 3
Sodium carbonate
RT
Room Temperature
(20-30° C.)
HCl
Hydrochloric acid
psi
pound per square inch
H 2 SO 4
Sulphuric acid
PBS
Phosphate buffer saline
Na 2 SO 4
Sodium sulphate
FCS
Fetal calf serum
DCM/
Dichloromethane
FBS
Fetal bovine serum
CH 2 Cl 2
RPMI
Roswell Park
ATP
Adenosine triphosphate
Memorial Institute
HRP
Horse Radish
ELISA
Enzyme Linked
Peroxidase
ImmunoSorbent Assay
LPS
Lipopolysaccharide
rpm
revolutions per minute
DATP
2′-deoxyadenosine
TLC
Thin Layer
5′-triphosphate
Chromatography
MTS
(3-(4,5-Dimethylthiazol-2-yl)-5-(3-
carboxymethoxyphenyl)-2-(4-sulfonyl)-
2H-tetrazolium)
Hepes
N-2-Hydroxyethylpiperazine-N′-2-ethanesulfonic acid
Mpk
Milligrams per kilograms
Intermediates
Preparation A: 6-Bromo-4-chloro-3-nitroquinoline
Step 1: 5-Bromo-2-(2-nitrovinylamino)benzoic acid
[0236] A suspension of 2-Amino-5-bromobenzoic acid (50 g, 231 mmol) in water-HCl (37%) (10:1) was stirred for 8 hours and was filtered (solution 1). Nitromethane (17 g, 278 mmol) was added over 10 minutes to a mixture of ice (70 g) and NaOH (31 g, 775 mmol) at 0° C. under stirring. After stirring for 1 hour at 0° C. and 1 hour at RT, this solution was added to a mixture of ice (56 g) and 84 mL of HCl (37%) at 0° C. (solution 2). Solution 1 and 2 were combined and the reaction mixture was stirred for 18 hours at RT. The yellow precipitate was filtered, washed with water and dried at 40° C. to obtain the title compound. The crude product was used directly for the next step.
[0237] Yield: 25 g (38%).
Step 2: 6-Bromo-3-nitroquinolin-4-ol
[0238] 5-Bromo-2-(2-nitrovinylamino)benzoic acid (Compound of step 1, 25 g, 87 mmol) and potassium acetate (10.5 g, 104 mmol) in acetic anhydride (112 mL, 1185 mmol) were stirred for 3 hours at 120° C. The precipitate was filtered, and washed with acetic acid till the filtrate was colorless. It was further washed with water and dried to obtain the title compound. Yield:
[0239] 15 g (64%); 1 H NMR (CDCl 3 , 500 MHz): δ 9.275 (s, 1H), 8.611-8.615 (d, 1H, J=2 Hz), 8.100-8.118 (d, 1H, J=9 Hz), 8.026-8.048 (dd, 1H, J=8.5 Hz, 2 Hz).
Step 3: 6-Bromo-4-chloro-3-nitroquinoline
[0240] 6-Bromo-3-nitroquinolin-4-ol (Compound of step 2, 20 g, 74.3 mmol) and POCl 3 (150 mL, 1613 mmol) were stirred for 45 minutes at 120° C. The mixture was cooled to RT and poured slowly into ice-water. The precipitate was filtered, washed with ice-cold water, and dissolved in CH 2 Cl 2 . The organic layer was washed with cold brine, and was dried over Na 2 SO 4 . The solvent was evaporated to dryness to obtain the title compound.
[0241] Yield: 8 g (38%); 1 H NMR (CDCl 3 , 500 MHz): δ 9.275 (s, 1H), 8.611-8.615 (d, 1H, J=2 Hz), 8.100-8.118 (d, 1H, J=9 Hz), 8.026-8.048 (dd, 1H, J=8.5 Hz, 2 Hz).
Preparation B: 2-(4-Aminophenyl)-2-methylpropanenitrile
Step 1: 2-Methyl-2-(4-nitrophenyl)propanenitrile
[0242] 4-Nitrophenyl acetonitrile (20 g, 123.45 mmol), tetrabutylammonium bromide (2.15 g, 6.6 mmol) and methyl iodide (58 g, 475.41 mmol) in CH 2 Cl 2 (150 mL) were added to NaOH (13.5 g, 337.5 mmol) in water (130 mL). The reaction mixture was stirred for 20 hours at RT. The organic layer was separated, was dried over Na 2 SO 4 , and was evaporated to dryness. The residue was dissolved in diethylether, was filtered over celite and solvent was evaporated to obtain the title compound. Yield: 18 g (76%); 1 H NMR (CDCl 3 , 300 MHz): δ 8.220-8.250 (d, 2H, J=9 Hz), 7.627-7.657 (d, 2H, J=9 Hz), 1.750 (s, 6H).
Step 2: 2-(4-Aminophenyl)-2-methylpropanenitrile
[0243] 2-Methyl-2-(4-nitrophenyl)propanenitrile (Compound of step 1, 16 g, 84.1 mmol) and Raney-Ni (4.16 g) were shaken in THF-MeOH [(1:1), 160 mL] under 40 psi of hydrogen for 10 hours at RT, After completion of reaction, the catalyst was filtered-off and the solvent was evaporated to dryness. The crude product was purified by column chromatography (silica gel, ethyl acetate in hexane) to obtain the title compound as oil.
[0244] Yield: 10 g (74%); 1 H NMR (DMSO-d 6 , 300 MHz): δ 7.091-7.119 (d, 2H, J=8.4 Hz), 6.533-6.561 (d, 2H, J=8.4 Hz), 5.135 (s, 2H), 1.568 (s, 6H); MS: m/z 161 (M + ).
Preparation C: 2-(4-(6-Bromo-3-nitroquinolin-4-ylamino)phenyl)-2-methyl propanenitrile
[0245] 6-Bromo-4-chloro-3-nitroquinoline (Compound of Preparation A, 18 g, 62 6 mmol) and 2-(4-aminophenyl)-2-methylpropanenitrile (Compound of Preparation B, 11 g, 68.9 mmol) was dissolved in acetic acid (350 mL) and the mixture was stirred for 2 hours. Water was added and the yellow precipitate was filtered off. The precipitate was washed with water, saturated aqueous NaHCO 3 and water. The yellow solid was dried to obtain the title compound. Yield: 19 g (74%); 1 H NMR (DMSO-d 6 , 300 MHz): δ 10.0 (s, 1H), 8.979 (s, 1H), 8.594 (s, 1H), 7.894-7.926 (d, 1H, J=9.6 Hz), 7.817-7.847 (d, 1H, J=9 Hz), 7.348-7.376 (d, 2H, J=8.4 Hz), 7.011-7.039 (d, 2H, J=8.4 Hz), 1.575 (s, 6H); MS: m/z 409 (M).
Preparation D: 2-(4-(3-Amino-6-bromoquinolin-4-ylamino)phenyl)-2-methyl propanenitrile
[0246] 2-(4-(6-Bromo-3-nitroquinolin-4-ylamino)phenyl)-2-methylpropane nitrile (Compound of Preparation C, 16 g, 42 mmol) was hydrogenated using Raney-Ni (7 g), THF-MeOH [(1:1), 250 mL] under 25 psi of hydrogen for 1 hour at RT. After completion of the reaction, the catalyst was filtered-off and the filtrate was evaporated to dryness to obtain the title compound. Yield: 13 g (88%); 1 H NMR (DMSO-d 6 , 300 MHz): δ 8.609 (s, 1H), 7.908 (s, 1H), 7.829-7.836 (d, 1H, J=2.1 Hz), 7.744-7.773 (d, 1H, J=8.7 Hz), 7.425-7.462 (dd, 1H, J=9 Hz, 2.1 Hz), 7.236-7.265 (d, 2H, J=8.7 Hz), 6.511-6.540 (d, 2H, J=8.7 Hz), 5.448 (s, 2H), 1.600 (s, 6H); MS: m/z 381 (M + ).
Preparation E: 4,6-Dichloro-3-nitroquinoline
Step 1: 5-Chloro-2-(2-nitrovinylamino)benzoic acid
[0247] A suspension of 2-amino-5-chlorobenzoic acid (50 g, 291.94 mmol) in H 2 O—HCl (37%) (10:1) was stirred for 8 hours and filtered (Solution 1). Nitromethane (15.5 g, 350 mmol) was added over 10 minutes to an ice-bath cooled mixture of ice (70 g) and NaOH (35 g, 820 mmol). After stirring for 1 hour at 0° C. and 1 hour at RT, the solution was added at 0° C. to a mixture of ice (56 g) and HCl (37%) (Solution 2). Solution 1 and 2 were combined and the reaction mixture was stirred for 18 hours at RT. The yellow precipitate was filtered, washed with water and dried in vacuo at 40° C. to obtain the title compound. The crude product was used for next step.
[0248] Yield: 26 g (30%).
Step 2: 6-Chloro-3-nitroquinolin-4-ol
[0249] 5-Chloro-2-(2-nitrovinylamino)benzoic acid (Compound of step 1, 24 g, 98.36 mmol) and potassium acetate (19.2 g, 196.72 mmol) in acetic anhydride (120 mL, 1200 mmol) were stirred for 3 hours at 120° C. The precipitate was filtered, washed with acetic acid and water and dried in vacuo to obtain the title compound. Yield: 15 g (64%); 1 H NMR (DMSO-d 6 , 300 MHz): δ 13.142 (s, 1H), 9.32 (s, 1H,), 8.159-8.166 (d, 1H, J=2.1 Hz), 7.822-7.859 (dd, 1H, J=8.7 Hz, 2.4 Hz), 7.734-7.763 (d, 1H, J=8.7 Hz); MS: m/z 225 (M + ).
Step 3: 4,6-Dichloro-3-nitroquinoline
[0250] 6-Chloro-3-nitroquinolin-4-ol (Compound of step 2, 5 g, 22.42 mmol) in POCl 3 (150 mL, 493 mmol) was stirred for 45 min at 120° C. The mixture was cooled to RT and poured slowly into ice-water. The precipitate was filtered, washed with ice-cold water, and dissolved in CH 2 Cl 2 . The organic phase was washed with cold brine and dried over Na 2 SO 4 . The organic solvent was evaporated to dryness to obtain the title compound.
[0251] Yield: 4.8 g (88%).
Preparation F: 2-(4-(6-Chloro-3-nitroquinolin-4-ylamino)phenyl)-2-methyl propanenitrile
[0252] A solution of 4,6-dichloro-3-nitroquinoline (Compound of Preparation E, 4.0 g, 16.46 mmol) and 2-(4-aminophenyl)-2-methylpropanenitrile (2.63 g, 16.46 mmol) in acetic acid (350 ml) was stirred for 2 hours. Water was added and the yellow precipitate was filtered off, washed with water and saturated aqueous NaHCO 3 . The yellow solid was dried to obtain the title compound. Yield: 5 g (83%); 1 H NMR (DMSO-d 6 , 300 MHz): δ 10.074 (s, 1H), 9.062 (s, 1H,), 8.552-8.558 (d, 1H, J=1.8 Hz), 7.995-8.025 (d, 1H, J=9 Hz), 7.875-7.912 (t, 1H,), 7.437-7.466 (d, 2H, J=8.4 Hz), 7.100-7.128 (d, 2H, J=8.4 Hz), 1.664 (s, 6H).
Preparation G: 2-(4-(3-Amino-6-chloroquinolin-4-ylamino)phenyl)-2-methyl propanenitrile
[0253] 2-(4-(6-Chloro-3-nitroquinolin-4-ylamino)phenyl)-2-methylpropanenitrile (Compound of Preparation F, 5 g, 13 6 mmol) and Raney-Ni (2 g) were shaken in 100 mL of THF-MeOH (1:1) under 25 psi of H 2 for 3 hours at RT. After completion of reaction, the catalyst was filtered-off and the filtrate was evaporated to dryness to obtain the title compound.
[0254] Yield: 3.5 g (66%); 1 H NMR (DMSO-d 6 , 300 MHz): δ 8.599 (s, 1H), 7.892 (s, 1H), 7.816-7.846 (d, 1H, J=9 Hz), 7.655-7.663 (d, 1H, J=2.4), 7.312-7349 (dd, 1H, J=8.7 Hz, 2.4 Hz), 7.233-7.262 (d, 2H, J=8.7 Hz), 6.510-6.538 (d, 2H, J=8.4 Hz), 5.457 (s, 2H), 1.598 (s, 6H); MS: m/z 337 (M + ).
Preparation H: 4-Chloro-6-methyl-3-nitroquinoline
Step 1: 5-Methyl-2-(2-nitrovinylamino)benzoic acid
[0255] A suspension of 2-amino-5-methylbenzoic acid (5 g, 33.11 mmol) in H 2 O—HCl (37%) (10:1) was stirred for 8 hours and filtered (Solution 1). Nitromethane (1.75 ml, 37.73 mmol) was added over 10 min to an ice-bath cooled mixture of ice (7 g) and NaOH (3.97 g, 99.9 mmol). After stirring for 1 hour at 0° C. and 1 hour at RT, the solution was added at 0° C. to ice (56 g) and HCl (37%, 84 mL) (Solution 2). Solution 1 and 2 were combined and the reaction mixture was stirred for 18 hours at RT. The yellow precipitate was filtered off, washed with water and dried in vacuum at 40° C. to obtain the title compound. The crude product was used for step 2. Yield: 3 g (41%); 1 HNMR (DMSO-d 6 , 300 MHz): δ 13.78 (bs, 1H), 12.944-12.989 (d, 1H, J=13.5 Hz), 7.973-8.040 (dd, 1H, J=13.4 Hz, 6.3 Hz), 7.819 (s, 1H), 7.623-7.652 (d, 1H, J=8.7 Hz), 7.460-7.548 (m, 1H), 6.700-6.721 (d, 1H, J=6.3 Hz), 2.402 (s, 3H); MS: m/z 223 (M −1 ).
Step 2: 6-Methyl-3-nitroquinolin-4-ol
[0256] 5-Methyl-2-(2-nitrovinylamino)benzoic acid (Compound of step 1, 1.5 g, 6.756 mmol) and potassium acetate (1.3 g, 13.51 mmol) were stirred in acetic anhydride (8 ml, 148 7 mmol) for 3 hours at 120° C. The precipitate was filtered and washed with acetic acid until the filtrate is colorless and then washed with water and dried in vacuo to obtain the title compound. Yield: 610 mg (64%); 1 H NMR (DMSO-d 6 , 300 MHz): δ 9.126 (s, 1H), 8.035 (s, 1H), 7.606 (s, 2H), 2.432 (s, 3H); MS: m/z 203 (M −1 ).
Step 3: 4-Chloro-6-methyl-3-nitroquinoline
[0257] 6-Methyl-3-nitroquinolin-4-ol (Compound of step 2, 610 mg) in POCl 3 (5 mL) was stirred for 45 min at 120° C. The mixture was cooled to RT and poured slowly into ice-water. The precipitate was filtered, washed with ice-cold water and dissolved in CH 2 Cl 2 . The organic phase was washed with cold brine, and the aqueous phase was discarded. After drying over Na 2 SO 4 , the organic solvent was evaporated to dryness to obtain the title compound. Yield: 600 mg (90%); 1 HNMR (DMSO-d 6 , 300 MHz: δ 9.299 (s, 1H), 8.192 (s, 1H,), 8.096-8.124 (d, 1H, J=8.4 Hz), 7.893-7.927 (dd, 1H, J=8.4 Hz, 1.8 Hz), 2.604 (s, 3H).
Preparation I: 2-Methyl-2-(4-(6-methyl-3-nitroquinolin-4-ylamino)phenyl) propanenitrile
[0258] 4-Chloro-6-methyl-3-nitroquinoline (Compound of Preparation H, 660 mg, 2.97 mmol) and 2-(4-aminophenyl)-2-methylpropanenitrile (570 mg, 3.56 mmol) were dissolved in acetic acid (10 ml) and stirred for 2 hours. Water was added and the yellow precipitate was filtered off, washed with water, saturated aqueous NaHCO 3 and water. The yellow solid was dried to obtain the title compound. Yield: 600 mg (58%); 1 H NMR (DMSO-d 6 , 300 MHz): δ 9.952 (s, 1H,), 9.016 (s, 1H), 8.184 (s, 1H), 7.890-7.918 (d, 1H, J=8.4 Hz), 7.699-7.727 (d, 1H, J=8.4 Hz), 7.421-7.445 (d, 2H, J=7.2 Hz), 7.082-7.108 (d, 2H, J=7.8 Hz), 2.284 (s, 3H), 1.660 (s, 6H); MS: m/z 347 (M + ).
Preparation J: 2-(4-(3-Amino-6-methyl-quinolin-4-ylamino)phenyl)-2-methyl propanenitrile
[0259] 2-(4-(6-Methyl-3-nitroquinolin-4-ylamino)phenyl)-2-methylpropanenitrile (Compound of Preparation 1,600 mg, 1.73 mmol) and 10% Pd—C (90 mg) were shaken in 15 mL of THF-MeOH (1:1) under 25 psi of hydrogen for 3 hours at RT. After completion of reaction, the catalyst was filtered-off and the filtrate was evaporated to dryness to obtain the title compound. Yield: 250 mg (46%); 1 H NMR (DMSO-d 6 , 300 MHz): δ 8.507 (s, 1H), 7.819 (s, 1H), 7.698-7.726 (d, 1H, J=8.4 Hz), 7.641 (s, 1H), 7.211-7.239 (d, 2H, J=8.4 Hz), 7.164-7.198 (dd, 1H, J=8.4 Hz, 1.5 Hz), 6.503-6.532 (d, 2H, J=8.7 Hz), 5.178 (s, 2H), 2.358 (s, 3 Hs), 1.593 (s, 6H); MS: m/z 317 (M + ).
Intermediate 1: 2-(4-(8-Bromo-2-oxo-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)-2-methyl propanenitrile
[0260] A solution of 2-(4-(3-amino-6-bromoquinolin-4-ylamino)phenyl)-2-methylpropanenitrile (Compound of Preparation D, 5 g, 13.1 mmol) and triethylamine (1.59 g, 15.7 mmol) in CH 2 Cl 2 (120 mL) was added over 40 minutes to a solution of triphosgene (4.3 g, 14.4 mmol) in CH 2 Cl 2 (80 mL) at 0° C. using ice-bath. The reaction mixture was stirred for 20 minutes at this temperature then was quenched with saturated aqueous NaHCO 3 , stirred for 5 minutes and extracted with CH 2 Cl 2 . The organic layer was dried over Na 2 SO 4 , filtered and solvent was evaporated to obtain the title compound. Yield: 3.2 g (60%); 1 H NMR (DMSO-d 6 , 300 MHz): δ 11.835 (s, 1H), 8.783 (s, 1H), 7.908-7.938 (d, 1H, J=9 Hz), 7.810-7.838 (d, 2H, J=8.4 Hz), 7.665-7.694 (d, 2H, J=8.7 Hz), 7.613-7.650 (dd, 1H, J=9 Hz, 1.8 Hz), 6.949-6.955 (d, 1H, J=1.8 Hz), 1.609 (s, 6H); MS: m/z 406 (M + ).
Intermediate 2: 2-(4-(8-Chloro-2-oxo-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)-2-methyl propanenitrile
[0261] A solution of 2-(4-(3-amino-6-Chloroquinolin-4-ylamino)phenyl)-2-methylpropanenitrile (Compound of Preparation G, 3.3 g, 9.8214 mmol) and triethylamine (1.34 g, 12.74 mmol) in CH 2 Cl 2 (120 mL) was added over 40 min to a solution of triphosgene (3.5 g, 11.7852 mmol) in 80 mL of CH 2 Cl 2 at 0° C. with an ice-bath. The reaction mixture was stirred for 20 min at this temperature then quenched with saturated aqueous NaHCO 3 , stirred for 5 min and extracted with CH 2 Cl 2 . The organic layer was dried over Na 2 SO 4 , filtered and evaporated in vacuo to obtain the title compound. Yield: 1.2 g (34%); 1 H NMR (DMSO-d 6 , 300 MHz): δ 12.190 (s, 1H), 8.921 (s, 1H), 8.069-8.100 (d, 1H, J=8.7 Hz), 7.807-7.835 (d, 2H, J=8.4 Hz), 7.641-7.694 (m, 3H), 6.808-6.815 (d, 1H, J=2.1 Hz), 1.766 (s, 6H); MS: m/z 363 (M + ).
Intermediate 3: 2-Methyl-2-(4-(8-methyl-2-oxo-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)propanenitrile
[0262] A solution of 2-(4-(3-amino-6-methyl-quinolin-4-ylamino)phenyl)-2-methylpropanenitrile (Compound of Preparation J, 190 mg, 0.6025 mmol) and triethylamine (0.12 ml, 0.901 mmol) in CH 2 Cl 2 (10 mL) was added over 40 min to a solution of triphosgene (195 mg, 0.6139 mmol) in 5 mL of CH 2 Cl 2 at 0° C. The reaction mixture was stirred for 20 min at this temperature then was quenched with saturated aqueous NaHCO 3 , stirred for 5 min and extracted with CH 2 Cl 2 . The organic layer was dried over Na 2 SO 4 , filtered and evaporated in vacuo to obtain the title compound as brown solid. Yield: 145 mg (70%); 1 H NMR (DMSO-d 6 , 300 MHz): δ 11.641 (s, 1H), 8.678 (s, 1H), 7.864-7.892 (d, 1H, J=8.4 Hz), 7.782-7.810 (d, 2H, J=8.4 Hz), 7.629-7.657 (d, 2H, J=8.4 Hz), 7.342-7.371 (d, 1H, J=8.7 Hz), 6.625 (s, 1H), 2.147 (s, 3H), 1.801 (s, 6H); MS: m/z 343 (M + ).
EXAMPLES
Example 1
2-(4-(8-Bromo-2-oxo-3-(4-(trifluoromethoxy)phenylsulfonyl)-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)-2-methylpropanenitrile
[0263] To a solution of 2-(4-(8-bromo-2-oxo-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)-2-methylpropanenitrile (Intermediate 1, 0.12 mmol) and triethylamine 24.2 mg (0.24 mmol) in DCM (6 ml) was added 4-(trifluoromethoxy)benzene-1-sulfonyl chloride (46.8 mg, 0.18 mmol) at 0° C. The reaction was stirred at RT for 3 hours. The reaction mixture was poured into cold water and organic layer was separated. The aqueous layer was extracted with DCM. The combined organic layer was washed with brine dried over sodium sulfate and evaporated to dryness. The crude product was purified by column chromatography (silica gel, 2% acetone in chloroform) to obtain the title compound.
[0264] Yield: 28 mg (18%); 1 H NMR (DMSO-d 6 , 300 MHz): δ 9.43 (s, 1H), 8.342-8.372 (dd, 1H, J=7.2, 1.8 Hz), 7.993-8.023 (d, 1H, J=9 Hz), 7.820-7.849 (d, 2H, J=8.7 Hz), 7.756-7.793 (dd, 1H, J=9, 2.1 Hz), 7.66-7.73 (m, 4H), 7.275-7.302 (d, 1H, J=8.1 Hz), 6.75-6.76 (d, 1H, J=2.1 Hz), 1.77 (s, 6H); MS: m/z 631 (M + ).
Example 2
2-(8-Bromo-1-(4-(2-cyanopropan-2-yl)phenyl)-2-oxo-1H-imidazo[4,5-c]quinolin-3 (2H)-ylsulfonyl)benzonitrile
[0265] To a solution of 2-(4-(8-bromo-2-oxo-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)-2-methylpropanenitrile (Intermediate 1, 0.12 mmol) and triethylamine (0.36 mmol) in DCM (6 ml) was added 2-cyanobenzene-1-sulfonyl chloride (0.18 mmol) at 0° C. The reaction was stirred at RT for 3 hours. The reaction mixture was poured into cold water and organic layer was separated. The aqueous layer was extracted with DCM. The combined organic layer was washed with brine dried over sodium sulfate and evaporated to dryness. The crude product was purified by column chromatography (silica gel, 2% acetone in chloroform) to obtain the title compound.
[0266] Yield: 25 mg (36%); 1 H NMR (CDCl 3 , 300 MHz): δ 9.72 (s, 1H), 8.51-8.538 (d, 1H, J=8.7 Hz), 8.02-8.05 (d, 1H, J=9 Hz), 7.83-7.93 (m, 3H), 7.729-7.757 (d, 2H, J=8.4 Hz), 7.66-7.69 (dd, 1H, J=9, 1.8 Hz), 7.474-7.502 (d, 2H, J=8.4 Hz), 7.019-7.025 (d, 1H, J=1.8 Hz), 1.81 (s, 6H); MS: m/z 572 (M + ).
Example 3
2-(4-(8-Bromo-2-oxo-3-(m-tolylsulfonyl)-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)-2-methylpropanenitrile
[0267] To a solution of 2-(4-(8-bromo-2-oxo-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)-2-methylpropanenitrile (Intermediate 1, 50 mg 0.12 mmol) and triethylamine (24.2 mg, 0.24 mmol) in dichloromethane (6 ml) was added 3-methylbenzene-1-sulfonyl chloride (36 mg, 0.18 mmol) at 0° C. The reaction was stirred at RT for 3 hours. The reaction mixture was poured into cold water and organic layer was separated. The aqueous layer was extracted with dichloromethane. The combined organic layer was washed with brine dried over sodium sulfate and evaporated to dryness. The crude product was purified by column chromatography (silica gel, 2% acetone in chloroform) to obtain the title compound. Yield: 22 mg (32%); 1 H NMR (DMSO d 6 , 300 MHz): δ 9.44 (s, 1H), 8.01 (s, 2H), 7.98 (s, 1H), 7.813-7.841 (d, 2H, J=8.4 Hz), 7.70-7.77 (m, 3H), 7.56-7.66 (m, 2H), 6.76-6.766 (d, 1H, J=1.8 Hz), 2.405 (s, 3H), 1.776 (s, 6H); MS: m/z 561 (M + ).
Example 4
2-(4-(8-Bromo-3-(2-methyl-5-nitrophenylsulfonyl)-2-oxo-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)-2-methylpropanenitrile
[0268] To a solution of 2-(4-(8-bromo-2-oxo-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)-2-methylpropanenitrile (Intermediate 1, 50 mg, 0.12 mmol) and triethylamine (24.4 mg, 0.24 mmol) in dichloromethane (6 ml) was added 2-methyl-5-nitrobenzene-1-sulfonyl chloride (53 mg, 0.18 mmol) at 0° C. The reaction was stirred at RT for 3 hours. The reaction mixture was poured into cold water and organic layer was separated. The aqueous layer was extracted with dichloromethane. The combined organic layer was dried over sodium sulfate and crude product was purified by column chromatography (silica gel, 2% acetone in chloroform) to obtain the title compound.
[0269] Yield: 35 mg (47%); 1 H NMR (DMSO-d 6 , 300 MHz): δ 9.39 (s, 1H), 8.83-8.844 (d, 1H, J=2.4 Hz), 8.488-8.524 (dd, 1H, J=8.4, 2.4 Hz), 7.98-8.009 (d, 1H, 9 Hz), 7.69-7.82 (m, 6H), 6.779-6.785 (d, 1H, J=1.8 Hz), 2.67 (s, 3H), 1.73 (s, 6H); MS: m/z 606 (M+1).
Example 5
2-(4-(8-Bromo-3-(3-fluoro-4-methylphenylsulfonyl)-2-oxo-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)-2-methylpropanenitrile
[0270] To a solution of 2-(4-(8-bromo-2-oxo-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)-2-methylpropanenitrile (Intermediate 1, 50 mg, 0.12 mmol) and triethylamine (24.4 mg, 0.24 mmol) in dichloromethane (6 ml) was added 3-fluoro-4-methylbenzene-1-sulfonyl chloride (37.5 mg, 0.18 mmol) at 0° C. The reaction was stirred at RT for 3 hours. The reaction mixture was poured into cold water and organic layer was separated. The aqueous layer was extracted with dichloromethane. The combined organic layer was washed with brine dried over sodium sulfate and evaporated to dryness. The crude product was purified by column chromatography (silica gel, 2% acetone in chloroform) to obtain the title compound.
[0271] Yield: 36 mg (50%); 1 H NMR (DMSO-d 6 , 300 MHz): δ 9.4 (s, 1H), 7.92-7.98 (m, 3H,), 7.784-7.7.812 (d, 2H, J=8.4 Hz), 7.67-7.74 (m, 3H), 7.59-7.64 (m, 1H), 6.72-6.726 (d, 1H, J=1.8 Hz), 2.17 (s, 3H), 1.74 (s, 6H); MS: m/z 579 (M + ).
Example 6
2-(4-(8-Bromo-3-(3,5-dimethylphenylsulfonyl)-2-oxo-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)-2-methylpropanenitrile
[0272] To a solution of 2-(4-(8-bromo-2-oxo-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)-2-methylpropanenitrile (Intermediate 1, 50 mg, 0.12 mmol) and triethylamine (24.4 mg (0.36 mmol) in dichloromethane (6 ml) was added 3,5-dimethylbenzene-1-sulfonyl chloride (0.18 mmol) at 0° C. The reaction was stirred at RT for 3 hours. The reaction mixture was poured into cold water and organic layer was separated. The aqueous layer was extracted with dichloromethane. The combined organic layer was washed with brine dried over sodium sulfate and evaporated to dryness. The crude product was purified by column chromatography (silica gel, 2% acetone in chloroform) to obtain the title compound. Yield: 25 mg (33.33%); 1 H NMR (CDCl 3 , 300 MHz): δ 9.58 (s, 1H), 7.957-7.987 (d, 1H, J=9 Hz), 7.79 (s, 2H), 7.699-7.727 (d, 2H, J=8.4 Hz), 7.605-7.642 (dd, 1H, J=9 Hz, 2.1 Hz), 7.425-7.453 (d, 2H, J=8.4 Hz), 7.29 (s, 1H), 6.96 (d, 1H, J=1.8 Hz), 2.36 (s, 6H), 1.79 (s, 6H); MS: m/z 575 (M + ).
Example 7
2-(4-(8-Bromo-2-oxo-3-(phenylsulfonyl)-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)-2-methylpropanenitrile
[0273] To a solution of 2-(4-(8-bromo-2-oxo-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)-2-methylpropanenitrile (Intermediate 1, 50 mg, 0.12 mmol) and triethylamine (24.4 mg, 0.36 mmol) in dichloromethane (6 ml) was added benzenesulfonyl chloride (31.8 mg, 0.18 mmol) at 0° C. The reaction was stirred at RT for 3 hours. The reaction mixture was poured into cold water and organic layer was separated. The aqueous layer was extracted with dichloromethane. The organic layer was dried on sodium sulfate and evaporated to dryness to obtain the title compound. Yield: 20 mg (29.7%); 1 H NMR (CDCl 3 , 300 MHz): δ 9.59 (s, 1H), 8.198-8.227 (d, 2H, J=8.7 Hz), 7.958-7.989 (d, 1H, J=8.7 Hz), 7.70-7.723 (d, 2H, J=6.9 Hz), 7.57-7.69 (m, 4H), 7.40-7.436 (d, 2H, J=8.7 Hz), 6.97-6.981 (d, 1H, J=2.1 Hz), 1.79 (s, 6H).
Example 8
2-(4-(8-Bromo-2-oxo-3-tosyl-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)-2-methylpropanenitrile
[0274] To a solution of 2-(4-(8-bromo-2-oxo-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)-2-methylpropanenitrile (Intermediate 1, 50 mg, 0.12 mmol) and triethylamine (24.4 mg, 0.36 mmol) in dichloromethane (6 ml) was added 4-methylbenzene-1-sulfonyl chloride (35.02 mg, 0.18 mmol) at 0° C. The reaction was stirred at RT for 3 hours. The reaction mixture was poured into cold water and organic layer was separated. The aqueous layer was extracted with dichloromethane. The combined organic layer was washed with brine dried over sodium sulfate and evaporated to dryness. The crude product was purified by column chromatography (silica gel, 2% acetone in chloroform) to obtain the title compound. Yield: 17 mg (25.37%); 1 H NMR (CDCl 3 , 300 MHz): δ 9.59 (s, 1H), 8.085-8.113 (d, 2H, J=8.4 Hz), 7.97-8.001 (d, 1H, J=9 Hz), 7.707-7.735 (d, 2H, J=8.4 Hz), 7.621-7.659 (dd, 1H, J=9.3, 2.1 Hz), 7.422-7.450 (d, 2H, J=8.4 Hz), 7.351-7.378 (d, 2H, J=8.1 Hz), 6.989-6.996 (d, 1H, J=2.1 Hz), 2.43 (s, 3H), 1.81 (s, 6H); MS: ink 561 (M + ).
Example 9
2-(4-(8-Bromo-2-oxo-3-(thiophen-2-ylsulfonyl)-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)-2-methylpropanenitrile
[0275] To a solution of 2-(4-(8-bromo-2-oxo-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)-2-methylpropanenitrile (Intermediate 1, 50 mg, 0.12 mmol) and triethylamine (24.4 mg, 0.36 mmol) in dichloromethane (6 ml) was added thiophene-2-sulfonyl chloride (32.88 mg, 0.18 mmol) at 0° C. The reaction was stirred at RT for 3 hours. The reaction mixture was poured into cold water and organic layer was separated. The aqueous layer was extracted with dichloromethane. The combined organic layer was washed with brine dried over sodium sulfate and evaporated to dryness. The crude product was purified by column chromatography (silica gel, 2% acetone in chloroform) to obtain the title compound. Yield: 14 mg (17.16%); 1 H NMR (DMSO-d 6 , 300 MHz): δ 9.37 (s, 1H), 8.229-8.246 (d, 1H, J=5.1 Hz), 8.160-8.172 (d, 1H, J=3.6 Hz), 7.982-8.012 (d, 1H, J=9 Hz), 7.822-7.850 (d, 2H, J=8.4 Hz), 7.779-7.785 (d, 1H, J=1.8 Hz), 7.720-7.748 (d, 2H, J=8.4 Hz), 7.31 (t, 1H, J=4.2 Hz), 6.763-6.770 (d, 1H, J=2.1 Hz), 1.78 (s, 6H).
Example 10
2-(4-(8-Bromo-3-(3-fluorophenylsulfonyl)-2-oxo-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)-2-methylpropanenitrile
[0276] To a solution of 2-(4-(8-bromo-2-oxo-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)-2-methylpropanenitrile (Intermediate 1, 50 mg, 0.12 mmol) and triethylamine (24.4 mg, 0.36 mmol) in dichloromethane (6 ml) was added 3-fluoro benzenesulfonyl chloride (35 mg, 0.18 mmol) at 0° C. The reaction was stirred at RT for 3 hours. The reaction mixture was poured into cold water and organic layer was separated. The aqueous layer was extracted with dichloromethane. The combined organic layer was washed with brine, dried over sodium sulfate and evaporated to dryness. The crude product was purified by column chromatography (silica gel, 2% acetone in chloroform) to obtain the title compound. Yield: 50 mg (44.99%); 1 H NMR (CDCl 3 , 300 MHz): δ 9.57 (s, 1H), 8.025-8.051 (d, 1H, J=7.8 Hz), 7.952-7.980 (d, 1H, J=8.4 Hz), 7.94 (m 1H,), 7.75 (d, 2H, J=9 Hz,), 7.63 7.674 (dd, 1H, J=9, 2.1 Hz), 7.56-7.61 (m, 1H), 7.438-7.466 (d, 2H, J=8.4 Hz), 7.38-7.42 (m, 1H), 6.99-6.996 (d, 1H, J=1.8 Hz), 1.80 (s, 6H); MS: m/z 565 (M + ).
Example 11
2-(4-(8-Bromo-2-oxo-3-(quinolin-8-ylsulfonyl)-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)-2-methylpropanenitrile
[0277] To a solution of 2-(4-(8-bromo-2-oxo-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)-2-methylpropanenitrile (Intermediate 1, 50 mg, 0.12 mmol) and triethylamine (24.4 mg, 0.36 mmol) in dichloromethane (6 ml) was added quinoline-8-sulfonyl chloride (40.98 mg, 0.18 mmol) at 0° C. The reaction was stirred at RT for 3 hours. The reaction mixture was poured into cold water and organic layer was separated. The aqueous layer was extracted with dichloromethane. The combined organic layer was washed with brine dried over sodium sulfate and evaporated to dryness. The crude product was purified by column chromatography (silica gel, 2% acetone in chloroform) to obtain the title compound. Yield: 32 mg (36.26%); 1 H NMR (DMSO-d 6 , 300 MHz): δ 9.60 (s, 1H), 8.70-8.836 (dd, 1H, J=7.5, 1.2 Hz), 8.561-8.757 (m, 1H), 8.54 (s, 1H), 8.46-8.492 (dd, 1H, J=8.4, 1.2 Hz), 8.0.25-8.058 (d, 1H, J=9.3 Hz), 7.869-7.921 (t, 1H, J=7.8 Hz), 7.74-7.79 (m, 3H), 7.581-7.623 (m, 1H), 7.534-7.563 (d, 2H, J=8.7 Hz), 6.752-6.758 (d, 1H, J=1.8 Hz), 1.21 (s, 6H); MS: m/z 598 (M + ).
Example 12
2-(4-(3-(4-Acetylphenylsulfonyl)-8-bromo-2-oxo-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)-2-methylpropanenitrile
[0278] To a solution of 2-(4-(8-bromo-2-oxo-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)-2-methylpropanenitrile (Intermediate 1, 50 mg, 0.12 mmol) and triethylamine (24.4 mg, 0.36 mmol) in dichloromethane (6 ml) was added 4-acetylbenzene-1-sulfonyl chloride (35.35 mg, 0.18 mmol) at 0° C. The reaction was stirred at RT for 3 hours. The reaction mixture was poured into cold water and organic layer was separated. The aqueous layer was extracted with dichloromethane. The combined organic layer was washed with brine dried over sodium sulfate and evaporated to dryness. The crude product was purified by column chromatography (silica gel, 2% acetone in chloroform) to obtain the title compound. Yield: 12 mg (17%); 1 H NMR (DMSO-d 6 , 300 MHz): δ 9.44 (s, 1H), 8.316-8.344 (d, 2H, J=8.4 Hz), 8.18-8.208 (d, 2H, J=8.4 Hz), 7.985-8.015 (d, 1H, J=9 Hz), 7.810-7.838 (d, 2H, J=8.4 Hz), 7.751-7.782 (d, 1H, J=9.3), 7.695-7.722 (d, 2H, J=8.4 Hz), 6.74 (s, 1H), 2.63 (s, 3H), 1.77 (s, 6H); MS: m/z 589 (M + ).
Example 13
2-(4-(8-Bromo-2-oxo-3-(3-(trifluoromethyl)phenylsulfonyl)-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)-2-methylpropanenitrile
[0279] To a solution of 2-(4-(8-bromo-2-oxo-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)-2-methylpropanenitrile (Intermediate 1, 50 mg, 0.12 mmol) and triethylamine (24.4 mg, 0.24 mmol) in dichloromethane (6 ml) was added 3-trifluoromethylbenzene-1-sulfonyl chloride (44 mg, 0.18 mmol) at 0° C. The reaction was stirred at RT for 3 hours. The reaction mixture was poured into cold water and organic layer was separated. The aqueous layer was extracted with dichloromethane. The combined organic layer was washed with brine dried over sodium sulfate and evaporated to dryness. The crude product was purified by column chromatography (silica gel, 2% acetone in chloroform) to obtain the title compound. Yield: 45 mg (60%); 1 H NMR (DMSO-d 6 , 300 MHz): δ 9.466 (s, 1H), 8.523-8.550 (d, 1H, J=8.1 Hz), 8.475 (s, 1H), 8.241-8.268 (d, 1H, J=8.1 Hz), 7.971-8.020 (m, 2H), 7.668-7.989 (m, 5H), 6.749-6.756 (d, 1H, J=2.1 Hz), 1.773 (s, 6H); MS: m/z 615 (M + ), 617 (M+2).
Example 14
2-(4-(8-Bromo-3-(3-methoxyphenylsulfonyl)-2-oxo-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)-2-methylpropanenitrile
[0280] To a solution of 2-(4-(8-bromo-2-oxo-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)-2-methylpropanenitrile (Intermediate 1, 50 mg, 0.12 mmol) and triethylamine (24.4 mg, 0.24 mmol) in dichloromethane (6 ml) was added 3-methoxybenzene-1-sulfonyl chloride (37.08 mg, 0.18 mmol) at 0° C. The reaction was stirred at RT for 3 hours. The reaction mixture was poured into cold water and organic layer was separated. The aqueous layer was extracted with dichloromethane. The combined organic layer was washed with brine dried over sodium sulfate and evaporated to dryness. The crude product was purified by column chromatography (silica gel, 2% acetone in chloroform) to obtain the title compound. Yield: 30 mg (42%); 1 H NMR (CDCl 3 , 300 MHz): δ 9.566 (s, 1H), 7.951-7.981 (d, 1H, J=9 Hz), 7.757-7.784 (d, 1H, J=8.1 Hz), 7.636-7.729 (m, 3H), 7.606-7.643 (dd, 1H, J=9 Hz, 2.1 Hz), 7.419-7.479 (m, 3H,), 7.208-7.230 (m, 1H), 6.957-6.963 (d, 1H, 1.8 Hz), 3.833 (s, 3H), 1.795 (s, 6H); MS: m/z 546 [M + −(OCH 3 )].
Example 15
2-(4-(8-Bromo-3-(3-bromophenylsulfonyl)-2-oxo-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)-2-methylpropanenitrile
[0281] To a solution of 2-(4-(8-bromo-2-oxo-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)-2-methylpropanenitrile (Intermediate 1, 50 mg, 0.12 mmol) and triethylamine (24.4 mg, 0.24 mmol) in dichloromethane (6 ml) was added 3-bromobenzene-1-sulfonyl chloride (46 mg, 0.18 mmol) at 0° C. The reaction was stirred at RT for 3 hours. The reaction mixture was poured into cold water and organic layer was separated. The aqueous layer was extracted with dichloromethane. The combined organic layer was washed with brine dried over sodium sulfate and evaporated to dryness. The crude product was purified by column chromatography (silica gel, 2% acetone in chloroform) to obtain the title compound. Yield: 40 mg (52%); 1 H NMR (DMSO-d 6 , 300 MHz): δ 9.444 (s, 1H), 8.352 (s, 1H), 8.208-8.234 (d, 1H, J=7.8 Hz), 8.050-8.074 (d, 1H, J=7.2 Hz), 7.985-8.015 (d, 1H, J=9 Hz), 7.821-7.849 (d, 2H, J=8.4 Hz), 7.776-7.7.782 (d, 1H, 1.8 Hz), 7.643-7.714 (m, 3H), 6.753-6.759 (d, 1H, J=2.1 Hz), 1.777 (s, 6H); MS: m/z 625 (M + ).
Example 16
2-(4-(8-Bromo-3-(3,5-difluorophenylsulfonyl)-2-oxo-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)-2-methylpropanenitrile
[0282] To a solution of 2-(4-(8-bromo-2-oxo-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)-2-methylpropanenitrile (Intermediate 1, 50 mg, 0.12 mmol) and triethylamine (24.4 mg, 0.24 mmol) in dichloromethane (6 ml) was added 3,5-difluorobenzene-1-sulfonyl chloride (38.26 mg, 0.18 mmol) at 0° C. The reaction was stirred at RT for 3 hours. The reaction mixture was poured into cold water and organic layer was separated. The aqueous layer was extracted with dichloromethane. The combined organic layer was washed with brine dried over sodium sulfate and evaporated to dryness. The crude product was purified by column chromatography (silica gel, 2% acetone in chloroform) to obtain the title compound.
[0283] Yield: 25 mg (35%); 1 H NMR (CDCl 3 , 300 MHz): δ 9.553 (s, 1H), 8.002-8.032 (d, 1H, J=9 Hz), 7.752-7.798 (m, 4H), 7.664-7.701 (dd, 1H, J=8.7, 2.1 Hz), 7.466-7.495 (d, 2H, J=8.7 Hz), 7.175 (m, 1H), 7.002-7.009 (d, 1H, J=2.1 Hz), 1.831 (s, 6H); MS: m/z 583 (M + ).
Example 17
2-(4-(8-Bromo-3-(2,4-difluorophenylsulfonyl)-2-oxo-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)-2-methylpropanenitrile
[0284] To a solution of 2-(4-(8-bromo-2-oxo-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)-2-methylpropanenitrile (Intermediate 1, 50 mg, 0.12 mmol) and triethylamine (49.75 mg, 0.49 mmol) in dichloromethane (6 ml) was added 2,4-difluorobenzene-1-sulfonyl chloride (52 mg, 0.25 mmol) at 0° C. The reaction was stirred at RT for 3 hours. The reaction mixture was poured into cold water and organic layer was separated. The aqueous layer was extracted with dichloromethane. The combined organic layer was washed with brine dried over sodium sulfate and evaporated to dryness. The crude product was purified by column chromatography (silica gel, 2% acetone in chloroform) to obtain the title compound. Yield: 30 mg (42%); 1 H NMR (DMSO-d 6 , 300 MHz): δ 9.31 (s, 1H), 8.21-8.24 (m, 1H), 7.968-7.998 (d, 1H, J=9.0 Hz.), 7.63-7.81 (m, 6H), 7.374-7.440 (m, 1H), 6.741-6.748 (d, 1H, J=2.1 Hz), 1.77 (s, 6H); Mass m/z: 583 (M + ).
Example 18
2-(4-(8-Bromo-3-(methylsulfonyl)-2-oxo-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)-2-methylpropanenitrile
[0285] To a solution of 2-(4-(8-bromo-2-oxo-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)-2-methylpropanenitrile (Intermediate 1, 50 mg, 0.12 mmol) and triethylamine (24.85 mg, 0.25 mmol) in dichloromethane (6 ml) was added methylsulfonyl chloride (28.20 mg, 0.25 mmol) at 0° C. The reaction was stirred at RT for 3 hours. The reaction mixture was poured into cold water and organic layer was separated. The aqueous layer was extracted with dichloromethane. The combined organic layer was washed with brine dried over sodium sulfate and evaporated to dryness. The crude product was purified by column chromatography (silica gel, 2% acetone in chloroform) to obtain the title compound. Yield: 28 mg (47%); 1 H NMR (DMSO-d 6 , 300 MHz): δ 9.214 (s, 1H), 7.953-7.984 (d, 1H, J=9.3 Hz), 7.85-7.88 (d, 2H, J=8.4 Hz), 7.72-7.76 (m, 3H), 6.771-6.778 (d, 1H, J=2.1 Hz), 3.3727 (s, 3H), 1.774 (s, 6H); MS: m/z 485 (M + ).
Example 19
2-(4-(8-Chloro-2-oxo-3-(m-tolylsulfonyl)-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)-2-methylpropanenitrile
[0286] To a solution of 2-(4-(8-chloro-2-oxo-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)-2-methylpropanenitrile (Intermediate 2, 50 mg, 0.14 mmol) and triethylamine (28 mg, 0.28 mmol) in dichloromethane (6 ml) was added 3-methylbenzene-1-sulfonyl chloride (40 mg, 0.21 mmol) at 0° C. The reaction was stirred at RT for 3 hours. The reaction mixture was poured into cold water and organic layer was separated. The aqueous layer was extracted with dichloromethane. The combined organic layer was washed with brine dried over sodium sulfate and evaporated to dryness. The crude product was purified by column chromatography (silica gel, 2% acetone in chloroform) to obtain the title compound. Yield: 29 mg (40%); 1 H NMR (CDCl 3 , 300 MHz): δ 9.605 (s, 1H), 8.023-8.093 (m, 3H), 7.72-7.748 (dd, 2H, J=6.6 Hz, 1.8 Hz), 7.44-7.551 (m, 5H), 6.855-6.862 (d, 1H, J=2.1 Hz), 2.44 (s, 3H), 1.82 (s, 6H); MS: m/z 517 (M + ).
Example 20
2-(8-Chloro-1-(4-(2-cyanopropan-2-yl)phenyl)-2-oxo-1H-imidazo[4,5-c]quinolin-3(2H)-ylsulfonyl)benzonitrile
[0287] To a solution of 2-(4-(8-chloro-2-oxo-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)-2-methylpropanenitrile (Intermediate 2, 50 mg, 0.14 mmol) and triethylamine (28 mg, 0.28 mmol) in dichloromethane (6 ml) was added 2-cyanobenzene-1-sulfonyl chloride (42 mg, 0.21 mmol) at 0° C. The reaction was stirred at RT for 3 hours. The reaction mixture was poured into cold water and organic layer was separated. The aqueous layer was extracted with dichloromethane. The combined organic layer was washed with brine dried over sodium sulfate and evaporated to dryness. The crude product was purified by column chromatography (silica gel, 2% acetone in chloroform) to obtain the title compound. Yield: 24 mg (33%); 1 H NMR (CDCl 3 , 300 MHz): δ 9.698 (s, 1H), 8.496-8.525 (d, 1H, 8.7 Hz), 8.093-8.123 (d, 1H, J=9 Hz), 7.823-7.920 (m, 3H), 7.71-7.739 (d, 2H, J=8.7 Hz), 7.525-7.563 (dd, 1H, J=9.3, 2.1 Hz), 7.46-7.488 (d, 2H, J=8.4 Hz), 6.863-6.870 (d, 1H, 2.1 Hz), 1.798 (s, 6H); MS: m/z 528 (M + ).
Example 21
2-Methyl-2-(4-(8-methyl-2-oxo-3-(m-tolylsulfonyl)-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)propanenitrile
[0288] To a solution of 2-(4-(8-methyl-2-oxo-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)-2-methylpropanenitrile (Intermediate 3, 100 mg, 0.29 mmol) and triethylamine (60 mg, 0.58 mmol) in dichloromethane (6 ml) was added m-methylbenzene-1-sulfonyl chloride (83.5 mg, 0.44 mmol) at 0° C. The reaction was stirred at RT for 3 hours. The reaction mixture was poured into cold water and organic layer was separated. The aqueous layer was extracted with dichloromethane. The combined organic layer was washed with brine dried over sodium sulfate and evaporated to dryness. The crude product was purified by column chromatography (silica gel, 2% acetone in chloroform) to obtain the title compound. Yield: 25 mg (17%); 1 H NMR (CDCl 3 , 300 MHz): δ 9.551 (s, 1H), 8.046-8.095 (d, 3H, J=8.4 Hz), 7.762-7.791 (d, 2H, J=8.7 Hz), 7.354-7.575 (m, 5H), 6.670 (s, 1H), 2.436 (s, 3H), 2.212 (s, 3H), 1.855 (s, 6H); MS: m/z 497 (M + ).
Example 22
2-(4-(3-(3-Fluorophenylsulfonyl)-8-methyl-2-oxo-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)-2-methylpropanenitrile
[0289] To a solution of 2-(4-(8-methyl-2-oxo-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)-2-methylpropanenitrile (Intermediate 3, 100 mg, 0.29 mmol) and triethylamine (60 mg, 0.58 mmol) in dichloromethane (6 ml) was added 3-fluorobenzene-1-sulfonyl chloride (84 mg, 0.44 mmol) at 0° C. The reaction was stirred at RT for 3 hours. The reaction mixture was poured into cold water and organic layer was separated. The aqueous layer was extracted with dichloromethane. The combined organic layer was washed with brine dried over sodium sulfate and evaporated to dryness. The crude product was purified by column chromatography (silica gel, 2% acetone in chloroform) to obtain the title compound. Yield: 20 mg (14%); 1 H NMR (DMSO-d 6 , 300 MHz): δ 9.341 (s, 1H), 8.039-8.059 (d, 2H, J=6 Hz), 7.939-7.967 (d, 1H, J=8.4 Hz), 7.683-7.811 (m, 6H), 7.469-7.499 (d, 1H, J=9 Hz), 6.433 (s, 1H), 2.112 (s, 3H), 1.780 (s, 6H); MS: m/z 501 (M + ).
Example 23
2-Methyl-2-(4-(8-methyl-3-(2-methyl-5-nitrophenylsulfonyl)-2-oxo-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)propanenitrile
[0290] To a solution of 2-(4-(8-methyl-2-oxo-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)-2-methylpropanenitrile (Intermediate 3, 100 mg, 0.29 mmol) and triethylamine (60 mg, 0.58 mmol) in dichloromethane (6 ml) was added 2-methyl-5-nitrobenzene-1-sulfonyl chloride (103.35 mg, 0.44 mmol) at 0° C. The reaction was stirred at RT for 3 hours. The reaction mixture was poured into cold water and organic layer was separated. The aqueous layer was extracted with dichloromethane. The combined organic layer was washed with brine dried over sodium sulfate and evaporated to dryness. The crude product was purified by column chromatography (silica gel, 2% acetone in chloroform) to obtain the title compound.
[0291] Yield: 20 mg (12%); 1 H NMR (CDCl 3 , 300 MHz): δ 9.560 (s, 1H), 9.155-9.163 (d, 1H, J=2.4 Hz), 8.384-8.420 (dd, 1H, J=8.4, 2.4 Hz), 8.050-8.079 (d, 1H, J=8.7 Hz), 7.696-7.724 (d, 2H, J=8.4 Hz), 7.538-7.564 (d, 1H, J=7.8 Hz), 7.458-7.486 (d, 3H, J=8.4 Hz), 6.708 (s, 1H), 2.760 (s, 3H), 2.236 (s, 3H), 1.742 (s, 6H); MS: m/z 542 (M + ).
Example 24
2-Methyl-2-(4-(8-methyl-2-oxo-3-(quinolin-8-ylsulfonyl)-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)propanenitrile
[0292] To a solution of 2-(4-(8-methyl-2-oxo-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)-2-methylpropanenitrile (Intermediate 3, 100 mg, 0.29 mmol) and triethylamine (60 mg, 0.58 mmol) in dichloromethane (6 ml) was added quinoline-8-sulfonyl chloride (100 mg, 0.44 mmol) at 0° C. The reaction was stirred at RT for 3 hours. The reaction mixture was poured into cold water and organic layer was separated. The aqueous layer was extracted with dichloromethane. The combined organic layer was washed with brine dried over sodium sulfate and evaporated to dryness. The crude product was purified by column chromatography (silica gel, 2% acetone in chloroform) to obtain the title compound. Yield: 32 mg (20%); 1 H NMR (DMSO-d 6 , 300 MHz): δ 9.468 (s, 1H), 8.700-8.729 (d, 1H, J=8.7 Hz), 8.539-8.558 (m, 2H), 8.449-8.479 (d, 1H, J=9 Hz), 7.974-8.004 (d, 1H, J=9 Hz), 7.864-7.916 (t, 1H), 7.716-7.744 (d, 2H, J=8.4 Hz), 7.519-7.600 (q, 1H), 7.470-7.491 (m, 3H), 6.435 (s, 1H), 2.118 (s, 3H), 1.743 (s, 6H); MS: m/z 534 (M + ).
Example 25
2-(4-(3-(4-Acetylphenylsulfonyl)-8-methyl-2-oxo-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)-2-methylpropanenitrile
[0293] To a solution of 2-(4-(8-methyl-2-oxo-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)-2-methylpropanenitrile (Intermediate 3, 100 mg, 0.29 mmol) and triethylamine (60 mg, 0.58 mmol) in dichloromethane (6 ml) was added 4-acetylbenzene-1-sulfonyl chloride (103.75 mg, 0.44 mmol) at 0° C. The reaction was stirred at RT for 3 hours. The reaction mixture was poured into cold water and organic layer was separated. The aqueous layer was extracted with dichloromethane. The combined organic layer was washed with brine dried over sodium sulfate and evaporated to dryness. The crude product was purified by column chromatography (silica gel, 2% acetone in chloroform) to obtain the title compound. Yield: 50 mg (33%); 1 H NMR (DMSO-d 6 , 300 MHz): δ 9.347 (s, 1H), 8.299-8.325 (d, 2H, J=7.8 Hz), 8.175-8.202 (d, 2H, J=8.1 Hz), 7.940-7.969 (d, 1H, J=8.7 Hz), 7.778-7.803 (d, 2H, J=7.5 Hz), 7.665-7.691 (d, 1H, J=7.8), 7.466-7.495 (d, 2H, J=8.7 Hz), 6.427 (s, 1H), 2.624 (s, 3H), 2.110 (s, 3H), 1.776 (s, 6H); MS: m/z 525 (M + ).
Example 26
2-(4-(8-Bromo-3-(morpholine-4-carbonyl)-2-oxo-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)-2-methylpropanenitrile
[0294] To a solution of 2-(4-(8-bromo-2-oxo-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)-2-methylpropanenitrile (Intermediate 1, 100 mg, 0.25 mmol) in dry DMF (5 mL), sodium hydride (12 mg, 0.27 mmol) was added at 0° C. under nitrogen atmosphere. After 15 minutes morpholine-4-carbonyl chloride (56.1 mg, 0.37 mmol) was added, and the reaction mixture was heated at 60° C. for 48 hours. The reaction mixture was concentrated in vacuum. The crude product was purified by column chromatography (silica gel, 3% acetone in chloroform) to obtain the title compound. Yield: 15 mg (11.73%); 1 H NMR (CDCl 3 , 300 MHz): δ 9.09 (s, 1H), 7.973-8.004 (d, 1H, J=9.3 Hz), 7.772-7.8 (d, 2H, J=8.4 Hz), 7.621-7.658 (dd, 1H, J=9 Hz, 2.1 Hz), 7.517-7.545 (d, 2H, J=8.4 Hz,), 7.057-7.064 (d, 1H, J=2.1 Hz), 3.67 (t, 4H,), 3.26 (t, 4H), 1.84 (s, 6H); MS: m/z 520 (M + ).
Example 27
(E)-2-(4-(8-Bromo-3-but-2-enoyl-2-oxo-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)-2-methylpropanenitrile
[0295] A mixture of 2-(4-(8-bromo-2-oxo-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)-2-methylpropanenitrile (Intermediate 1, 470 mg, 1.16 mmol) and sodium acetate (95 mg, 1.16 mmol) was heated at 110-120° C. in crotonic anhydride (2 ml) for four hours. Reaction mixture was cooled to RT. Water was added and extracted with Ethyl acetate. Ethyl acetate layer was washed with brine, dried over sodium sulfate and concentrated. The crude product was purified by column chromatography (silica gel, 2% acetone in chloroform) to obtain the title compound. Yield: 305 mg (55%); 1 H NMR (CDCl 3 , 300 MHz): δ 9.819 (s, 1H), 7.946-7.976 (d, 1H, J=9 Hz), 7.666-7.795 (d, 2H, J=8.7 Hz), 7.606-7.643 (dd, 1H, J=9 Hz, 2.1 Hz), 7.49-7.576 (m, 3H), 7.35-7.47 (m, 1H), 7.00-7.01 (d, 1H, J=1.8 Hz), 2.038 (d, 3H, J=6 Hz), 1.833 (s, 6H); MS: m/z 475 (M + ).
Example 28
2-(4-(8-Bromo-2-oxo-3-(2-propylpentanoyl)-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)-2-methylpropanenitrile
[0296] A mixture of 2-(4-(8-Bromo-2-oxo-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)-2-methylpropanenitrile (Intermediate 1, 25 mg, 0.06 mmol) and sodium acetate (5 mg, 0.06 mmol) was heated at 110-120° C. in valproic anhydride (1 ml) for four hours. Reaction mixture was cooled to RT. Water was added and extracted with ethyl acetate. Ethyl acetate layer was washed with brine, dried over sodium sulfate and concentrated. The crude product was purified by column chromatography (silica gel, 2% acetone in chloroform) to obtain the title compound. Yield: 12 mg (38%); 1 H NMR (CDCl 3 , 300 MHz): δ 9.849 (s, 1H), 7.98-8.01 (d, 1H, J=9 Hz), 7.78-7.81 (d, 2H, J=8.7 Hz), 7.63-7.67 (dd, 1H, J=9, 2.1 Hz), 7.54-7.57 (d, 2H, J=8.1 Hz), 7.02-7.03 (d, 1H, J=1.8 Hz), 2.38 (m, 1H), 1.84 (s, 6H), 1.67 (m, 4H), 1.49 (m, 4H), 0.9 (m, 6H); MS: m/z 533 (M + ).
Example 29
(E)-2-(4-(8-Bromo-3-cinnamoyl-2-oxo-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)-2-methylpropanenitrile
[0297] To a solution of 2-(4-(8-bromo-2-oxo-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)-2-methylpropanenitrile (Intermediate 1, 30 mg, 0.074 mmol) and triethylamine (70 mg, 0.69 mmol) in dichloromethane (6 ml) was added cinnamoyl chloride (18 mg, 148 mmol) at 0° C. The reaction was stirred at RT for 3 hours. The reaction mixture was poured into cold water and organic layer was separated. The aqueous layer was extracted with dichloromethane. The combined organic layer was washed with brine dried over sodium sulfate and evaporated to dryness. The crude product was purified by column chromatography (silica gel, 2% acetone in chloroform) to obtain title compound. 1 H NMR (CDCl 3 , 300 MHz): δ 9.921 (s, 1H), 8.204-8.257 (d, 1H, J=15.9 Hz), 8.071-8.123 (d, 1H, J=15.6 Hz), 7.983-8.013 (d, 1H J=9 Hz), 7.806-7.834 (d, 2H, J=8.4 Hz), 7.63-7.68 (m, 3H), 7.569-7.597 (d, 2H, J=8.4 Hz), 7.396-7.412 (m, 3H), 7.059-7.066 (d, 1H, J=2.1 Hz), 1.858 (s, 6H); MS: m/z 539 (M + ).
Example 30
2-(4-(3-Benzoyl-8-bromo-2-oxo-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)-2-methylpropanenitrile
[0298] Sodium hydride (30 mg, 0.75 mmol) was added to dry DMF (5 ml) in a nitrogen atmosphere. The reaction flask was cooled in an ice-bath to 0° C., and 2-(4-(8-bromo-2-oxo-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)-2-methylpropanenitrile (Intermediate 1, 100 mg, 0.25 mmol) was added. After 15 minutes benzoyl chloride (42 mg, 0.29 mmol) was added, and the reaction mixture was heated at 50° C. for 24 hours. The reaction mixture was concentrated in vacuum. The crude product was purified by column chromatography (silica gel, 2% acetone in chloroform) to obtain the title compound. Yield: 13 mg (10%); 1 H NMR (DMSO-d 6 , 300 MHz): δ 9.410 (s, 1H), 7.998-8.028 (d, 1H, J=9 Hz), 7.939-7.963 (d, 2H, J=7.2 Hz), 7.848-7.876 (d, 2H, J=8.4 Hz), 7.764-7.792 (d, 3H, J=8.4 Hz), 7.644-7.669 (m, 1H), 7.48-7.56 (m, 2H), 6.865-6.872 (d, 1H, J=2.1 Hz), 1.78 (s, 6H); MS: m/z 511 (M+1).
Example 31
8-Bromo-1-(4-(2-cyanopropan-2-yl)phenyl)-N-(4-methoxyphenyl)-2-oxo-1H-imidazo[4,5-c]quinoline-3(2H)-carboxamide
[0299] To a solution of 2-(4-(8-bromo-2-oxo-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)-2-methylpropanenitrile (Intermediate 1, 50 mg, 0.12 mmol) and triethylamine (18.18 mg, 0.18 mmol) in dichloromethane (6 ml) was added 1-isocyanato-4-methoxybenzene (26.82 mg, 0.18 mmol) at 0° C. The reaction was stirred at RT for 3 hours. The reaction mixture was poured into cold water and organic layer was separated. The aqueous layer was extracted with dichloromethane. The combined organic layer was washed with brine dried over sodium sulfate and evaporated to dryness. The crude product was purified by column chromatography (silica gel, 2% acetone in chloroform) to obtain the title compound Yield: 25 mg (22.82%); 1 H NMR (DMSO-d 6 , 300 MHz): δ 8.785 (s, 1H), 7.81-7.94 (m, 4H), 7.62-7.69 (m, 3H), 6.95 (s, 1H), 6.47-6.63 (m, 4H), 3.51 (s, 3H), 1.79 (s, 6H); MS: m/z 556 (M + ).
Example 32
N-benzyl-8-bromo-1-(4-(2-cyanopropan-2-yl)phenyl)-2-oxo-1H-imidazo[4,5-c]quinoline-3(2H)-carboxamide
[0300] To a solution of 2-(4-(8-bromo-2-oxo-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)-2-methylpropanenitrile (Intermediate 1, 50 mg, 0.12 mmol) and triethylamine (18 mg, 0.18 mmol) in dichloromethane (6 ml) was added (isocyanatomethyl)benzene (24.57 mg, 0.18 mmol). The reaction mixture was stirred at RT for 2 hours. Then the reaction mixture was poured on to water. The organic layer was separated. The aqueous layer was extracted with dichloromethane. The combined organic layer was washed with brine, dried over sodium sulfate and evaporated to dryness. The crude product was purified by column chromatography (silica gel, 1% MeOH in chloroform) to obtain the title compound. Yield: 18 mg (20%); 1 H NMR (CDCl 3 , 300 MHz): δ 9.89 (s, 1H), 8.95 (t, 1H), 7.978-8.008 (d, 1H, J=9 Hz), 7.762-7.790 (d, 2H, J=8.4 Hz), 7.614-7.651 (dd, 1H, J=9, 1.8 Hz), 7.500-7.529 (d, 2H, J=8.7 Hz), 7.27-7.38 (m, 5H), 7.018-7.025 (d, 1H, J=2.1 Hz), 4.642-4.611 (d, 2H, J=5.7 Hz), 1.82 (s, 6H); MS: m/z 540 (M + ).
Example 33
8-Bromo-N-(2-bromophenyl)-1-(4-(2-cyanopropan-2-yl)phenyl)-2-oxo-1H-imidazo[4,5-c]quinoline-3(2H)-carboxamide
[0301] To a suspension of 2-(4-(8-bromo-2-oxo-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)-2-methylpropanenitrile (Intermediate 1, 0.050 g, 0.12 mmol) and potassium fluoride (0.010 g, 0.18 mmol) in dry benzene (6 ml) was added 1-bromo-2-isocyanatobenzene (0.036 g, 0.12 mmol) at RT. The reaction was stirred at reflux temperature for 6 hours. The reaction mixture was cooled and poured into cold water, extracted with ethyl acetate (2×20 ml). Organic layer was washed with water dried over sodium sulfate and concentrated. The crude product was crystallized in ethyl acetate\pet ether to obtain the title compound. Yield: 0.017 g (22%); 1 H NMR (DMSO-d 6 , 300 MHz): δ 11.82 (s, 1H), 8.78 (s, 1H), 7.90 (d, 1H, J=9 Hz), 7.81 (d, 2H, J=8.1 Hz), 7.61-7.65 (m, 3H), 7.28 (d, 1H, J=8.1 Hz), 6.95-7.05 (m, 2H), 6.74 (d, 1H, 7.8 Hz), 6.41 (t, 1H, 7.2 Hz), 1.79 (s, 6H); MS: m/z 606 (M + ).
Example 34
8-bromo-N-(2-chloroethyl)-1-(4-(2-cyanopropan-2-yl)phenyl)-2-oxo-1H-imidazo[4,5-c]quinoline-3(2H)-carboxamide
[0302] To a suspension of 2-(4-(8-bromo-2-oxo-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)-2-methylpropanenitrile (Intermediate 1, 0.040 g, 0.10 mmol) and potassium fluoride (0.010 g, 0.17 mmol) in dry benzene (6 ml) was added 1-chloroethyl isocyanate (0.015 g, 0.14 mmol) at RT. The reaction was stirred at reflux temperature for 6 hours. The reaction mixture was cooled and poured into cold water, extracted with ethyl acetate (2×20 ml). Organic layer was washed with water dried over sodium sulfate and concentrated. The crude product was triturated with diethylether to obtain the title compound. Yield: 0.030 g (60%); 1 H NMR (DMSO-d 6 , 300 MHz): δ 9.654 (s, 1H), 8.80-8.91 (t, 1H), 7.97-8.00 (d, 1H, J=9 Hz), 7.877-7.905 (d, 2H, J=8.4 Hz), 7.775-7.803 (d, 2H, J=8.4 Hz), 7.725-7.763 (dd, 1H, J=9, 2.1 Hz), 6.805-6.811 (d, 1H, J=1.8 Hz), 3.80-3.84 (q, 2H), 3.533-3.574 (t, 2H), 1.809 (s, 6H); MS: m/z 514 (M + ).
Example 35
N-allyl-8-bromo-1-(4-(2-cyanopropan-2-yl)phenyl)-2-oxo-1H-imidazo[4,5-c]quinoline-3(2H)-carboxamide
[0303] To a suspension of 2-(4-(8-bromo-2-oxo-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)-2-methylpropanenitrile (Intermediate 1, 0.040 g, 0.10 mmol) and potassium fluoride (0.009 g, 0.147 mmol) in dry benzene (6 ml) was added allylisocyanate (0.010 g, 0.10 mmol) at RT. The reaction was stirred at reflux temperature for 6 hours. The reaction mixture was cooled and poured into cold water, extracted with ethyl acetate (2×20 ml). Organic layer was washed with water dried over sodium sulfate and concentrated. The crude product was triturated with ethyl acetate, filtered and filtrate was purified by column chromatography (silica gel, 2% acetone in chloroform) to obtain the title compound. Yield: 0.020 g (41%); 1 H NMR (DMSO-d 6 , 300 MHz): δ 9.653 (s, 1H), 8.723-8.761 (t, 1H), 7.971-8.001 (d, 1H, J=9 Hz), 7.874-7.903 (d, 2H, J=8.7 Hz), 7.769-7.798 (d, 2H, J=8.7 Hz), 7.723-7.761 (dd, 1H, J=9, 2.1 Hz), 6.808-6.814 (d, 1H, J=1.8 Hz), 5.904-5.996 (m, 1H), 5.234-5.296 (dd, 1H, J=17.1, 1.2 Hz), 5.134-5.173 (dd, 1H, J=10.5, 1.2 Hz), 4.010-4.045 (t, 2H), 1.806 (s, 6H); MS: m/z 492 (M + ).
Example 36
2-(4-(3-Acetyl-8-chloro-2-oxo-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)-2-methylpropanenitrile
[0304] A mixture of 2-(4-(8-chloro-2-oxo-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)-2-methylpropanenitrile (Intermediate 2, 80 mg, 0.22 mmol) and sodium acetate (27.06 mg, 0.33 mmol) was heated at 50° C. in acetic anhydride (2 ml) for 3 hours. Reaction mixture was cooled to RT. Water was added and extracted with chloroform. Chloroform layer was washed with brine, dried over sodium sulfate and concentrated. The crude product was purified by column chromatography (silica gel, 2% acetone in chloroform) to obtain the title compound.
[0305] Yield: 26 mg (29%); 1 H NMR (CDCl 3 , 300 MHz): δ 9.796 (s, 1H), 8.039-8.070 (d, 1H, J=9.3 Hz), 7.764-7.792 (d, 2H, J=8.4 Hz), 7.499-7.537 (m, 3H), 6.861-6.868 (d, 1H, J=2.1 Hz), 2.822 (s, 3H), 1.83 (s, 6H); MS: m/z 405 (M + ).
Example 37
2-(4-(3-Benzoyl-8-chloro-2-oxo-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)-2-methylpropanenitrile
[0306] Sodium hydride (22 mg, 0.557 mmol) was added to dry DMF (5 mL) in a nitrogen atmosphere. The reaction flask was cooled in an ice-bath to 0° C., and 2-(4-(8-chloro-2-oxo-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)-2-methylpropanenitrile (Intermediate 2, 100 mg, 0.27 mmol) was added. After 15 minutes benzoyl bromide (61 mg, 0.33 mmol) was added, and the reaction mixture was heated at 50° C. for 24 hours. The reaction mixture was concentrated in vacuum. The crude product was purified by column chromatography (silica gel, 2.5% acetone in chloroform) to obtain the title compound. Yield: 30 mg (23%); 1 H NMR (DMSO-d 6 , 300 MHz): δ 9.372 (s, 1H), 8.048-8.078 (d, 1H, J=9 Hz), 7.905-7.929 (d, 2H, J=7.2 Hz), 7.810-7.839 (d, 2H, J=8.7 Hz), 7.730-7.759 (d, 2H, J=8.7 Hz), 7.611-7.666 (m, 2H), 7.449-7.523 (m, 2H), 6.698-6.705 (d, 1H, J=2.1 Hz), 1.752 (s, 6H); MS: m/z 467 (M + ).
Example 38
(E)-2-(4-(3-But-2-enoyl-8-chloro-2-oxo-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)-2-methylpropanenitrile
[0307] A mixture of 2-(4-(8-chloro-2-oxo-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)-2-methylpropanenitrile (Intermediate 2, 179 mg, 0.50 mmol) and sodium acetate (40 mg, 0.50 mmol) was heated at 110-120° C. in crotonic anhydride (2 ml) for 4 hours. Reaction mixture was cooled to RT. Water was added and extracted with ethyl acetate. Ethyl acetate layer was washed with brine, dried over sodium sulfate and concentrated. The crude product was purified by column chromatography (silica gel, 2% acetone in chloroform) to obtain the title compound. Yield: 84 mg (39%); 1 H NMR (CDCl 3 , 300 MHz): δ 9.813 (s, 1H), 8.028-8.058 (d, 1H, J=9 Hz), 7.76-7.79 (dd, 2H, J=8.7, 1.8 Hz), 7.49-7.54 (m, 3H), 7.37-7.49 (m, 2H), 6.86-6.87 (d, 1H, J=2.1 Hz), 2.018-2.037 (d, 3H, J=6 Hz), 1.832 (s, 6H); MS: m/z 431(M + ).
Example 39
(E)-2-(4-(3-But-2-enoyl-8-methyl-2-oxo-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)-2-methylpropanenitrile
[0308] In a mixture of 2-(4-(8-methyl-2-oxo-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)-2-methylpropanenitrile (Intermediate 3, 100 mg, 0.29 mmol) and sodium acetate (28.77 mg, 35.5 mmol), crotonic anhydride (1 ml) was added drop-wise at RT and the reaction mixture was heated at 110° C. for 3 hours. The reaction mixture was passed through a silica gel column in chloroform as eluent to obtain the title compound.
[0309] Yield: 30 mg (26%); 1 H NMR (DMSO-d 6 , 300 MHz): δ 9.564 (s, 1H), 7.912-7.940 (d, 1H, J=8.4 Hz), 7.837-7.862 (d, 2H, J=7.5 Hz), 7.724-7.749 (d, 2H, J=7.5), 7.485 (s, 1H), 7.442-7.449 (d, 1H, J=2.1 Hz), 7.285-7.332 (m, 1H), 6.474 (s, 1H), 2.13 (s, 3H), 1.990-2.009 (d, 3H, J=5.7 Hz), 1.811 (s, 6H); MS: m/z 411 (M+1).
Example 40
8-Bromo-N-(2-chloroethyl)-1-(4-(2-cyanopropan-2-yl)phenyl)-2-oxo-1H-imidazo[4,5-c]quinoline-3(2H)-carbothioamide
[0310] To a solution of 2-(4-(8-bromo-2-oxo-2,3-dihydro-1H-imidazo[4,5-c]quinolin-1-yl)phenyl)-2-methylpropanenitrile (Intermediate 1, 50 mg, 0.12 mmol) and triethylamine (18.18 mg, 0.18 mmol) in dichloromethane (6 ml) was added 1-chloro-2-isothiocyanatoethane (21.87 mg, 0.18 mmol) at 0° C. The reaction was stirred at RT for 3 hours. The reaction mixture was poured into cold water and organic layer was separated. The aqueous layer was extracted with dichloromethane. The combined organic layer was washed with brine dried over sodium sulfate and evaporated to dryness. The crude product was purified by column chromatography (silica gel, 2% acetone in chloroform) to obtain the title compound. Yield: 10 mg (15%); 1 H NMR (CDCl 3 , 300 MHz): δ 9.945 (s, 1H), 7.966-7.996 (d, 1H, J=9 Hz), 7.745-7.773 (d, 2H, J=8.4 Hz), 7.615-7.645 (dd, 1H, J=9, 2.1 Hz), 7.516-7.544 (d, 2H, J=8.4 Hz), 7.082-7.089 (d, 1H, J=2.1 Hz), 4.289-4.344 (t, 2H), 3.411-3.467 (t, 2H), 1.82 (s, 6H); MS: m/z 491 (M−HCl).
Pharmacology
[0311] The efficacy of the present compounds can be determined by a number of pharmacological assays well known in the art, such as described below. The exemplified pharmacological assays, which follow herein, have been carried out with the compounds of the present invention.
Example 41
Protocol for PI3Kα assay
[0312] The assay was designed as in the reference, Cell, 2006, 125, 733-47 (Supplemental Data), the disclosure of which is incorporated by reference for the teaching of the assay.
[0000] The kinase reaction was carried out in a 25 μL volume in a 1.5 mL microcentrifuge tube. The reaction mixture consisted of kinase buffer (10 mM Hepes, pH 7.5, 50 mM MgCl 2 ), 20 ng PI3Kα kinase (Millipore, USA), 12.5 μg phosphatidylinositol (PI), 10 μM ATP and 1 μCi 32 γ P dATP. Compounds of Example 1-40 were added at concentrations (stock solution was prepared in DMSO and subsequent dilutions were made in kinase buffer) as mentioned in the table. The reaction mixture was incubated at 30° C. for 20 minutes and was terminated by adding 1:1 mixture of MeOH and chloroform. The tube contents were mixed on a vortex mixer and centrifuged at 10000 rpm for 2 minutes. 10 μL of the organic (lower) phase was spotted on to a TLC plate (silica, mobile phase: n-propanol and 2 M glacial acetic acid in 65:35 ratio). The plates were dried and exposed to an X-ray film. The bands appearing as a result of 32 γ P incorporation in PI were quantitated using the QuantityOne (BioRad, USA) densitometry program. PI-103 (Calbiochem, USA) was used as a standard.
Results: % inhibition of PI3Kα at 100 nM and 1000 nM is indicated in Table 1.
[0000] TABLE 1 Example % inhibition of Example % inhibition of No. PI3Kα No. PI3Kα At 100 nM 2 + 3 + 6 ++ 7 + 8 + 13 + 17 + 18 + 20 + 30 ++ 32 + 33 ++ 36 + 37 + At 1000 nM 27 + 38 + % Inhibition Ranges + 50% ≧ % Inhibition ≧ 10% ++ % Inhibition > 50%
Conclusion: Certain compounds of the present invention were found to inhibit PI3K expression.
Example 42
PI3K and mTOR Activity Assay
[0313] The assay was designed as in the reference, Biochemical Journal, 2000, 350, 717-722, the disclosure of which is incorporated by reference for the teaching of the assay.
[0314] Seed cells (Ovarian cell line A2780, ATCC) were plated in a 96 well microtitre plate at a density of 50,000 cells/cm 2 in appropriate complete cell culture medium. The cells were allowed to adhere for 18-24 hours. The cells were allowed to starve for 24 hours. The cells were pretreated (in triplicates) with the compounds of Example 1-40 (stock solution was prepared in DMSO and subsequent dilutions were made in kinase buffer) at a concentration of 10 μM for one hour. Then the cells were stimulated with 20% FCS for 30 minutes. A typical assay would consist of a set of unstimulated cells, a set of stimulated cells and a set of cells treated with compounds of Example 1-40 and a set of cells treated with the stimulator. The medium was discarded. The cells were fixed with 100 μL of 3.7% formaldehyde for 15 minutes. The formaldehyde was discarded by inverting the plate and tapping it on a thick tissue paper layer to remove traces. The cells were washed and permeabilized with 200 μL PBS+Triton-X 100 solution (hereafter referred to as PBS-Triton, containing 0.1% triton-X 100 in 1×PBS) three times, incubating the cells each time for 5 minutes. 100 μL blocking solution (10% FCS in PBS-Triton) was added and incubated for 1 hour at 25° C. The blocking solution was discarded and cells were incubated with the primary antibody in PBS-Triton at a dilution of 1:500 for 1 hour at RT (25° C.). [The primary antibody is Phospho-AKT (Ser 473); Cell Signaling; USA, Cat. No. 9271]. The primary antibody solution was discarded and the cells were washed 3 times with PBS-Triton solution and incubated with the HRP-conjugated secondary antibody in PBS-Triton at a dilution of 1:500 for 1 hour at RT (25° C.). The cells were washed 3 times with PBS-Triton followed by two washes with PBS (to remove traces of triton-X 100). The OPD (o-phenylene diamine dihydrochloride) substrate was prepared for detection of the signal by dissolving one tablet set (two tablets) of SigmaFast OPD (Sigma, USA, Cat No. P9187) in 20 mL distilled water. It should be kept protected from light. 100 μL OPD solutions was added to the wells and the plate was incubated in the dark for 3-5 minutes (depending upon the development of the color). The reaction was stopped by adding 50 μL 2 NH 2 SO 4 . The absorbance was measured at 490 nm. The values were expressed in the treated samples, in terms of percentage or fold decrease in AKT phosphorylation with respect to the induced sample. PI-103 (Calbiochem, USA) was used as a standard.
[0000] Results: % Inhibition of PI3 kinase activity at 10 μM is indicated in Table 2.
% Inhibition of mTOR at 10 μM is indicated in Table 3.
[0000]
TABLE 2
% Inhibition
Example
of PI3K α
Example
% Inhibition of PI3K α
No.
(Cell-based) at 10 μM
No.
(Cell-based) at 10 μM
2
+
3
+
6
+
17
++
27
++
30
+
38
++
[0000]
TABLE 3
% Inhibition
of mTOR
(Cell-based)
% Inhibition of mTOR
Example No.
at 10 μM
Example No.
(Cell-based) at 10 μM
27
++
30
+
37
+
38
++
% Inhibition Ranges
+ 50% ≧ % Inhibition ≧ 10%
++ % Inhibition > 50%
Example 43
Cytotoxicity Assay
Propidium Iodide Assay
[0316] The assay was designed as in the reference, Anticancer Drugs, 2002, 13, 1-8, the disclosure of which is incorporated by reference for the teaching of the assay.
[0317] Cells from cell lines as mentioned in the table given below were seeded at a density of 3000 cells/well in a white opaque 96-well plate. Following incubation at 37° C./5% CO 2 for a period of 18-24 hours, the cells were treated with various concentrations (stock solution was prepared in DMSO and subsequent dilutions were made in media as per ATCC guidelines) of the compounds of Example 1-40 was for a period of 48 hours. At the end of treatment, the spent culture medium was discarded, the cells were washed with 1×PBS and 200 μl of 7 μg/ml propidium iodide was added to each well. The plates were frozen at −70° C. for at least 24 hours. For analysis, the plates were brought to RT, allowed to thaw and were read in PoleStar fluorimeter with the fluorescence setting. The percentage of viable cells in the non-treated set of wells was considered to be 100 and the percentage viability following treatment was calculated accordingly. IC 50 values were calculated from graphs plotted using these percentages. Table 4 depicts the IC 50 values of compounds of Example 1-40 in individual cell lines.
[0318] The abbreviations for the Cell Lines as used in Table 4 are:
[0000]
Type of
Cancer
Abbreviation
Cell Line
Abbreviation
Lung
C1
A549
C1a
H460
C1b
Prostate
C2
PC3
C2a
Ovarian
C3
A2780
C3a
OVCAR 3
C3b
Colon
C4
HCT116
C4a
Pancreatic
C5
PANC 1
C5a
AsPC 1
C5b
BxPC3
C5c
Breast
C6
MDA MB 231
C6a
MDA MB 468
C6b
MCF7
C6c
BT 549
C6d
T47D
C6e
Glioblastoma
C7
U 373
C7a
U 87 MG
C7b
[0000]
TABLE 4
Example No.
Cell Lines
1
2
3
4
5
6
9
10
11
12
C1
C1a
−−
−−
++
++
++
+
++
++
+
++
C1b
++
+++
+++
++
++
+
−−
−−
−−
++
C2
C2a
++
+++
+++
++
++
++
−−
−−
−−
+
C3
C3a
+++
+++
+++
−−
−−
−−
+++
++
+
++
C3b
++
++
++
+
+
+
−−
−−
−−
−−
C4
C4a
−−
−−
++
+
+
+
+
++
+
+
C5
C5a
−−
−−
++
−−
−−
−−
+
+
+
−−
C5b
−−
−−
++
−−
−−
−−
−−
−−
−−
−−
C5c
−−
−−
+++
−−
−−
−−
−−
−−
−−
−−
C7
C7a
+
+
+
+
+
+
−−
−−
−−
−−
C7b
−−
−−
++
++
++
+
−−
−−
−−
−−
Example No.
Cell Lines
13
15
17
18
19
21
22
23
24
C1
C1a
+
+
++
++
+++
+
+
+
−−
C1b
+
−−
++
+++
++
−−
−−
−−
+
C2
C2a
+
−−
++
++
++
−−
−−
−−
+
C3
C3a
−−
+
+++
+++
−−
−−
−−
−−
+
C3b
+
−−
−−
−−
+
−−
−−
−−
−−
C4
C4a
+
++
++
++
+
+
+
+
+
C5
C5a
−−
+
−−
−−
−−
−−
−−
−−
−−
C5b
−−
−−
++
++
−−
−−
−−
−−
−−
C5c
−−
−−
++
++
+
−−
−−
−−
−−
C7
C7a
+
−−
−−
−−
−−
−−
−−
−−
−−
C7b
+
−−
−−
−−
−−
−−
−−
−−
−−
Example No.
Cell Lines
25
27
30
31
33
36
37
38
39
C1
C1a
+
+++
++
++
++
++
++
+++
+
C1b
+
+++
+++
−−
++
+++
++
+++
−−
C2
C2a
+
+++
++
−−
+
+
++
+++
−−
C3
C3a
+
+
+++
+
−−
−−
−−
+
−−
C3b
−−
+++
+++
−−
+
+
++
+++
−−
C4
C4a
−−
++
+++
+
+
+
+
+
+
C5
C5a
−−
+++
++
+
−−
−−
−−
+++
−−
C5b
−−
+++
++
−−
−−
−−
−−
+++
−−
C5c
−−
−−
+++
−−
−−
−−
−−
−−
−−
C6
C6a
−−
+++
−−
−−
−−
−−
−−
+++
−−
C6b
+
−−
−−
−−
−−
−−
−−
−−
−−
C6c
−−
+++
−−
−−
−−
−−
−−
+++
−−
C6d
+
+++
−−
−−
−−
−−
−−
+++
−−
C6e
−−
+++
−−
−−
−−
−−
−−
+++
−−
C7
C7a
−−
−−
+++
−−
+
+
+
−−
−−
C7b
−−
−−
−−
−−
+
+
+
−−
−−
IC 50 Ranges in μM
+ IC 50 > 3
++ 3 ≧ IC 50 > 1
+++ 1 ≧ IC 50
−− Not Tested
Example 44
In Vitro Screening to Identify Inhibitors of IL-6 and TNF-α
Human Monocyte Assay
[0319] The assay was designed as in the reference, Physiol. Res., 2003, 52, 593-598, the disclosure of which is incorporated by reference for the teaching of the assay.
[0320] Peripheral blood mononuclear cells (hPBMC) were harvested from human blood and suspended in RPMI 1640 culture medium containing 10% FCS, 100 U/mL penicillin and 100 mg/mL streptomycin (assay medium). Monocytes in the hPBMCs were counted using a Coulter Counter following which the cells were resuspended at 2×10 5 monocytes/mL. A cell suspension containing 2×10 4 monocytes was aliquoted per well of a 96-well plate. Subsequently, the hPBMCs were incubated for 4-5 hours at 37° C. under 5% CO 2 (During the incubation, the monocytes adhered to the bottom of 96-well plastic culture plate). Following the incubation, the non-adherent lymphocytes were washed with assay medium and the adherent monocytes re-fed with assay medium. After a 48-hour incubation period (37° C., 5% CO 2 ), monocytes were pretreated with various concentrations of compounds of Example 1-40 (prepared in DMSO) or vehicle (0.5% DMSO) for 30 minutes and stimulated with 1 μg/ml LPS ( Escherchia coli 0111:B4, Sigma Chemical Co., St. Louis, Mo.). The incubation was continued for 5 hours at 37° C., 5% CO 2 . Supernatants were harvested, assayed for IL-6 and TNF-α by ELISA as described by the manufacturer (BD Biosciences, USA). Dexamethasone (10 μM) was used as standard for this assay. The 50% inhibitory concentration (IC 50 ) values were calculated by a nonlinear regression method. In all experiments, a parallel plate was run to ascertain the toxicity of compounds of Example 1-40. The toxicity was determined using the MTS assay as described in Am. J. Physiol. Cell Physiol., 2003, 285, C813-C822. The results are indicated in table 4 and 5.
[0321] Results: Several compounds in this series show potent anti-inflammatory activity as evidenced by (i) robust inhibition of induced cytokine production and (ii) greater than 10 fold difference between IC 50 for toxicity and IC 50 for cytokine inhibition.
[0322] Biological results for IL-6 and TNFα inhibition are indicated in Table 5 and Table 6 respectively.
[0000]
TABLE 5
Example No.
IL-6 (IC 50 )
Example No.
IL-6 (IC 50 )
1
++
2
+++
3
+++
4
+++
6
+
9
++
10
+
11
+
12
+
14
+++
15
+++
17
+++
18
+++
21
+++
22
++
25
+
27
++++
30
++++
32
+
33
+
37
++++
38
++++
39
++++
[0000] TABLE 6 Example No. TNFα (IC 50 ) Example No. TNFα (IC 50 ) 2 ++++ 27 ++++ 30 ++++ 33 ++++ 37 ++++ 38 ++++ IC 50 Ranges in μM + IC 50 > 30 ++ 30 ≧ IC 50 > 10 +++ 10 ≧ IC 50 > 1 ++++ IC 50 ≦ 1
Conclusion: Certain compounds of the present invention were found to be TNF-α and IL-6 inhibitors.
Example 45
In vivo Studies
[0323] In-vivo efficacy of the compounds of the present invention was tested in colorectal cancer (cell line HCT116) tumor model Animals were housed and cared for in accordance with the Guidelines in force published by CPCSEA (Committee for the Purpose of Control and Supervision of Experiments on Animals), Tamil Nadu, India. Procedures using laboratory animals were approved by the IAEC (Institutional Animal Ethics Committee) of the Research Center of Piramal Life Sciences Limited, Mumbai, India.
[0324] Compound storage: All the compounds including standard were stored at 4-8° C. in an amber colored bottle. The compounds in solutions were also maintained at 4-8° C. in a refrigerator. Sample for animal injection was made fresh everyday.
[0325] Dose preparation: Required compound was weighed and mixed with 0.5% (w/v) carboxymethyl cellulose (CMC) and triturated with Tween-20 (secundum artum) with gradual addition of water to make up the final concentration.
[0326] Efficacy study in SCID mice: Severely Combined Immune-Deficient (SCID strain-CBySmn.CB17-Prkdc scid /J, The Jackson Laboratory, Stock #001803) male mice weighing about 20 g of 6-9 weeks old were used in the study.
[0327] HCT116 cells were grown in McCoy's 5A medium containing 10% fetal calf serum in 5% CO 2 incubator at 37° C. Cells were pelleted by centrifugation at 1000-rpm for 10 minutes. Cells were resuspended in sterile 1×PBS to get a count of 25×10 6 cells per mL, 0.2 mL of this cell suspension (corresponding to 5×10 6 cells) was injected by subcutaneous (s.c.) route in SCID mice. Mice were observed every alternate day for palpable tumor mass. Once the tumor size reached a size of 5-7 mm in diameter, animals were randomized into respective treatment groups. Dose was administered every day for 14 days. Tumor size was recorded on every second day.
[0328] Tumor weight (mg) was estimated according to the formula for a prolate ellipsoid: {Length (mm)×[width (mm) 2 ]×0.5}assuming specific gravity to be one and π to be three. Tumor growth in compound treated animals was calculated as
[0000] T/C (Treated/Control)×100% and Growth inhibition Percent (GI %) was [100−T/C %].
[0000] Certain representative compounds within the scope of the present invention show moderate to significant in vivo antitumor activity in HCT116 xenograft model.
[0000]
% growth inhibition on
Example
14 th day
No. of mice per group
Dose (Oral)
27
36
7
50 mpk
30
35
7
50 mpk
38
17
7
50 mpk
Conclusion:
[0329] All three compounds showed oral efficacy.
[0330] It should be noted that, as used in this specification and the appended claims, the singular forms “a”, “an”, and “the” include plural referents unless the content clearly dictates otherwise. Thus, for example, reference to a composition containing “a compound” includes a mixture of two or more compounds. It should also be noted that the term “or” is generally employed in its sense including “and/or” unless the content clearly dictates otherwise.
[0331] All publications and patent applications in this specification are indicative of the level of ordinary skill in the art to which this invention pertains.
[0332] The invention has been described with reference to various specific and preferred embodiments and techniques. However, it should be understood that many variations and modifications may be made while remaining within the spirit and scope of the invention. | The present invention provides the compounds of formula (I):
The present invention relates to imidazo[4,5-c]quinoline derivatives of formula (I), process for their preparation, pharmaceutical compositions containing them and their use in the treatment of diseases mediated by phosphatidylinositol-3-kinase (PBK) and/or mammalian target of rapamycin (mTOR) and/or tumor necrosis factor-α (TNF-oc) and/or interleukin-6 (IL-6), particularly in the treatment of cancer and inflammation. | 2 |
TECHNICAL FIELD
[0001] The present invention relates to nonwoven structures, and more particularly to a structure of laminate construction having multiple layers of nonwoven material in overlying adhesive bonded relationship to one another. In addition, the structure may also be characterized by a relatively high thickness and density. A method for forming such a structure is also provided.
BACKGROUND OF THE INVENTION
[0002] It is well known to form nonwoven structures through the needle punching of staple fibers. In such an operation, a plurality of barbed needles are passed through a collection of such fibers in a repeating fashion so as to result in the intimate entanglement of such fibers with one another. As the level of entanglement is increased, the individual fibers are formed into a cohesive fiber batt. Continued needling of the fiber batt tends to increase the density and structural integrity thereof due to increasing levels of entanglement between the individual component fibers.
[0003] In some applications it is desirable to use nonwoven structures of relatively substantial thickness due to the performance characteristics associated with such materials. Those performance characteristics may include enhanced structural integrity, abrasion resistance, rigidity and/or noise dampening properties. However, the production of such high thickness materials may require the use of specialized and/or dedicated equipment thereby increasing the cost of production.
[0004] In some applications such as metal wiping or polishing operations, it may further be desirable for the structure to be characterized by a combination of substantial thickness and density so as to prolong the useful life of the article. However, the production of articles exhibiting characteristics of both substantial thickness and high density has been generally difficult to achieve in an efficient manner using standard needling equipment and practices due to the substantial number of needle passes required to produce such a product.
[0005] It would be desirable to have a highly efficient and cost effective method of producing nonwoven structures of relatively substantial thickness using standard needling equipment. In particular, it would be desirable to have a method to produce nonwoven structures of virtually any desired thickness without regard to needle length and needling equipment limitations.
[0006] The difficulties associated with the production of high thickness nonwoven structures are further compounded in the production of higher density products. In particular, it has been found that in order to obtain higher density materials, the product must undergo a substantially increased level of needling which tends to increase manufacturing cost. In addition, as the thickness of the article is increased, the resistance encountered by the needles is likewise increased thereby tending to damage or dislodge the individual needles used in the operation. Furthermore, even if the needles are not damaged or dislodged, the product which can be produced is nonetheless limited in thickness by the finite length of the needles which are used.
SUMMARY OF THE INVENTION
[0007] The present invention provides advantages and alternatives over the prior art by providing a nonwoven structure of virtually any desired thickness which may be produced in a highly efficient and cost effective manner. The present invention utilizes a laminate construction wherein individually formed lengths of fiber batting such as air laid or needle punched batting are adhesively bonded to one another by intermediate layers of adhesive to achieve a composite laminate structure of desired thickness. The adhesive bonding is preferably achieved through utilization of an adhesive disposed in localized fashion between the layers of fiber batting which may otherwise be substantially free of any adhesive constituent. The adhesive may be activated within a heated press or calender thereby bonding the individual layers of fiber batting together. The adhesive may be in the form of an activatable sheet material or fabric which may be lightly secured in place between layers of fiber batting through use of a needling operation preceding adhesive bonding such that there is a combination of mechanical and adhesive bonding between adjacent layers of fiber batting. Other adhesives such as liquid adhesives may also be utilized. The structure may be built to any desired thickness through the addition of layers of fiber batting material.
[0008] The present invention provides yet further advantages and alternatives over the prior art by providing a nonwoven structure characterized by both substantial thickness and enhanced density which may be produced in a highly efficient and cost effective manner. The present invention utilizes a laminate construction wherein individually formed lengths of enhanced density fiber batting of thickness as may be formed on standard needle looms are adhesively bonded to one another to achieve a composite laminate structure of virtually any desired thickness. The adhesive bonding is preferably achieved through utilization of an adhesive disposed in localized fashion between the layers of fiber batting which may otherwise be substantially free of any adhesive component. The adhesive may be activated within a heated press or calender thereby bonding the individual layers of fiber batting together and further increasing the density of the structure. The resultant structure of high density material may be built to any desired thickness through the addition of further layers.
[0009] According to one potentially preferred aspect of the present invention, these advantages and features may be accomplished by providing a structure having a plurality of layers of nonwoven fiber batting bonded in laminating relation to one another by a localized adhesive disposed between the layers. The adhesive between the layers of fiber batting preferably extends across the interface between the adjacent layers so as to at least partially penetrate each of the layers thereby enhancing the bond strength between the layers. The bond strength between the layers and the uniformity of the resultant bonded structure may be further enhanced by forcibly intermingling the fibers from at least one layer of batting with the material forming the adhesive such as by needling prior to activation of the adhesive such that a portion of the fibers forming the layers of batting extends across the adhesive between the bonded layers thereby giving rise to both mechanical and adhesive bonding between the individual layers of batting.
[0010] In accordance with another potentially preferred aspect of the present invention, the structure may be characterized by a thickness of about 6.35 mm or greater.
[0011] In accordance with still another potentially preferred aspect of the present invention, the structure may be characterized by a density in the range of about 0.10 to about 0.55 grams per cubic centimeter.
[0012] In accordance with yet another potentially preferred aspect of the invention, the structure may be formed from individual fiber batting layers which are either similar or dissimilar in terms of construction and/or fiber composition.
[0013] In accordance with yet another potentially preferred aspect of the invention, the structure may be formed using multiple adhesive layers which are either similar or dissimilar from one another.
[0014] According to yet a further potentially preferred aspect of the invention, the adhesive utilized to bond the layers of nonwoven fiber batting together may be either a liquid or dry adhesive. Such dry adhesives may be in the form of an activatable solid such as a film or fabric-like web.
[0015] In accordance with still a further aspect of the present invention, the adhesive utilized to bond the layers of nonwoven fiber batting together may be activated in selected areas such that the bonding between the layers is in a pattern.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] The present invention will now be described, by way of example only, with reference to the accompanying drawings, in which:
[0017] FIG. 1 . illustrates an embodiment of a nonwoven structure according to the present invention.
[0018] FIG. 2 is a flow diagram of the steps performed in a potentially preferred process for formation of a nonwoven structure according to the present invention;
[0019] FIG. 3 illustrates the formation of a preliminary fiber batt for subsequent processing according to the potentially preferred process of the present invention;
[0020] FIG. 4 illustrates the needling of a plurality of fiber batts as formed in FIG. 3 so as to combine such batts into an enhanced density batting material;
[0021] FIG. 5 illustrates the formation of a sandwich structure of adhesive between layers of enhanced density batting material as formed in FIG. 4 ; and
[0022] FIG. 6 illustrates the delivery of a sandwich structure as may be formed in FIG. 5 to a press or calender unit for activation of the adhesive within the sandwich structure.
[0023] While the invention has been illustrated and generally described above and will hereinafter be described in detail in connection with certain potentially preferred embodiments and practices, it is to be understood that both the foregoing general description as well as the illustrated embodiments and practices and corresponding detailed description are exemplary and explanatory only and are not to be construed as restrictive of the invention in any way. On the contrary, it is intended that the present invention shall extend to all alternatives, modifications and equivalents as may embrace the principles of this invention within the true spirit and scope thereof.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0024] Referring now to the drawings, in FIG. 1 , there is shown a cross section of a nonwoven structure 10 according to the present invention. The nonwoven structure 10 is contemplated to be useful in a number of applications as may require relatively substantial thickness in either low or high density constructions. One such application which is particularly contemplated is the wiping or polishing of metal articles (now shown) such as steel rolls and the like. As will be appreciated, such polishing operations may require the nonwoven structure 10 to have sufficient fiber density to avoid undue degradation during the wiping or polishing operation. Moreover, it may be desirable for the nonwoven structure 10 to have a sufficient thickness to avoid the need for repair or replacement on a frequent basis.
[0025] As illustrated, the nonwoven structure 10 preferably includes a first layer 14 of a nonwoven fiber batting adhesively bonded to a second layer 16 of nonwoven fiber batting by an adhesive 18 in a manner to be discussed further hereinafter. It is to be understood that for illustrative purposes, the relative thickness of the adhesive layers within the nonwoven structure 10 is greatly enlarged, whereas in the potentially preferred embodiment, the adhesive will preferably occupy a relatively thin cross section within the nonwoven structure 10 thereby being substantially unnoticeable and giving the appearance of a single continuous layer. According to the illustrated and potentially preferred embodiment, the nonwoven structure 10 may further include at least a third layer of nonwoven fiber batting 24 bonded in laminated relation to the first layer 14 of nonwoven fiber batting by a layer of adhesive 20 thereby forming a structure 10 having three layers of nonwoven fiber batting 14 , 16 , 24 and two layers of adhesive 18 , 20 .
[0026] While the nonwoven structure 10 as illustrated in FIG. 1 , may be potentially preferred for some applications, it is contemplated that a greater or fewer number of layers of nonwoven fiber batting may likewise be incorporated as desired. Thus, by way of example only, it is contemplated that one or more additional layers (not shown) of nonwoven fiber batting may be bonded to the outer surfaces 27 , 28 of the illustrated nonwoven structure 10 by additional layers of adhesive so as to form a composite structure of any thickness as may be desired. It is likewise contemplated that one or more layers of material other than nonwoven fiber batting such as woven, knit, stitched, or thermal bonded material may also be incorporated into the laminate in substitution for one or more layers of fiber batting to thereby derive the aesthetic and/or functional characteristics of such material.
[0027] According to the illustrated and potentially preferred embodiment of the present invention, the layers 14 , 16 , 24 of the nonwoven structure 10 are preferably formed from a plurality of staple fibers which have been joined into a substantially cohesive and stable structure by needling operations as are well known to those of skill in the art. It is contemplated that the staple fibers which make up the layers 14 , 16 , 24 of nonwoven fiber batting may be of any type suitable for entanglement. By way of example only, and not limitation, such fibers may include polyester fibers, wool fibers, polypropylene fibers, acrylic fibers, NOMEX® fibers, acetate fibers, aramid fibers, rayon fibers, and blends thereof. Fibers characterized by a linear density in the range of about 2 denier to about 15 denier having an average staple length in the range of about 50 mm to about 105 mm may be preferred. Polyester fibers may be particularly preferred. It is contemplated that the layers 14 , 16 , 24 need not include any internal adhesive constituent due to the bonding provided by the individual layers of adhesive 18 , 20 , although such a constituent may be included if desired.
[0028] While in many instances it may be desirable that each of the layers 14 , 16 , 24 of nonwoven fiber batting be substantially similar in character and composition to one another, it is likewise contemplated within the scope of the present invention that such layers may be dissimilar in terms of chemical composition of the materials forming such layers and/or in terms of the physical character of such layers. As will be appreciated, in the event that the third layer 24 of nonwoven fiber batting is dissimilar to the second layer 16 of nonwoven fiber batting, the outer surfaces 27 , 28 of the nonwoven structure 10 will have differing character and consequently different performance characteristics which may be desired in some applications.
[0029] While the layers of adhesive 18 , 20 may be substantially similar to one another, it is contemplated that the layers of adhesive 18 , 20 may also differ from one another in physical and/or chemical character including melting point or chemical resistance such that the performance of such layers will differ across the final nonwoven structure 10 . By way of example only, it is contemplated that the material forming the adhesive layers may differ in the event that the layers of nonwoven fiber batting are dissimilar in different regions of the structure 10 .
[0030] FIGS. 2-6 illustrate one potentially preferred process for forming the nonwoven structure 10 according to the present invention which is characterized by both substantial thickness and density. As illustrated, according to such potentially preferred process, nonwoven staple fibers 30 which have undergone traditional carding and cross lapping are conveyed from a cross lapper 32 to a batt-forming needle loom 34 . As the fibers 30 are conveyed through the batt-forming needle loom 34 , the needles thereof are reciprocated through the cross lapped fibers so as to enhance the entanglement thereof and to thereby produce a roll of fiber batting material 38 which may be taken up on an A-frame or other support device 40 . Such fiber batting material will preferably have a thickness in the range of about 2 mm to about 10 mm with a density in the range of about 0.065 to about 0.075 grams per cubic centimeter and will most preferably have a thickness of about 5.2 mm with a density of about 0.072 grams per cubic centimeter.
[0031] As illustrated in FIG. 4 , following the formation of the rolls of fiber batting material 38 , according to the potentially preferred practice of the present invention a plurality of such rolls of fiber batting material 38 may thereafter be conveyed to a combining and densification station 50 . At the combining and densification station 50 , the batting material 38 is conveyed in layered orientation to a combining needle loom 52 which serves to substantially connect the layers of fiber batting material 38 together. The resultant combined material is thereafter transported through densifying needle looms, 53 , 54 which are preferably arranged in series with the combining needle loom 52 as shown. The resultant product is an enhanced density batting material 56 which preferably has a thickness in the range of about 3 mm to about 19 mm with a density in the range of about 0.1 to about 0.4 grams per cubic centimeter and will most preferably have a thickness of about 5.7 mm with a density of about 0.24 grams per cubic centimeter.
[0032] According to the potentially preferred practice of the present invention, following formation of the enhanced density batting material 56 , a plurality of such rolls of enhanced density batting material 56 are thereafter conveyed to a laminate formation station 60 as illustrated in FIG. 5 . At the laminate formation station 60 the enhanced density batting material 56 is preferably conveyed in overlying and underlying relation to intermediate layers of adhesive material 62 thereby forming a sandwich structure 66 in which the adhesive material 62 is disposed between the layers of enhanced density batting material 56 . While the formation of a sandwich structure 66 incorporating only three layers of enhanced density batting material 56 is illustrated thereby corresponding substantially to the illustrated nonwoven structure 10 in FIG. 1 , it is to be understood that a larger number of layers of enhanced density batting material 56 may likewise be formed into a sandwich structure 66 with intermediate layers of adhesive material 62 between such layers if desired. It is likewise contemplated that materials other than batting material such as woven, knit, stitched, or thermal bonded material may be substituted for one or more of the rolls of enhanced density batting material 56 during formation of the sandwich structure 66 so as to derive the properties of such materials.
[0033] According to the potentially preferred practice, the resultant layered sandwich structure 66 is thereafter conveyed through an entangling needle loom 64 which serves to mechanically intermingle a portion of the fibers from one or more layers of enhanced density batting material 56 with the adhesive material 62 and with the adjacent layer of batting or other material as may be incorporated within the sandwich structure 66 thereby mechanically binding the layers of the sandwich structure 66 together and increasing overall strength. Such a mechanical joining operation preferably results in a portion of the fibers 30 extending substantially across the thickness of the layered sandwich structure 66 and thus through multiple layers of the nonwoven article 10 formed therefrom as best seen in FIG. 1 .
[0034] While the adhesive material may be any wet or dry adhesive as may be suitable to bind the adjacent layers of nonwoven material together, it is contemplated that the adhesive material 62 will preferably be a dry adhesive in web form such as a film or generally scrim-like fabric construction so as to promote the ease of use of the adhesive in roll form and to further permit the relatively easy mechanical intermingling to be carried out by the entangling needle loom 64 . The adhesive material is preferably of a nature such that it can be activated upon demand through the application of a predetermined driving force such as heat, hot gas, chemical interaction, ultrasonic energy, radio frequency radiation waves and the like. The adhesive utilized will also preferably not substantially alter the physical character of nonwoven batting material in features such as filtration, fluid retention and fluid transfer. Further, it is contemplated that the adhesive should provide necessary resistance to heat, humidity and chemical interaction so as to avoid any premature delamination. In particular, it is contemplated that the adhesives utilized should be useful over a wide range of temperatures from about minus 30 degrees Celsius to about 180 degrees Celsius. One such heat activated adhesive which may be particularly preferred is a spunbond adhesive fabric believed to be available under the trade designation SPUNFAB® adhesive fabric from Dry Adhesive Technologies Inc. having a place of business at Cuyahoga Falls, Ohio, USA. According to the potentially most preferred embodiment, the adhesive is the SPUNFAB® type PA1001 polyamide adhesive fabric. However, other such adhesive fabrics of polyester, polyolefin, and ternary systems are also contemplated.
[0035] It is to be appreciated that in some instances the utilization of the entangling needle loom 64 to mechanically bond the adhesive material 62 between the layers of nonwoven fiber batting may be avoided if proper placement of the adhesive between the layers of nonwoven fiber batting is maintained. However, in the event that the entangling operation is carried out, the resultant sandwich structure which preferably incorporates three layers of nonwoven batting material 56 and two layers of adhesive material 62 will preferably have a density in the range of about 0.1 to about 0.4 grams per cubic centimeter and will most preferably have a density of about 0.27 grams per cubic centimeter.
[0036] While the resultant sandwich material 66 is illustrated as being collected in roll form, in any event that such sandwich material has a thickness greater than about 25 mm, it may be preferable to collect such material as a flat sheet for further processing.
[0037] According to the potentially preferred practice of the present invention wherein the adhesive material 62 is activated by heat, following the relative placement of the adhesive material 62 between the layers of batting material 56 , the resultant sandwich material 66 is thereafter passed to a heated platen press or calender unit 70 as will be well known to those of skill in the art. Upon introduction to the heated platen press or calender unit 70 , the sandwich material 66 is subjected to heat and pressure so as to activate the adhesive and further enhance the density of the batting material 56 as may be desired up to about 0.55 grams per cubic centimeter. Such activation results in the adhesive material 62 undergoing a phase transformation from solid to viscous fluid thereby permitting the adhesive material to flow into the overlying and underlying batting material 56 so as to form an adhesive bond between such materials. Within the press or calender unit 70 , shims are preferably utilized at the edges of the sandwich material 66 so as to obtain a controlled degree of compression within the batting material 56 . After cooling to stabilize the activated adhesive material 62 , the felt structure 10 according to the present invention is obtained.
[0038] While bonding along the entire surface of the adjacent layers of batting material 56 may be desirable in many instances, it is also contemplated that activation may be selective so as to result in a discontinuous patterned bond such that some areas are left unbonded. By way of example only, it is contemplated that such a patterned bond may be effected in an efficient manner through use of directional bonding procedures including the application of radio frequency radiation or ultrasonic energy.
[0039] In the event that additional thickness is desired, it is contemplated that the composite which exits the press or calender unit 70 may be returned to the laminate formation station 60 for the application of additional layers of nonwoven batting 56 and intermediate adhesive material 62 so as to form an expanded sandwich material. If desired, a mechanical bonding operation may be performed at the entangling needle loom 64 to hold such additional layers of nonwoven batting 56 in place against the outer surface 27 , 28 ( FIG. 1 ) of the previously formed composite. The expanded sandwich material may thereafter be passed through the heated platen press or calender unit 70 for activation of the newly applied adhesive material. This procedure for the addition of material may thereafter be repeated until such time as a desired thickness is achieved.
[0040] It is contemplated that the lamination process according to the present invention may be useful in the formation of nonwoven structures 10 of virtually any thickness characterized by either a high or low density although it may be most useful in the production of nonwoven structures characterized by a thickness of greater than or equal to about 6.3 mm. In the event that a high density product is desired, the procedures as outlined above may be utilized. In the event that a lower density product is desired, the procedures which result in material densification may be substantially curtailed although the use of mechanical entanglement between adjacent layers may still be potentially preferred.
[0041] The procedures and features of the present invention may be further understood through reference to the following non limiting example:
EXAMPLE
[0042] A felt structure was formed of 3 denier 76.2 mm polyester staple fiber by carding, cross lapping and needling the fiber to form preliminary fiber batts having a thickness of about 5.2 mm and a density of about 0.071 grams per cubic centimeter. Four of such preliminary fiber batts were thereafter combined and densified in a three stage needling loom thereby forming an enhanced density fiber batt having a thickness of about 5.7 mm and a density of about 0.238 grams per cubic centimeter. Three of such enhanced density fiber batts were thereafter passed through a single stage needling loom in sandwiching relation to two layers of a scrim fabric of meltable polyamide adhesive having an area density of about 27.1 grams per square meter thereby binding the scrim fabric between the fiber batts such that fibers from the fiber batts and the scrim fabric are mechanically entangled. The resulting sandwich structure had a thickness of about 15 mm and a density of about 0.27 grams per cubic centimeter. The sandwich structure was thereafter passed to a heated platen press where it was subjected to a pressure of 14.2 Kg per square cm at 155 degrees Celsius. Shims having a thickness of 14 mm were inserted on either side of the sandwich structure to limit compression. After cooling, the resultant product was measured to have a thickness of about 12.7 mm and a density of about 0.32 grams per cubic centimeter. The resultant product was useful as a pad for the wiping and polishing of metal articles. | A nonwoven composite structure having a plurality of layers of nonwoven fiber batting bonded in laminating relation to one another by a localized adhesive disposed between the layers. The adhesive between the layers of fiber batting preferably extends across the interface between the adjacent layers so as to at least partially penetrate each of the layers thereby enhancing the bond strength between the layers. The bond strength between the layers and the uniformity of the resultant bonded structure may be further enhanced by forcibly extending fibers from at least one layer of batting through the material forming the adhesive such as by needling prior to activation of the adhesive such that a portion of the fibers forming the layers of batting extends across the adhesive between the bonded layers. | 3 |
BACKGROUND AND SUMMARY OF INVENTION
This invention relates to a method and apparatus for handling business forms and, more particularly, for transporting compacted forms.
This invention is an improvement on the printed forms transport (hereafter "PFT") of Wallace Computer Services, Inc., of Hillside, Ill. and also the competitive prior art transport seen in U.S. Pat. No. 5,061,233.
The PFT is a receiver for zig-zag folded forms which normally have been generated by a computer printer and folder/compactor. These machines operate at high speed and it is difficult to coordinate them with other machines employed by companies who process large volumes of business forms. Most notably, the output of the computer printer and folder/compactor goes to a machine called an inserter--sometimes referred to as a forms utilization unit. In many instances, the machinery creating the final forms is located in one section of a forms processing plant while the inserter(s) are located in another area. This has necessitated the need for transport from the first to the second area. It was for this purpose that the PFT and '233 constructions were developed.
The transports or carts of the prior art had the disadvantages of being cumbersome, expensive, and difficult to use. In particular there was a difficulty in splicing the forms from a subsequent run to a previous run so as to have continuous operation at the inserter.
All of the drawbacks of the prior art have been solved according to the instant invention by modifying the prior art PFT by providing a removable flat plate dolly at the forms entering end. This dolly not only performs the function of delimiting the length of the stack of zig-zag folded forms but additionally serves as a convenient, inexpensive and highly reliable wheeled transport between the generation and finishing areas of the plant or factory.
Other objects and advantages of the invention may be seen in the details set down in the ensuing specification.
BRIEF DESCRIPTION OF DRAWINGS
The invention will be explained in conjunction with the accompanying drawings, in which
FIG. 1 is a perspective view of the prior art receiver shown during the loading operation;
FIG. 2 is a perspective view of the prior art receiver in the process of transferring the forms to the inserter;
FIG. 3 is a fragmentary perspective view of the inventive receiver from the end equipped with the novel dolly;
FIG. 4 is another perspective view of the invention shown with the dolly in loaded condition and ready for transport;
FIGS. 5-8 are schematic views showing the overall operation of the inventive receiver and relating respectively to loading, unloading onto the dolly, transporting and inserting/feeding the inserter;
FIG. 9 is a fragmentary perspective view of the preferred embodiment of the invention and showing the dolly inserted in place at the entering end of the receiver box means preparatory to transport;
FIG. 10 is another fragmentary perspective view which differs from FIG. 9 in showing that a portion of the zig-zag folded forms at the very end of the run has been pulled away from the dolly and laid on the zig-zag folded stack;
FIG. 11 is another fragmentary perspective view and showing the use of a strap for securing the zig-zag folded stack in place;
FIG. 12 is another fragmentary perspective view and features a subsequent step in the operation of the invention wherein the box means of the receiver is tilted from the condition illustrated in FIG. 11;
FIG. 13 is another fragmentary perspective view of the operation of the invention and with the receiver box means disposed vertically so that the stack is entirely supported on the dolly;
FIG. 14 is a perspective view of a subsequent operation wherein the dolly has been removed from its position on the receiver and a flat plate pressed on the stack to prevent undesirable curl;
FIG. 15 is a fragmentary perspective view of the dolly supporting the stack and equipped with the anti-curl plate and with the stack strapped in place;
FIG. 16 is another fragmentary perspective view showing the dolly in the process of being moved from the folder/compactor location to an inserter location;
FIG. 17 is a fragmentary perspective view showing a new stack on a new dolly having its top or leading end form spliced to the trailing end form of a preceding stack, the preceding stack being in the process of being fed into the inserter;
FIG. 18 is another fragmentary perspective view showing the splicing being completed between the two stacks and the previous stack having its forms fed into the inserter;
FIG. 19 is a perspective view of a hand truck advantageously employed in collecting empty dollies and showing a first dolly being installed on the hand truck for removal from the inserter area back to the folder/compactor area;
FIG. 20 is a view subsequent in the operation of the phase of the invention of returning the dolly to the folder/compactor area wherein the anti-curl plate is in the process of being installed over the dolly;
FIG. 21 is still another perspective view showing a second dolly being installed on the hand truck above the anti-curl plate which was installed in the showing in FIG. 20;
FIG. 22 is a fragmentary end elevational view of the inventive receiver as seen from the "closed" end of the box means which supports the compacted stack and which features a part of the supporting surface of the dolly at the upper portion of the view;
FIG. 23 is a side elevational view of the inventive receiver in the condition depicted in FIG. 22;
FIG. 24 is another side elevational view, somewhat schematic showing the receiver with the box means vertically disposed so that the dolly is located on the floor for removal to another area; and
FIG. 25 is a perspective view of the inventive receiver as seen from the closed end and with the box means tilted for compacting the stack preparatory to removal of the dolly.
DETAILED DESCRIPTION
Prior Art
Referring to FIG. 1, the symbol FC designates generally a folder-compactor which develops a stream of zig-zag folded forms in a partially compacted condition--the forms being designated F. The forms are seen to be supported on a box means B which is the upper portion of the receiver generally designated R. The box means portion is supported on the undercarriage U portion of the receiver R. The undercarriage U includes a generally rectangular wheel-equipped chassis C.
After a predetermined number of forms have been introduced into the box means B, an end plate E (see FIG. 2) is inserted to delimit the end or size of the stack--the end plate E being seen at the center bottom of FIG. 2. Thereafter, the receiver is moved from the folder/compactor FC to the inserter I. In FIG. 2, the forms F are being seen in the process of being introduced into the inserter I--being threaded over turning means T at both the top and bottom of the box means B.
The Invention
Reference is now made to FIG. 3 wherein the numeral 30 designates generally the inventive receiver which includes an undercarriage 31 which is generally the same as the undercarriage of the prior art--but with changes in construction to permit the novel operation of the instant invention.
The number 32 designates a box means mounted on the undercarriage 31 which is generally analogous in function to that of the prior art box means B. Here the end wall 33 at the closed end of the box means 32 is straight--not having the curved end wall configuration W of the prior art PFT of FIG. 1.
A significant change from the prior art is found in the removably mounted dolly 34 which is supported on posts 35 extending upwardly from the corners at the open end of the box means 32.
The dolly 34 includes by having a flat plate 36 and four casters or wheels 37 to promote easy shifting of the dolly 34 from place to place. Additionally, the underside of the plate 36 has retractable strap means as at 38 and 39 which develop the confinement of completed stacks as seen in FIG. 4. The straps 38, 39 are similar to automobile seat belts in being spring loaded for easy retractability. However, other strapping constructions may be employed.
In FIG. 4, the box means 32 is seen to be vertically oriented so that the dolly 34 can be rolled away from the posts 35 and wherein the stack S (topped with an anti-curl plate 40) is strapped in place by the straps 38 and 39. A variety of strapping can be employed but we find it advantageous to use strapping with a Velcro-type fastening.
Operation Generally
In FIG. 5, the receiver 30 is seen in the process of being loaded. For example, the loading comes in from the folder/compactor FC to the box means 32 and wherein the undercarriage 31 has the box mean 32 disposed horizontally. The posts 35 are ready for dolly insertion.
FIG. 6 illustrates a subsequent step in the operation where the stack is now unloaded from the box means 32 and supported on the dolly 34. FIG. 7 shows the dolly 34 with the strapping 38, 39 around the stack of forms in the process of being transported from one location to another.
Finally, FIG. 8 shows the step of inserting/feeding which embodies the top forms of the stack S being fed into the inserter I. It will be appreciated that it is simple to switch from face up to face down feeding merely by rotating the dolly 180°. This is in studied contrast to the operation of the prior art transports which required a laborious rethreading operation.
Operation in Detail
Reference is first made to FIG. 9. There, the receiver 30 has been moved away from the folder/compactor and the dolly 34 has been installed in the posts 35 so as to serve as a limiting means or separator between two consecutive sets of zig-zag folded forms.
As seen in FIG. 10, the next step in the operation is to pull several trailing end forms F' away from the dolly 35 and lay the same over the zig-zag folded accumulation F--not yet a stack. These forms F'--that have been withdrawn from what will become the bottom of the stack--will be used as seen in FIGS. 17 and 18 to serve as the downstream portion of the splice with the top forms of a following stack. Thus, the invention provides the desired "first in, first out" operation of the form without difficulty.
In FIG. 11, the free end of the strap 38 is seen to be secured at 41 to the closed end wall 33 of the box means 32--a suitable latching means 41 being provided on the outside of end wall 33 in the form of a Velcro-type strip.
In FIG. 12, the now-strapped accumulation of forms with the trailing end forms F' also strapped, is pivoted to about a 70° orientation and becomes, for all practical purposes, a compacted stack. This 70° arc was the extent of the pivoting allowed in the prior art PFT. It is utilized here to cause the various forms in the stack to settle in a stable position prior to removal of the dolly. Pivoting from the horizontal directly to the vertical sometimes causes, the stack to become serpentine --so that it might fall off the dolly during movement from one work station to another. But by momentarily stopping the pivotal movement before reaching the vertical, the forms can even themselves out against the bottom wall 32a of the box means 32.
In FIG. 13, the box means 32 has been pivoted to the vertical orientation so that the stack of forms (still strapped) is supported on the dolly in a stabilized fashion. Such an orientation was not possible nor contemplated in the prior art PFT.
In FIG. 14, the strap 38 has been detached from the latching means 41 and the anti-curl plate 40 is seen laying on the top of the stack. The dolly 34 has been slid off of the angle iron posts 35 and is ready for strapping and relocation.
In FIG. 15 the straps 38, 39 have been installed around the stacks and the plate 40--more particularly through the U-shaped handle 40a of the plate 40. In FIG. 16, a pulling handle 42 has been installed in appropriate holes 36a (see FIG. 3) in the plate 36 of the dolly 34 so that the dolly can be pulled easily from the stacking location to the inserter location.
The remaining views FIGS. 17-21 depict operations performed at the inserter site. In FIG. 17 the leading or top end forms F" of a subsequent stack S' on the dolly 34' are being aligned with the trailing end forms F' of the stack S being fed into the inserter. Again, the stack S' has its trailing end forms F 1 pulled out so as to be ready for splicing when the stack S' is being fed into the inserter. It will be noted that the anti-curl plate 40 has been removed.
The splicing is depicted in FIG. 18 and thereafter the feeding of the forms from the stack S is continued until forms are depleted and then taken from the stack S'. Thereafter, the dolly 34 can be removed from its location adjacent the inserter and the forms from stack S' on dolly 34' fed into the inserter without pause or delay.
After a dolly has been emptied of its stack, it is placed on a hand truck 43 (see FIG. 19). The hand truck is advantageously equipped with a pipe rod 44 and the dolly 34 has an aligning hole 45 for insertion over the pipe rod 44. The next step is seen in FIG. 20 and consists of installing the anti-curl plate 40 over the pipe rod 44--the anti-curl plate being a partner with the dolly as can be seen in FIG. 17. Thereafter, another dolly 134 can be installed over the pipe rod 44 and thus a whole series of dollies and anti-curl plates are installed on the hand truck 43 for convenient and easy relocation to the folder/compactor site.
Undercarriage
The undercarriage 31 is seen in greater detail in FIGS. 22-25. Turning first to FIG. 25, the undercarriage is seen to include a generally H-shaped chassis 46 (also see FIG. 9) which is made up of longitudinal members 47, 48 integrated with transverse members 49 and 50 near the mid points of the longitudinal members, i.e., spaced from the ends. Mounted at the ends of the longitudinal members 47, 48 are wheels or casters 51--four of which are provided as can be appreciated from a comparison of FIGS. 24 and 25.
A pair of uprights 52, 53 extend upwardly from the longitudinal members 47, 48 respectively (see also FIG. 22) and are positioned between the transverse members 49, 50. At their upper ends, the uprights 52, 53 are connected by a cross shaft 54.
Journaled on the cross shaft 54 are trapezoidally shaped plates 55 and 56 (compare the upper portions of FIGS. 22 and 23). Fixed to the trapezoidally shaped plates 55, 56 is a subframe 57 which is generally rectangular in outline--and which carries the box means 32--see, for example, FIG. 9. The subframe 57 and therefore the box means 32 are pivotable between a loading position (horizontal) as seen in FIG. 23 and a discharge position (vertical) as seen in FIG. 24.
Interconnected between the trapezoidally shaped plates 55, 56 and the frame 46 are a pair of shock absorbers 58, 59--best seen in FIG. 22. More particularly, the upper ends of the shock absorbers 58, 59 are pivotally connected to a cross shaft 60 which extends between the trapezoidally shaped plates 55, 56. At their bottom ends, the shock absorbers 58, 59 are pivotally connected to a lower cross shaft 61 (still referring to FIG. 22). It will be noted particularly from FIG. 23 that the upper connection of the shock absorbers to the cross shaft 60 is eccentric to the cross shaft 54. The cross shaft 61 to which the bottom ends of the shock absorbers 58, 59 are connected is itself interconnected between the lower extremities of the uprights 52, 53.
A latching means generally designated 62 and which includes a foot pedal 63 (see the lower left hand portion of FIG. 23) is provided to maintain the box means 32 in two different orientations. The details of the latching means 62 will be described hereinafter but first we describe the operation of the parts of the undercarriage 31 described thus far.
Undercarriage Operation
The beginning of the operation of the undercarriage starts with the box means 32 oriented horizontally as seen in FIG. 23. Depressing the foot pedal 63 unlatches the upper portion of the undercarriage so as to permit pivoting movement of the box means 32. This is conveniently started by grasping the handle means 64 on the closed end wall 33 of the box means 32 (see the upper portion of FIG. 25). The box means 32 and the subframe 57 can then be pivoted away from its horizontal orientation. It will be appreciated that at this stage, the dolly 34 is already installed on the posts 35 (see particularly FIG. 23). As lifting pressure is exerted on the box means 32 through the handle means 64, the shock absorbers 58, 59 contract from the showings in FIGS. 22, 23 to that illustrated schematically in FIG. 24 and designated 58'.
Latching Means
The latching means 62 can be best appreciated from FIG. 22 and include spring-loaded dowels 65, 66 which engage holes in the trapezoidally shaped plates 55, 56 in different portions thereof. For example, in FIG. 23 where the box means 32 is disposed horizontally, the dowels 65, 66 engage aligned openings 67, 68 (see also FIG. 22) in the plates 55, 56 respectively.
We also provide a second pair of openings as at 69 (see the upper central portion of FIG. 23) for maintaining the box means 32 in an orientation of about 70° away from the horizontal. This permits an advantageous further compaction of the now-developing stack of predetermined number of forms. This was as far as the box means B of the prior art PFT was able to pivot (see FIG. 2). This limitation occurred because the chassis C of the prior art PFT was rectangular rather than H-shaped, thereby preventing pivoting of the box means 32 to a vertical orientation. Also, because there was no thinking about a vertical orientation in the prior art PFT, the sides of the generally rectangular chassis C were closer than what we have provided in the instant invention. However, the latching means of the prior art PFT was generally the same as depicted here, i.e., the use of a pedal actuated dowels to fix the box means B in a horizontal loading position and a 70° position--the difference being that in the prior art the 70° position was the unloading position while here it is an intermediate position for compacting the stack prior to transfer. But for the purpose of disclosing an operative embodiment, we describe the details further of the latching means 62.
The connection between the foot pedal 63 and the dowels 65, 66 includes a pair of cables 71, 72--see the lower central portion of FIG. 22. These are partially entrained around pulleys 73, 74 which are fixed to a cross member 75--see also FIG. 25. The cables 71, 72 are threaded through the pulleys 73, 74 so as to extend transversely and are connected to the inner ends of the dowels 65, 66, respectively--as best seen in the upper left and right hand portions of FIG. 22. The dowels 65, 66 are spring-loaded as by coil springs 76, 77 so as to be urged outwardly and against the trapezoidally shaped plates 55, 56 and into engagement with openings 67, 68 (for horizontal disposition) and openings 69 (for the 70° orientation).
Summary of Operation
The invention is employed in transporting zig-zag folded, compacted forms on a receiver generally designated 30 (see FIG. 5). The receiver 30 includes an undercarriage 31 and a box means 32. As can be seen best in FIG. 3, the box means has a pair of longitudinally extending sides terminating in a closed end 33 and an open end opposite the closed end 33. The box means also has an open top and a planar bottom 32a for the support of a predetermined number of zig-zag folded forms as at F in FIG. 9. The receiver is generally of the construction of the prior art as illustrated in FIGS. 1 and 2, particularly the undercarriage portion 31. An important difference, however, is in the construction of the chassis 46 of the invention which is H-shaped as contrasted to the rectangular chassis C of the prior art PFT. It will be appreciated that the chassis 46 of the instant invention need not necessarily be H-shaped, but can take other configurations--so long as the end near the dolly has a recess permitting the box means to be disposed vertically, i.e., a generally C-shaped or open end below the open end of the box means 32.
The operation starts with the step of introducing a string of interconnected zig-zag folded, partially compacted business forms into the open end of the box means and onto the planar bottom thereof as is illustrated relative to the prior art in FIG. 1. The string of forms issues from a folder compactor FC.
In the invention, after a predetermined number of forms have been introduced into the box means 32, a flat-topped dolly 34 is inserted into posts 35 (see FIG. 3) at the open end of the box means 32. This mounting of the dolly in post means serves both to delimit and confine the predetermined number of forms which eventually will be provided in a vertical stack. The angle shaped post means permits easy insertion of the dolly and movement thereof to the FIG. 11 showing.
Once the dolly 34 has been inserted in place, the end of the now-developed predetermined number of forms which is immediately adjacent to the dolly is lifted from its position and overlaid as at F' (see FIG. 10) on the accumulated zig-zag folded predetermined number of forms. The few form lengths--a form length being defined as one or more that lie between adjacent transverse folds--constitute the last or tailing form lengths of the predetermined number just introduced into the box means 32. Thereafter, a retractable strap 38 mounted on the underside of the dolly 34 is pulled over the box means 32 and the end portion F' for securement to a fastening portion 41--as seen in FIG. 11. We have found it advantageous to equip the end portions of the straps 38, 39 with Velcro-type fastening means and the same can be used for the portion 41. With the predetermined number of forms arranged as seen in FIG. 11 and with the trailing end portion F' superposed on the predetermined number of forms as seen in FIG. 11, the box means 32 is pivoted through about a 70° arc as depicted in FIG. 12. This serves to further compact--or recompact--the predetermined number of forms also without the possibility of the forms teetering on the dolly which could occur should the box means 32 be pivoted from the horizontal directly through a 90° arc to the vertical.
To achieve this pivoting, the foot pedal 63 (see FIGS. 11 and 23) is depressed which retracts dowels 65, 66 (see the upper central right and left hand portions of FIG. 22) from latching openings 67, 68 in the trapezoidally shaped mounting plates 55, 56 (compare the upper left and right hand portions of FIG. 22 with the upper central portion of FIG. 23). This retraction of the dowels 65, 66 permits the box means 32 to be pivoted through a vertical arc which can be achieved conveniently by grasping the handle means 64 on the closed end wall 33 of the box means 32 as seen in the upper portion of FIG. 25. The pivoting is against the urging of shock absorbers 58, 59 which are interconnected between the box means (via the trapezoidally shaped plates 55, 56) and a bottom portion of the receiver, notably the bottom portions of uprights 52, 53 (see the lower right and left hand portions of FIG. 22).
After the box means 32 has been pivoted to the 70° orientation as depicted in FIG. 12 wherein the dowels now enter the aligned openings 69 (compare FIG. 12 with FIGS. 23 and 24), the predetermined number of forms now recompacted into a stack, is oriented vertically as seen in FIG. 13 with the stack being designated by the symbol S.
The next step in the operation is depicted in FIG. 14 where the stack S which is independently supported on the dolly 34 is moved away from the receiver 30 and, more particularly, off of the post means 35 which had initially supported the dolly when it was first inserted to delimit and confine the predetermined number of forms.
Also shown in FIG. 14 is the application of an anti-curl plate 40 on the top of the stack S and which consists of a planar plate advantageously equipped with an integral handle of inverted U-shape as at 40a.
The next step in the procedure is to clamp the stack S against the dolly 34 as illustrated in FIG. 15 so that the movement of the dolly 34 to a different location will not disturb the stack S. At this time, the trailing end portion F' is also confined advantageously by the straps 38, 39 by virtue of the straps being located along the sides of the dolly 34 that are aligned with the folds of the zig-zag folded stack S.
The dolly includes a flat plate 36 (see FIGS. 16 and 19) which is equipped with a pair of openings 36a--see FIG. 19. It is into these openings that the pulling handle means 42 is inserted as seen in FIG. 16 and the dolly 36 relocated to an area or position of further processing. Normally this will be a processing machine such as an inserter or stuffer wherein the business forms which have been previously printed with variable information (name, address, billing in dollars, etc.) are inserted into envelopes along with advertising or other promotional material.
At this new site, as seen in FIG. 17, the anti-curling plate 40 is removed and the end portion F' is brought up the top of the stack S' and aligned with the trailing form F" of an almost depleted stack S. The portions F' and F" are spliced together by means of tape T (see FIG. 18) so that the introduction of forms into the inserter I (see FIG. 2) can be carried out without stopping. Also, it will be appreciated that the forms are processed in a "first in-first out" sequence. In other words, the form lengths which are first printed with variable information by a computer printer associated with the folder compactor FC are those that are first introduced into the inserter I--and without any difficult intervening manipulative steps. Further, with this splicing, it does not make any difference where the dolly is inserted to limit the number of forms transferred. The last of one stack always is connected to the first of the next stack.
When a dolly 34 has been freed from its associated stack, it can be conveniently carried to a nearby hand truck 43 which is equipped with an upright pole 44. Each dolly 34 is equipped with a central opening 45 which is generally within the rectangular configuration defined by the casters 37 on the dolly 34 and which fits over the pole 44--as can be seen in FIG. 19. Thereafter, the associated anti-curl plate 40 is also ensleeved over the pole 44 by virtue of being equipped with a similar opening and thereafter the sequence repeated for further dollies as at 134' in FIG. 21. It will be appreciated that it is only necessary to have one receiver which is reasonably complicated and therefore expensive whereas an unlimited number of inexpensive, uncomplicated dollies can be used in the inventive procedure.
While in the foregoing specification a detailed description of an embodiment of the invention has been set down for the purpose of illustration, many variations in the details hereingiven may be made by those skilled in the art without departing from the spirit and scope of the invention. | Apparatus and method for handling compacted business forms including a receiver having a horizontally disposed receiving surface and posts at one end thereof for the receipt of a dolly adapted to delimit and confine a predetermined number of forms on the receiver horizontal surface. The receiver is pivotable to position the dolly on the floor with the predetermined number of forms existing as a stack. Confinement straps associated with the dolly hold the stack in place while the dolly is separated from the receiver and relocated to a processing machine for performing further operations on the forms, the dolly being equipped with mounting holes for returning the dolly on a hand truck to the receiver. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of U.S. patent application Ser. No. 11/382,127 (DIB 0102 IA), filed May 8, 2006, which claims the benefit of, and is a continuation-in-part of, U.S. Non-Provisional application Ser. No. 11/380,501 (DIB 0102 PA), filed Apr. 27, 2006.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to an assembly comprising a torque fitting used to secure a length of tubing to a port of a fluid manifold, a fluid valve assembly, a fluid container, or other type of fluid-handling device. The present invention also relates more generally to hardware device where it may be advantageous to control the application of torque to a threaded body portion.
BRIEF SUMMARY OF THE INVENTION
[0003] The present invention relates to an assembly comprising a multi-use torque fitting configured to couple a length of tubing to a fluid port in a hermetically sealed or substantially leak-proof manner. Generally, the configuration of the fitting prevents over-tightening or over-compression of a compressible seal formed at an end of the length of tubing and engaged between the fitting and a fluid-handling device to which the fitting is coupled while ensuring sufficient compression of the seal between the fitting and the port of the fluid-handling device.
[0004] In accordance with one embodiment of the present invention, an assembly comprises a torque fitting and a length of tubing. The torque fitting comprises a threaded body portion, a torque-limiting body portion, and a tubing channel. The threaded body portion and the torque-limiting body portion are arranged substantially concentrically along a longitudinal axis of the fitting, while the channel is oriented along the longitudinal axis of the fitting and defines a cross-sectional area sufficient to accommodate the length of tubing along the axis. The threaded body portion comprises a sealing edge on the underside of the threaded body portion and a mechanical thread defining a compressive direction of rotation and a decompressive direction of rotation. The threaded body portion and the torque-limiting body portion are configured such that, below a threshold level of torque applied to the torque-limiting body portion, rotation of the torque-limiting body portion in the compressive direction of rotation forces the threaded body portion to rotate with the torque-limiting body portion; above the threshold level of torque applied to the torque-limiting body portion, rotation of the torque-limiting body portion in the compressive direction of rotation fails to force the threaded body portion to rotate with the torque-limiting body portion; and rotation of the torque-limiting body portion in the decompressive direction of rotation forces the threaded body portion to rotate with the torque-limiting body portion. The length of tubing comprises a compressible seal formed at an end of the length of tubing and is accommodated by the channel of the torque fitting such that the compressible seal is positioned to cooperate with the sealing edge to prevent substantial fluid leakage when the assembly is applied to a fluid-handling device.
[0005] In accordance with another embodiment of the present invention, one of the threaded body portion or the torque-limiting body portion of the torque fitting of the assembly comprises a lever, while the other of the threaded body portion or the torque-limiting body portion comprises an abutment. The lever comprises a first arresting surface and a yielding surface and the abutment comprises a second arresting surface and an engaging surface. The lever and the abutment are configured such that the yielding surface of the lever and the engaging surface of the abutment engage when torque below a threshold level is applied in rotating the torque-limiting body portion in a compressive direction of rotation. The lever and the abutment are further configured such that the engaging surface contacts the yielding surface and the lever deflects an amount sufficient to allow the lever to bypass the abutment when torque above the threshold level is applied in rotating the torque-limiting body portion in the compressive direction of rotation. The deflection of the lever by the abutment causes the lever to flex toward the body portion comprising the lever and away from the body portion comprising the abutment. The lever is configured with a degree of elasticity sufficient to enable repetitive flexion of the lever, while the first and second arresting surfaces are configured to arrest relative rotation between the threaded body portion and the torque-limiting body portion when engaged. The length of tubing comprises a compressible seal formed at an end of the length of tubing is accommodated by the channel of the torque fitting such that the compressible seal is positioned to cooperate with the sealing edge to prevent substantial fluid leakage when the assembly is applied to a fluid-handling device.
[0006] In accordance with another embodiment of the present invention, the assembly further comprises a fluid-handling device in addition to the torque fitting and the length of tubing. The length of tubing comprises a compressible seal formed at an end of the length of tubing and is accommodated by the channel of the torque fitting such that the compressible seal is compressed between the sealing edge of the threaded body portion and a port of the fluid-handling device to prevent substantial fluid leakage at a tube and port interface.
[0007] In accordance with yet another embodiment of the present invention, the torque-limiting body portion and the threaded body portion do not necessarily include a channel for accommodating a length of tubing and are contemplated as being more generally applicable to any hardware device where it may be advantageous to control the application of torque to a threaded body portion. The threaded body portion may, for example, be utilized in place of a conventional bolt or screw as hardware for mechanical securement.
[0008] Accordingly, it is an object of the present invention to present a multi-use torque fitting and an assembly comprising the torque fitting and objects conjoined thereby. Other objects of the present invention will be apparent in light of the description of the invention embodied herein.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0009] The following detailed description of specific embodiments of the present invention can be best understood when read in conjunction with the following drawings, where like structure is indicated with like reference numerals and in which:
[0010] FIG. 1 is an illustration of an embodiment of a torque fitting according to the present invention comprising a threaded body portion, a torque-limiting body portion, and a channel.
[0011] FIG. 2 is an illustration of an embodiment of an assembly according to the present invention comprising a torque fitting of the present invention and a length of tubing.
[0012] FIG. 3 is an illustration of an embodiment of a torque fitting according to the present invention wherein an engagement between an abutment and a lever forces the threaded body portion to rotate in a compressive direction of rotation with the torque-limiting body portion.
[0013] FIG. 4 is an illustration of an embodiment of a torque fitting according to the present invention wherein a deflection of the lever by the abutment fails to force the threaded body portion to rotate in a compressive direction of rotation with the torque-limiting body portion.
[0014] FIG. 5 is an illustration of an embodiment of a torque fitting according to the present invention wherein engagement between the abutment and the lever forces the threaded body portion to rotate in a decompressive direction of rotation with the torque-limiting body portion.
[0015] FIG. 6 is an illustration of an embodiment of a torque fitting according to the present invention wherein an engagement between an abutment and a lever forces the threaded body portion to rotate with the torque-limiting body portion and wherein a deflection of the lever by the abutment fails to force the threaded body portion to rotate with the torque-limiting body portion.
DETAILED DESCRIPTION
[0016] Referring initially to FIGS. 1-6 , the torque fitting 10 generally comprises a threaded body portion 20 , a torque-limiting body portion 30 , and a tubing channel 40 . The threaded body portion 20 and the torque-limiting body portion 30 typically are arranged substantially concentrically along a longitudinal axis 12 of the fitting 10 . As is clearly shown in FIG. 2 , the channel 40 is oriented along this longitudinal axis 12 of the fitting 10 extending through opposite ends of the fitting and defines a cross-sectional area sufficient to accommodate a length of tubing 50 along this axis 12 . The threaded body portion 20 , meanwhile, generally comprises a mechanical thread 22 defining a compressive direction of rotation, as shown by the clockwise directional arrow depicted in FIGS. 3 and 4 , and a decompressive direction of rotation, as shown by the counter-clockwise directional arrow depicted in FIG. 5 .
[0017] As will be described in detail with FIGS. 3-6 below, the threaded body portion 20 and the torque-limiting body portion 30 generally are configured such that when torque below a threshold level is applied to the torque-limiting body portion 30 , rotation of the torque-limiting body portion 30 in the compressive direction of rotation forces the threaded body portion 20 to rotate with the torque-limiting body portion 30 . Therefore, the fitting 10 rotates in the compressive direction of rotation such that the fitting 10 may compress a compressible seal 52 positioned between the fitting 10 and another object, e.g., a port of a fluid-handling device. When, however, torque above the threshold level is applied to the torque-limiting body portion 30 , rotation of the torque-limiting body portion 30 in the compressive direction of rotation fails to force the threaded body portion 20 to rotate with the torque-limiting body portion 30 . Here, as torque above the threshold level is applied, only the torque-limiting body portion 30 of the fitting 10 continues to rotate in the compressive direction of rotation, while the threaded body portion 20 fails to rotate, thereby precluding any further compression of the compressible seal 52 . This configuration of the fitting 10 precludes substantial fluid leakage at a point of tube/port interface.
[0018] Fluid leakage at the point of tube/port interface or premature seal degradation may occur if a fitting is over-tightened or if the seal is over-compressed. More specifically, the seal 52 may deform, crack, or otherwise degrade if too much compression is applied to the seal. Alternatively, fluid leakage may occur if a fitting is under-tightened, resulting in an under-compression of the compressible seal 52 . The fitting 10 of the present invention, described in greater detail below, is configured to prevent over-compression of the seal 52 while ensuring sufficient compression of the seal 52 . The configuration of the fitting 10 enables the torque-limiting body portion 30 to force the rotation of the threaded body portion 20 to a point where sufficient compression is applied to the compressive seal 52 without compromising the integrity of the seal 52 or allowing fluid to bypass the seal 52 . The fitting 10 allows a user to rotate the torque-limiting body portion 30 in the compressive direction of rotation until it fails to force the threaded body portion 20 to rotate with the torque-limiting body portion 30 . The fitting 10 is configured such that the appropriate amount of compression is reached at the point at which the torque-limiting body portion 30 fails to force the threaded body portion 20 to rotate with it in the compressive direction of rotation. This condition will be readily apparent to the user as a significant drop in rotational resistance in the torque-limiting body portion 30 will occur. As will be understood from the detailed description of the particular embodiment of the fitting presented below, the user may also note an audible click once the appropriate amount of compression is reached.
[0019] The threaded body portion 20 and the torque-limiting body portion 30 generally are further configured such that rotation of the torque-limiting body portion 30 in the decompressive direction of rotation forces the threaded body portion 20 to rotate with the torque-limiting body portion 30 , regardless of the level of torque applied to the body portion 30 . Therefore, the threaded boy portion 20 and the torque-limiting body portion 30 both rotate together in the decompressive direction of rotation.
[0020] As depicted in FIGS. 3-6 , the threaded body portion 20 comprises a lever 60 and the torque-limiting body portion 30 comprises an abutment 70 . The lever 60 comprises a first arresting surface 62 and a yielding surface 64 , while the abutment 70 comprises a second arresting surface 72 and an engaging surface 74 . Referring to FIG. 3 , the yielding surface 64 and the engaging surface 74 are configured to engage such that when torque below the threshold level is applied to the torque-limiting body portion 30 , the engagement of the yielding surface 64 and the engaging surface 74 forces the threaded body portion 20 to rotate with the torque-limiting body portion 30 . This condition remains until the appropriate amount of compression is applied to the compressible seal 52 .
[0021] Specifically, as is illustrated in FIGS. 3 and 4 , the engaging surface 74 contacts the yielding surface 64 and deflects the lever 60 when torque is applied in rotating the torque-limiting body portion 30 in the compressive direction of rotation. In the illustrated embodiment, this deflection of the lever 60 by the abutment 70 causes the lever 60 to flex toward the threaded body portion 20 and away from the torque-limiting body portion 30 . The degree of this deflection will vary depending upon the torque applied in rotating the torque-limiting body portion 30 in the compressive direction of rotation. FIG. 3 illustrates a condition where the degree of deflection is minimal and, as such, the torque-limiting body portion 30 will force the threaded body portion 20 to rotate with it in the compressive direction of rotation. FIG. 4 illustrates a condition where the amount of torque applied to the torque limiting body portion has reached or exceeded a threshold level of torque. Under this condition, the torque-limiting body portion 30 will not force the threaded body portion 20 to rotate with it in the compressive direction of rotation because the lever 60 deflects an amount sufficient to allow the lever 60 to bypass abutment 70 . The torque-limiting body portion 30 rotates substantially freely around the threaded body portion 20 in the compressive direction of rotation once the lever 60 has bypassed the abutment 70 . The lever 60 is preferably provided with a degree of elasticity that is sufficient to enable repetitive deflection of the lever 60 .
[0022] The fitting 10 is configured such that the amount of compression applied to the seal 52 is established by the size and shape of the abutment 70 and the size, shape, and rigidity of the lever 60 . Specific examples of means for tailoring the degree of torque that can be applied to the threaded body portion are given below. However, it is noted that those practicing the present invention should appreciate that a wide array of lever and abutment characteristics can be configured to tailor the amount of torque that can be applied to the threaded body portion.
[0023] For example, the rigidity of the lever, which can be a function of many factors (composition, size, shape, orientation, thickness, etc.), can be tailored to determine the amount of torque that can be applied to the threaded body portion 20 via the torque-limiting body portion 30 . The less rigid the configuration of the lever 60 , the lower the threshold level of torque applied. The more rigid the configuration of the lever 60 , the higher the threshold level of torque applied. Once the threshold level of torque is exceeded, the engagement between the yielding surface 64 and the engaging surface 74 is lost such that the lever 60 bypasses the abutment 70 and no further compression can be applied to the compressible seal 52 .
[0024] As a further example, the degree to which the abutment 70 protrudes from the otherwise uniform surface of the body portion carrying the abutment 70 and the degree to which the yielding surface 62 of the lever 60 extends into the corresponding depth dimension defined by the abutment 70 can also be tailored to determine the amount of torque that can be applied to the threaded body portion 20 . As we note above, a given degree of deflection is required for the lever 60 to bypass the abutment 70 . Those practicing the present invention can configure the fitting 10 to permit application of a relatively large degree of torque by providing a relatively large abutment 70 and configuring the lever 60 to protrude a relatively large extent into the depth defined by the abutment. In contrast, a smaller abutment 70 or a smaller lever protrusion will permit application of a relatively low degree of torque.
[0025] As shown in FIG. 5 , the engagement of the first and second arresting surfaces 62 , 72 forces the threaded body portion 20 to rotate with the torque-limiting body portion 30 when the torque-limiting body portion 30 rotates in the decompressive direction of rotation. Stated differently, the first and second arresting surfaces 62 , 72 are configured to arrest relative rotation between the threaded body portion 20 and the torque-limiting body portion 30 when the arresting surfaces 62 , 72 are engaged.
[0026] In defining the present invention, reference is made to a condition where the lever 60 bypasses the abutment 70 . This recitation should not be taken to require that the torque limiting body portion 30 comprises the lever 60 . Rather, the bypass condition is merely utilized herein to relate to a condition of relative motion between the lever 60 and abutment 70 , when a threshold level of torque is reached, without regard to which body portion comprises the lever 60 . It is further contemplated by the present invention that the threaded body portion 20 may comprise the abutment 70 , while the torque-limiting body portion 30 may comprise the lever 60 . The present invention also contemplates that a body portion of the fitting 10 may comprise more than one lever 60 , while the other body portion of the fitting 10 may comprise more than one abutment 70 . Further, the threaded body portion 20 may be configured such that the mechanical thread 22 may be positioned on an exterior surface, an interior surface, or both, of the threaded body portion 20 . It is contemplated that the embodiment illustrated in FIG. 6 is simply another embodiment of a torque fitting varied from the embodiment shown in FIGS. 3-5 , but which operates in much the same way as that described herein with respect to FIGS. 3-5 .
[0027] Referring again to FIGS. 1 and 2 , the threaded body portion 20 of the fitting 10 may further comprise an end that comprises a sealing edge 24 . This sealing edge 24 may be configured as a flat face on the underside of the threaded body portion 20 and generally is configured to cooperate with a compressible seal 52 formed at the end of the length of tubing 50 . It is contemplated that the compressible seal 52 may be distinct from or integral with the tubing 50 and may take the form of a gasket, o-ring, or other sealing device. For example, in one embodiment, clearly shown in FIG. 2 , the compressible seal 52 is integral with the tubing 50 and is presented as a flanged portion formed at the end of the length of tubing 50 . This flanged portion is configured to extend over the sealing edge 24 of the threaded body portion 20 . Thus, as the fitting 10 rotates in the compressive direction of rotation, it compresses the seal 52 between the sealing edge 24 and a surface of the port of the fluid-handling device. This compressive seal 52 , in coordination with the sealing edge 24 , is configured to prevent substantial fluid leakage at the tube/port interface. This compression achieved by the fitting 10 generally is enabled by the port's composition of a threaded surface that corresponds with the mechanical thread 22 of the threaded body portion 20 .
[0028] FIG. 2 shows that the present invention may also relate to an assembly comprising the fitting 10 and a length of tubing 50 that is accommodated by the channel 40 of the fitting 10 . This assembly may further comprise the aforementioned fluid-handling device having a port and, in addition, a gasket, o-ring, or other sealing device.
[0029] It is noted that terms like “preferably,” “commonly,” “generally,” and “typically” are not utilized herein to limit the scope of the claimed invention or to imply that certain features are critical, essential, or even important to the structure or function of the claimed invention. Rather, these terms are merely intended to highlight alternative or additional features that may or may not be utilized in a particular embodiment of the present invention.
[0030] For the purposes of describing and defining the present invention it is noted that the term “assembly” is utilized herein to represent a combination of components and individual components, regardless of whether the components are combined with other components. For example, an “assembly” according to the present invention may comprise a fluid manifold having a port and a gasket, o-ring, or other sealing device in addition to a torque fitting 10 according to the present invention.
[0031] For the purposes of describing and defining the present invention it is noted that the term “substantially” is utilized herein to represent the inherent degree of uncertainty that may be attributed to any quantitative comparison, value, measurement, or other representation. The term “substantially” is also utilized herein to represent the degree by which a quantitative representation may vary from a stated reference without resulting in a change in the basic function of the subject matter at issue.
[0032] Having described the invention in detail and by reference to specific embodiments thereof, it will be apparent that modifications and variations are possible without departing from the scope of the invention defined in the appended claims. More specifically, although some aspects of the present invention are identified herein as preferred or particularly advantageous, it is contemplated that the present invention is not necessarily limited to these preferred aspects of the invention. | The present invention relates to embodiments of an assembly comprising a multi-use torque fitting and a length of tubing. The torque fitting generally comprises a threaded body portion and a torque-limiting body portion, wherein the threaded body portion and the torque-limiting body portion are arranged substantially concentrically along a longitudinal axis of the fitting. The length of tubing, meanwhile, generally comprises a compressible seal formed at its end. Generally, the torque fitting is configured to couple the length of tubing to a fluid port in a hermetically sealed or substantially leak-proof manner by providing a degree of compression to the compressible seal of the length of tubing sufficient to prevent substantial fluid leakage at the tube/port interface. | 5 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation of provisional application Ser. No. 60/556,277 entitled “Fiber Optic Fault Locating and Mapping Device” filed on Mar. 25, 2004, the contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a fiber-optic fault locating and mapping device and, more specifically, to the use of a signaling tool in combination with cable locating equipment to accurately identify a fault location.
2. Description of the Prior Art
A variety of technologies are currently available for troubleshooting cable problems, such as cable breaks or cable faults. Each of these technologies serves a specific purpose and enables a technician to locate and isolate faults. For example, cable-locating equipment is currently used to locate a cable that may have a fault. Fault-locating equipment is currently used to locate a fault in a cable. Operators are traditionally trained in either cable-locating equipment or in fault-locating equipment.
A variety of different types of cables are deployed in communication systems. Some of the most notable are twisted pair cables, coaxial cables, and fiber-optic cables. Cable-locating equipment and fault-locating equipment are each individually used to troubleshoot particular types of cable systems; specifically, both technologies are individually used to troubleshoot fiber-optic cables.
A conventional fiber-optic cable consists of a plurality of fibers surrounded by a protective layer. The fibers are often bundled together and the protective layer surrounding the cables includes a variety of protective materials including a metal sheath. In conventional cable-locating equipment, a tone is communicated on the metal sheath so that a technician in the field can locate the fiber-optic cable. Approximately, every 50 miles or so, a cable-locating box is deployed on the cable. A tone is generated and communicated along the metal sheath of the cable. The technician is able to use equipment to detect the tone and ultimately locate the cable.
When a cable may be damaged, if there is no physical damage above ground, a technician cannot visually locate the cable. In conventional cable troubleshooting, the technician may use a transmitting device to dial into a cable-locating box and turn on the cable tone. Once the cable tone is turned on and is emanating from the cable, the technician may sweep the area in the general location of the cable to locate the cable. The technician can locate the cable using the signature of the tone. For example, when there is sheath damage in the cable, the cable tone either stops after the location of the sheath damage or diminishes after the location of the sheath damage. As a result, based on the level of the tone, the technician is able to locate the sheath damage.
However, it should be appreciated that it may take a substantial amount of time to locate the general area that the tone is emanating from since the range of conventional systems is about 25 miles. To precisely determine a cable location may take a substantial amount of time requiring that the technician traverse large areas. This of course increases the amount of time required to locate the cable and results in longer outage times for customers.
Another technology used to troubleshoot cable problems is an Optical Time Domain Reflectometer (OTDR). An OTDR transmits a light signal down a fiber and then measures the reflected light. When a fault or termination point occurs in a fiber, the light reflects off of the fault or termination point. For example, the OTDR collects irregularities from the fiber through signals reflected back from the fiber after a pulsed signal is placed on the fiber. These irregularities are averaged and plotted and will show any imperfections in the glass. The lasers used in an OTDR have a very broad spectrum and will only show the worst irregularity. On the other hand, a narrowly spaced laser will show all irregularities (i.e., those that are valid faults and those that are not). Therefore, it is sometimes difficult to tune the lasers to get the optimum laser spacing and fault detection.
Geographic maps are created when fiber-optic lines are installed, but often they are not representative of the actual installation. The OTDR can be used to measure the linear distance of the fault based on the time it takes the reflected light to return to the point of origin. However, with current OTDR systems, it is difficult to relate the OTDR reading to a geographic location. As a result, it is difficult to specifically isolate the fault.
Thus, although there are a variety of technologies deployed for troubleshooting cables, a better system for troubleshooting cables is needed.
SUMMARY OF THE INVENTION
A method and apparatus for locating a cable and isolating a fault is presented. In one embodiment, a method is presented that enables a technician to locate a cable and isolate a fault in the cable. An integrated cable-troubleshooting system that performs both cable location and fault isolation is presented. In one embodiment, the functionality of a cable tone-generator is integrated with the functionality of an Optical Time Domain Reflectometer (OTDR).
In one embodiment, an integrated cable-troubleshooting system is implemented. The cable-troubleshooting system includes an OTDR for monitoring a fiber-optic cable. The OTDR connects to the fiber-optic cable, which terminates at a fiber cabinet. If there is a fault at 10,000 feet, the OTDR scans the fiber. Fault information specifying the location of the fault is placed into an electronic message. When a technician dials into the integrated cable-troubleshooting system to turn on a cable locating tone, the electronic message would tell the technician that there is a fault at 10,000 feet.
Once the cable-locating module is turned on, a cable tone is transmitted down the sheath of the fiber-optic cable. The integrated cable-troubleshooting system has a communication interface (i.e., telephone access) that the technician can dial into. In one embodiment, the technician inputs a security code to access the cable-locating module and a code to turn on the cable-locating module. As such, the technician can turn the locating tone on and off. Using the combined information from the OTDR with the cable-locating tone, the technician is able to locate the cable and isolate the fault.
A cable-troubleshooting system comprises an OTDR generating fault location information detailing a distance of a fault in a fiber-optic cable. In one embodiment, the fault location information identifies a linear distance to a fault. The cable-troubleshooting system further comprises a cable-locating module that is coupled to the OTDR. The cable-locating module may be coupled to the OTDR through a communication path, a CPU, a memory, a communication interface, etc. The cable-locating module generates a tone on the fiber-optic cable, whereby the fault-location information in combination with the tone is used to locate the cable and isolate the fault.
In one embodiment, a technician may use the combined information to locate the cable. In another embodiment, a computer, robot, etc. may use the combined information to locate the cable and isolate the fault.
A method of operating a cable-troubleshooting system comprises the steps of detecting a fault in a fiber-optic cable in response to operating an OTDR; and generating a tone on the fiber-optic cable to identify the fiber-optic cable in response to detecting the fault on the fiber-cable.
A method of troubleshooting a fiber-optic cable comprises the steps of operating an OTDR to generate fault information; generating a signal in response to generating the fault information; and operating a cable-locating module in response to generating the signal.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 displays a flow diagram implementing the teachings of the present invention.
FIG. 2 displays a network implementing the teachings of the present invention.
FIG. 3 displays an integrated cable-locating and fault-locating assembly.
DESCRIPTION OF THE INVENTION
While the present invention is described herein with reference to illustrative embodiments for particular applications, it should be understood that the invention is not limited thereto. Those having ordinary skill in the art and access to the teachings provided herein will recognize additional modifications, applications, and embodiments within the scope thereof and additional fields in which the present invention would be of significant utility.
FIG. 1 displays a flow diagram implementing the teachings of the present invention. Using an integrated cable-troubleshooting system, at step 100 , an OTDR is placed into operation to generate a continuous monitoring signal on a fiber-optic cable. At step 102 , the OTDR identifies a fault and records the fault information (i.e., distance to the fault location, time of fault, type of fault, etc.). The cable-troubleshooting system communicates the fault information to a technician as stated at 104 . The communication may be a landline communication, a wireless communication, a computer communication, etc. In one embodiment, an electronic communication, such as an email message or wireless telephone call including the fault information, is sent to the technician.
The technician receives the call and the fault information generated by the OTDR as stated at 106 . The technician places a call to the integrated cable-troubleshooting system and turns on a cable-locating module implemented in the integrated cable-troubleshooting system as stated at 108 . At step 110 , the cable-locating module begins to operate generating a signal/tone on the cable. At step 112 , the technician uses a signal detection unit to detect the signal/tone in combination with the OTDR-generated fault information to isolate the location of the cable and the fault in the cable.
FIG. 2 displays a network implementing the teachings of the present invention. A cable-troubleshooting system 200 includes a cable-locating module 202 and an OTDR 204 . A fiber-optic cable 208 is shown. The fiber-optic cable 208 is connected through a fiber termination panel 206 . The cable-locating module 202 is connected to a cable-locating unit 210 through a connection cable 212 . The cable-locating unit 210 is connected to the sheath of the fiber-optic cable 208 .
During operation, a fault may occur at a location designated by 209 . The fault may occur for a variety of reasons. The OTDR 204 continuously sends a signal down the fiber-optic cable 208 . Therefore, when the fault shown at location 209 occurs, the OTDR 204 will be able to detect the location shown as 209 and the optical distance of the fault location at 209 . In another embodiment, if there is a cut in the fiber-optic cable 208 , the OTDR 204 would immediately raise an alarm and report the optical distance to the cable-locating module 202 , where this information could be given to a technician calling in to the integrated cable-troubleshooting system 200 . In the alternative, the OTDR 204 may trigger the operation of the cable-locating module 202 , upon detection of a fault. In yet another embodiment, either the OTDR 204 or the cable-locating module 202 may generate a call to the technician making the technician aware of the problem. For example, the OTDR 204 may contact the technician immediately after identifying a fault. The OTDR 204 may turn on the cable-locating module 202 and then contact the technician after turning on the cable-locating module 202 . In another embodiment, after identifying a fault, the OTDR 204 may turn on the cable-locating module 202 and then the cable-locating module 202 may initiate the call to the technician with the required fault information from the OTDR 204 . In another embodiment, the OTDR 204 and/or the cable-locating module 202 may communicate with the integrated cable-troubleshooting system 200 and the cable-troubleshooting system 200 may communicate with the technician. It should be appreciated that a variety of permutations and combinations are possible and each is contemplated and within the scope of the present invention.
Irrespective of which of the foregoing methods is used, the response provides a significant improvement over the standard restoration objective set for restoring a cable of 2.5 hours. The technician may then drive to the apparent geographic location of the fault based on the information generated via the cable-troubleshooting system 200 . When the technician arrives, an acoustic signaling tool can be used to generate a signal from above ground that is picked up by the cable-locating module 210 . In one embodiment, when combined with the fault information, an accuracy of less than 30 feet may be experienced. For example, if the fault was 10,000 feet away from the fiber termination panel 206 and the technician was at 7,000 feet, the cable-troubleshooting system 200 would provide the information “you are 3,000 feet from the fault” in the electronic message. This process will continue until the technician is at the damage site and will lead the technician quickly and directly to the fault. Moreover, the process is not dependent on the accuracy of cable location drawings or a technician's ability to interpret the various milestones on the drawings.
In another embodiment, a technician can find the general path of the fiber-optic cable 208 by using the cable-location unit 210 . The cable location unit 210 will direct the technician to the location of the fiber-optic cable 208 , but no other information is provided. For example, the technician can locate the fiber-optic cable 208 by calling the cable-locating module 202 via a telephone and turning on the cable-locating module 202 , which will generate a tone that will travel down the fiber-optic cable's 208 metallic sheath. Once the cable has been located, the technician can use the fault information provided by the OTDR 204 .
In one embodiment, the cable-troubleshooting system 200 includes a narrow pulsed laser (i.e., OTDR 204 ). Footage from the fiber termination panel 206 to the fault location 209 can be recorded via the cable-troubleshooting system 200 and the technician can call into the cable-troubleshooting system 200 (i.e., OTDR 204 or cable-locating module 202 ) to obtain fault location information. Once this information is obtained, the technician must travel along the right of way to find the fault location 209 . Often there is no obvious disturbance above ground at the fault location 209 . The optical distance given by the OTDR 204 may not be the same as the geographical location along the fiber path. A known disturbance device (oscillator) can be used by the technician to generate a signal along the fiber path, and the OTDR 204 can detect this signal. The location of the disturbance can be compared to the end of fiber and calculations can be made to show the relationship of the known disturbance to the end of the fiber. This will aid the technician in locating a fiber fault location 209 and ultimately enable a geographic location to be determined.
FIG. 3 displays a cable-troubleshooting system 200 . The cable-troubleshooting system 200 includes a cable-locating module 314 and an OTDR 316 . The cable-locating module 314 includes all of the functionality required to generate a locating tone on a cable sheath. The cable-locating module 314 may be implemented in hardware and/or software and may represent an entire cable-locating module including the necessary functionality of a cable-locating module. For example, the cable-locating module 314 may include the memory, communication interface, CPU, etc. necessary to fully operate as a cable-locating module 314 . In the alternative, the cable-locating module 314 may share the CPU 302 , memories 313 and 304 , and communication interface 318 with the OTDR 316 .
The OTDR 316 may be implemented in hardware and/or software and may include the entire functionality required to operate as an OTDR. For example, the OTDR 316 may include the memory communication interface, CPU, etc. necessary to fully operate as an OTDR. In the alternative, the OTDR 316 may share the CPU 302 , memories 313 and 304 , and communication interface 318 with the cable-locating module 314 .
In one embodiment, the CPU 302 may direct all operation of the cable-troubleshooting system 200 using instructions stored in storage memory 313 and/or internal memory 304 . In another embodiment, CPU 302 may coordinate operation of a CPU (not shown in FIG. 3 ) located in the cable-locating module 314 and a CPU (not shown in FIG. 3 ) located in the OTDR 316 . Communication path 310 provides communication for the various components in the cable-troubleshooting system 200 . For example, after detecting a fault with the OTDR 316 , an operation signal may be sent across the communication path 310 to the cable-locating module 314 to turn on the cable-locating module 314 . In one embodiment, both the cable-locating module 314 and the OTDR 316 may communicate through the communication interface 318 . In addition, instructions that direct cable-locating module 314 and OTDR 316 may be stored in the storage memory 313 and the internal memory 304 .
cable-troubleshooting system 200 may operate using a variety of methods and still remain within the scope of the present invention. For example, a) the cable-locating module 314 and the OTDR 316 may each work autonomously; b) the cable-locating module 314 and the OTDR 316 may work cooperatively; c) the cable-locating module 314 and the OTDR 316 automatically work together.
In a first embodiment, the cable-locating module 314 and the OTDR 316 may each work autonomously. For example, during operation, the OTDR 316 may continuously monitor a fiber-optic cable. Once a fault is identified, the OTDR 316 may store the fault information, such as distance to the fault in the OTDR 316 . The OTDR 316 may then communicate this information through the communication path 310 to the communication interface 318 . The communication interface 318 may communicate this information to a technician. The technician may then dial into the cable-troubleshooting system 200 through the communication interface 318 . The technician may enter an access code and a security code. The communication interface 318 may communicate the security code across the communication path 310 to the cable-locating module 314 and turn on a cable tone in the fiber-optic cable. Using the cable-locating tone, the technician is able to locate the fiber-optic cable and using the fault information from the OTDR 316 , locate the fault in the cable.
In a second embodiment, the cable-locating module 314 and the OTDR 316 may each work cooperatively. For example, during operation, the OTDR 316 may continuously monitor a fiber-optic cable. Once a fault is identified, the OTDR 316 may store the fault information, such as the optical distance to the fault in the OTDR 316 . The OTDR 316 may then communicate this information through the communication path 310 to the communication interface 318 . In addition, the OTDR 316 may communicate information across the communication path 310 and turn on the cable-locating module 314 . The communication interface 318 may communicate the optical distance information and “cable locating module—on” status information to a technician. Using the cable-locating tone, the technician is able to locate the fiber-optic cable and using the fault information from the OTDR, the technician is able to locate the fault in the cable.
In a third embodiment, the cable-locating module 314 and the OTDR 316 automatically work together. For example, automated procedures may be used to operate the OTDR 316 . Instructions directing the automated procedures may be found in RAM 306 , ROM 308 , and storage memory 313 . A CPU 302 may control the operation of the OTDR 316 based on these automated procedures. The automated procedures may include procedures to change the start/stop time of the OTDR 316 , procedures to adjust the performance of the OTDR 316 , procedures to log measurements of the OTDR 316 into memory and then respond accordingly, etc.
During operation, the OTDR 316 may continuously monitor a fiber-optic cable. Once a fault is identified, the OTDR 316 may store the fault information, such as the optical distance to the fault in the internal memory 304 or in a storage memory 313 . Under direction of the CPU 302 , the OTDR 316 may then communicate this information through the communication path 310 to the communication interface 318 . In addition, the CPU 302 may then direct the communication of information across the communication path 310 and turn on the cable-locating module 314 . The CPU 302 may control the operation of the cable-locating module 314 based on automated procedures. The automated procedures may include procedures to change the starustop time of the cable-locating module 314 , procedures to adjust the performance of the cable-locating module 314 , procedures to log the operation of the cable-locating module 314 into memory and then respond accordingly, etc. The communication interface 318 may communicate the optical distance information and “cable locating unit—on” status information to a technician. Using the cable locating tone, the technician is able to locate the fiber cable and using the fault information from the OTDR, the technician is able to locate the fault in the cable.
While the present invention is described herein with reference to illustrative embodiments for particular applications, it should be understood that the invention is not limited thereto. Those having ordinary skill in the art and access to the teachings provided herein will recognize additional modifications, applications, and embodiments within the scope thereof and additional fields in which the present invention would be of significant utility.
It is, therefore, intended by the appended claims to cover any and all such applications, modifications, and embodiments within the scope of the present invention. | In accordance with the teachings of the present invention, a method and apparatus is presented for troubleshooting a fiber-optic cable. A fiber-optic, cable-troubleshooting system includes an integrated Optical Time Domain Reflectometer (OTDR) for generating an optical distance to a fault and a cable-locating module for presenting a tone on a fiber-optic cable. A technician uses the tone to locate the fiber-optic cable and the optical distance to locate the fault in the fiber-optic cable. | 7 |
BACKGROUND OF THE INVENTION
The invention relates to a stage tracer used in an information processor to obtain information about errors occurring in the information processor.
The stage tracer stores the intermittent or solid changes in the internal signals of the information processor, i.e. the signals indicating the instantaneous operating conditions of the registers and the controlling flip-flop in the information processor, in a memory. When an abnormal phenomenon such as an error happens, the stage tracer stops the writing operation in the memory and then provides error information useful in analyzing causes of errors by delivering the content of the memory.
In a conventional stage tracer, the internal signals (i.e. signals to be observed) appearing at the various points in the information processor are transferred through signal lines from their source points to the memory. Namely, only one memory is provided in a suitable position in the information processor and all the internal signals are gathered and stored in the memory. In general, the memory should preferably have a capacity of several hundred words (about several hundred bits/word).
The conventional stage tracer of this type, however, can not be free from the following problems and therefore remains to be improved.
Namely, the number of the signal lines for transmitting internal signals from the flip-flops or the selected registers in the packages to the common memory must be equal to the number of the internal signals themselves, i.e. as many as more than several hundreds. Also, more than several hundred connector pins are needed for signal lines in the packages so that the assembly process and wiring process become complicated, the resulting product being disadvantageous from the standpoint of cost. Moreover, the signal lines to be used must be rather long. Accordingly, the signals tend to be attenuated or noises are apt to be mixed into the signals. To prevent these tendencies, the signals must be passed through gates, which serve as amplifiers, before being sent through the signal lines. Furthermore, the lengths of the signal lines vary depending upon the respective internal signals, i.e. the positions of the packages from which the internal signals are taken out, and therefore the internal signals indicative of the operating conditions of registers and flip-flops at the same time point reach the memory at different instants so that an exact record of internal signals is impossible. Consequently, some measures should be taken to provide phase-controlling flip-flops for the respective internal signals so as to be able to write all the internal signals in the memory simultaneously. Thus, the conventional stage tracer, which needs amplifying gates and flip-flops, incurs an increase in the cost associated with the transmission of the internal signals. Moreover, since the internal signals are transferred through long signal lines, it often happens that the waveforms of the internal signals are distorted and that an exact record of the internal signal becomes impossible. This means that errors cannot be correctly recorded and therefore that the causes of the errors cannot be properly analyzed.
FIG. 1 schematically shows a conventional stage tracer as described above.
In FIG. 1, an internal signal (1) sent from a register or a control flip-flop provided in a package 7 mounted on a mother board 13, is further sent through a timing phase controlling flip-flop 1 and an amplifying gate 2 and then taken in a cable package 8 provided on the board 13. The internal signal (1) is then transmitted through a signal line (i.e. cable) 16 to a cable package 9 mounted on a board 14 and further to a memory package 10 mounted on the board 14. A series of internal signals thus taken in the memory package 10 are simultaneously set in a write data register (hereinafter referred to write register) 4 and then written in a common memory 5. On the other hand, an internal signal (2) in a package 11 mounted on a board 15 is in phase with the setting timing of the register 4 and therefore a phase control flip-flop need not be provided. The internal signal (2) is taken out of the package 11 via an amplifying gate 6, sent through a cable 17 connecting a cable package 12 with the cable package 9 to the memory package 10, and written in the memory 5 through the write register 4. Other internal signals from the packages 7 and 11 and from packages not shown are written in the memory 5 in like manner. Now, a reference numeral 18 designates a connecter pin.
SUMMARY OF THE INVENTION
The object of this invention is to provide a stage tracer free from the above described drawbacks incidental to the conventional stage tracer.
To attain this object, the stage tracer according to this invention employs a discrete type structure which comprises plural tracing units each including a memory and the associated read/write control logic unit, and a common control unit for controlling the tracing units.
Namely, memory devices are not concentrated at a place in the circuit, but discretely provided in the respective tracing units. Signals to be observed are directly written in the memories of the associated tracing units. The tracing units are so interconnected that the contents of the memories in the respective tracing units may be sequentially read onto a data bus which is in common with all the tracing units. The operation of writing or reading internal signals in or out of the memory in one tracing unit is performed by the read/write control logic unit incorporated in the tracing unit in question under the control of the common control unit.
Such a discrete type stage tracer as described above, embodying this invention can be realized with ease and at low cost through the recently developed semiconductor technology. Namely, a single tracing unit comprising a memory and the associated read/write control logic unit is formed in a single chip and this chip, like an ordinary logic element, is mounted on a package in the information processor, which package contains internal signals to be observed. With this configuration, internal signals can be directly written in the associated memory without any amplifying gate and phase-controlling flip-flop and yet the internal signals can be recorded with high fidelity. This constitution is also advantageous from the standpoint of cost. The signal lines between the tracing units and the common control unit consist only of signal lines for controlling the reading and writing and a data bus in common with all the tracing units and therefore the number of the signal lines used in this invention is smaller than that of the signal lines used in the conventional stage tracer. According to this invention, a data bus consisting of only one signal line can suffice for an embodiment of the smallest scale. Also, since each tracing unit has its read/write control logic unit, the number of signal lines for read/write controls can be lessened. Thus, according to this invention, the stage tracer of discrete type needs a much smaller number of signal lines than the conventional stage tracer which requires about several hundred signal lines for the transmission of internal signals. Accordingly, the number of pins of each package can also be leassened.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 schematically shows the structure of a conventional stage tracer.
FIG. 2 schematically shows the structure of a discrete type stage tracer as an embodiment of this invention.
FIG. 3 shows in block diagram a concrete example of the tracing unit used in the stage tracer shown in FIG. 2.
DESCRIPTION OF THE PREFERRED EMBODIMENT
An embodiment of this invention, i.e. a discrete type stage tracer, will now be described with the aid of the attached drawings.
FIG. 2 schematically shows the structure of a discrete type stage tracer as an embodiment of this invention. Reference numerals 21 and 22 indicate tracing units mounted respectively on packages 26 and 27 in which internal signals or signal groups (1) and (2) to be observed in the information processor appear. In this embodiment, it is assumed that the packages 26 and 27 are mounted on a mother board 32. For the convenience of description, only two tracing units are shown in FIG. 2, but in practical applications more tracing units are needed and usually mounted on the packages provided on other boards. The tracing units 21 and 22 are connected, through control signal line group 25 and a line (or lines) 24 serving as a data bus and via a cable package 28 on the board 32 and a cable package 29 on a board 34, with a common control unit 23 mounted on a package 30.
Each of the tracing units 21 and 22 comprises a memory having a capacity of several words (several bits per word) and the associated read/write control logic unit. The common control unit 23 delivers write and read instructions for the respective tracing units through the control signal line group 25. Since the internal signal groups (1) and (2) are directly supplied respectively to the tracing units 21 and 22 through no transmission lines, amplifying gates and phase-controlling flip-flops need not be inserted. The content of the memory of each tracing unit 21 or 22 is serially read out, e.g. biy by bit, onto the data bus 24 under the control of the common control unit 23. The common control unit 23 edits the data bits on the data bus 24 into a word for the stage tracer and then delivers the edited word to an external apparatus such as, for example, a console printer or a display console through an I/O unit not shown.
FIG. 3 shows a concrete and preferable example of the tracing unit described above.
Reference numeral 104 indicates a memory such as a RAM and as its read/write control logic unit are provided an address register 101, a bit selection register 102, an AND circuit 103, +1 circuit 105 and a multiplexer 106. The AND circuit 103 receives a write mode line 111 and a write timing line 108 of the control signal line group 25. The address register 101 and the bit selection register 102 receive address line 107. The output of the multiplexer 106 is connected with, a data bus 24 of, for example, one signal line. In the write mode in which internal signals are to be written in the memory 104, a signal "1" is delivered onto the write mode line 111 and timing pulses are supplied to the timing line 108 so as to provide the optimal timing for simultaneously writing all the internal signals sent through a signal line group 109 in the associated tracing unit. As a result, a write pulse "1" is supplied from the AND circuit 103 to the WE (write enable) terminal of the memory 104 so that the internal signals supplied to the D IN terminal are sequentially written in the memory 104 in response to the write pulse. At this time, address information for specifying a write address for the memory 104 is supplied bit-serially to the address register 101 through the address line 107 so that the address register 101 accesses an address of the memory. Accordingly, the internal signals are simultaneously stored in the predetermined addresses in response to the write pulse.
The internal signals thus written in are the signals indicative of the operating conditions at the same time point of the selected registers and flip-flops on the package on which the tracing unit associated with the internal signals in question is mounted. The write pulse is so supplied at a suitable timing to each tracing unit that all the internal signals supplied to the unit are simultaneously written in the associated memory. The content of the address register 101 is applied to the +1 circuit 105 and incremented by unity (+1) thereby. The incremented value is applied to the address register 101 in response to the write pulse and set therein. The address register 101 accesses the next address of the memory 104. Accordingly, the internal signals indicative of the operating conditions at the next time point of the selected registers and flip-flops are simultaneously written in the addresses specified by the content of the address register 101 in response to the next write pulse. Thus, when internal signals are written sequentially in all the addresses in the memory 104, the content of the address register is restored to the first value and then the succeeding internal signals are again written in the first, second, . . . and the last addresses sequentially. In this case, the formally written contents are sequentially erased in response to the writing of the comming internal signals.
In this way, while the information processor is normally operating, internal signals are sequentially written in the memory 104 in each tracing unit. The memory 104 therefore stores internal signals written therein during a period of time determined depending on its memory capacity.
When an error in a register or a flip-flop of the information processor is detected, the common control unit 23 causes the signal on the write mode line 111 to take a value "0" so that the read mode is assumed in which the internal signals stored in the memory are to be read out. In this read mode, the address information delivered by the common control unit 23 and sent bit-serially through the address line 107 is sequentially set in the address register 101 and the bit selection register 102. First, the content of the address in the memory 104, specified in accordance with the content of the address information set in the address register 101 (i.e. internal signals indicative of operating conditions at a time point) is read out of the output terminal D OUT and supplied to the multiplexer 106. At this time, the bit selection register 102 sequentially specifies the output of the multiplexer 106 in response to the address information sent thereto through the address line 107. The multiplexer 106 selects one bit out of the read data and deliver it to the common control unit 23 through the data bus 24, which one bit is specified by the bit selection register 102. All the bits read out of the memory 104 into the multiplexer 106 are therefore delivered onto the data bus 24. Now, only a part of the bits read out into the multiplexer may be selectively delivered on the data bus 24. The address signal specifying the next address is applied to the address register 101 through the address line 107 and therefore the internal signals at the next time point are read out of the memory 104 and then supplied to the multiplexer 106. The bits delivered from the multiplexer 106 are sequentially specified by the bit selection register 102 and supplied onto the data bus 24. After all the contents of the memory 104 have been read out and supplied to the common control unit 23, they are then supplied for analysis to an external apparatus (e.g. printer or display console) through an I/O unit not shown. Now, since the write signal is not delivered in the read mode, the +1 circuit does not deliver any signal to the address register.
In the above embodiment, only one signal line is used as a data bus and the bits set in the multiplexer 106 must be read out bit by bit, that is, only one bit must be read out at a time, onto the data bus 24. However, if plural signal lines are used as a data bus, it is possible to read out several bits from the multiplexer at a time and to supply them onto the data bus. In that case, the plural bits delivered at a time may indicate the internal signals indicative of the operating conditions of the selected registers and flip-flops at a time point. Now, only a part of the data stored in the memory may be selectively read out on the data bus 24.
As described above, according to the discrete type stage tracer embodying this invention, the internal signals of an information processor can be recorded with high fidelity and moreover the reduction of the cost of the resultant product can be easily achieved. | A stage tracer comprising a plurality of tracing units which are physically independent of one another and each of which includes a memory unit and the associated read/write control logic unit, and a common control unit provided physically independent of and electrically connected with the tracing units, to supply desired control signals to the respective read/write control logic units. In each tracing unit, under the control of the common control unit, the read/write control logic unit causes the signals to be observed to be written in the memory unit and also causes the content of the memory unit to be read out onto the data bus common with all the tracing units. | 6 |
This is a continuation-in-part of copending U.S. application Ser. No. 08/021,949filed Feb. 23, 1993.
BACKGROUND OF THE INVENTION
This invention relates generally to a method and apparatus for measuring sleeping positions of an individual. More specifically, the present invention relates to a method and apparatus for measuring sleeping positions of an individual using a coordinate measuring machines (or CMM's) .
Devices for measuring an individual are known.
U.S. Pat. No. 4,425,713 discloses a postureometer instrument for measuring, in inches and degrees, posture deviations of a human body in an upright position. This device includes a base with a calibrated post, having a multiple number of adjustable pins for contact with the spinal column. It further includes a pair of elevatable yokes on the post, which are calibrated in degrees of angle, and include spaced arms having calibrated and adjustable pins for measuring various posture deviations.
U.S. Pat. No. 4,135,498 discloses a device for making physical measurements with respect to the body of a patient. The device includes a non-opaque sheet-form viewing screen mounted on a frame. The screen includes centrally located, vertically extending graduations and a graduated, horizontally extending measuring bar mounted for vertical movement relative to the vertical graduations on the screen. A rotatable angle measuring arm and an associated indicator plane is mounted for movement along the measuring bar. An x-ray light box is pivoted for movement into and out of an operative position behind the screen.
U.S. Pat. No. 3,890,958 discloses a physiological diagnostic apparatus for determining the location of, and shifts in, the center of gravity of the human body. The apparatus incorporating a body support member engaged upon a base assembly for pivoting about a transverse axis, a load responsive device located beneath the body support member in a portion thereof remote from its pivot axis, a processor for receiving signals from the load responsive device, and a readout instrument for accepting the output from the processor for display of the center of gravity behavior.
U.S. Pat. No. 4,760,851 discloses a method of performing 3-dimensional skeletal analysis on a patient. The apparatus for performing the analysis includes a digitizer, the digitizer being adapted to accept either a scanning digitizer tip or a point digitizer tip. The method including the steps of placing the patient in a variety of upright positions relevant to musculoskeletal problems and performing a series of rolling scans, with the scanning digitizer tip and single point landmark digitizations of musculoskeletal landmarks, with the point digitizer tip to obtain 3-dimensional skeletal data. The data is analyzed in order to provide clinically relevant 3-dimensional information relating to musculoskeletal quantities and imbalances. The apparatus further includes an upright column support and a retractable column support movable along the support column for supporting the patient. The digitizer includes a plurality of rotatable transducers and a plurality of link members linking the rotatable transducers. The digitizer is connected at one end to the support column and has a free end. The free end of the digitizer is adapted to accept the digitizer tip. The apparatus also includes a computer with the output of the digitizer connected to the computer to provide data to the computer for computing the position of the point or group of points on the patient's body in 3-dimensional space.
Further, it will be appreciated that everything in the physical world occupies volume or space. Position in a space may be defined by length, width and height which, in engineering terms, is often called an X, Y, Z coordinate. The X, Y, Z numbers represent the dimensions of length, width and height or three dimensions. Three-dimensional objects are described in terms of position and orientation; that is, not just where an object is but in what direction it points. The orientation of an object in space can be defined by the position of three points on the object. Orientation can also be described by the angles of alignment of the object in space. The X, Y, and Z coordinates can be most simply measured by three linear scales. In other words, if you lay a scale along the length, width and height of a space, you can measure the position of a point in the space.
Presently, coordinate measurement machines or CMM's measure objects in a space using three linear scales. These devices are typically non-portable, expensive and limited in the size or volume that can be easily measured.
FARO Technologies, Inc. of Lake Mary, Fla. (the assignee of the present invention) has successfully produced a series of electrogoniometer-type digitizing devices for the medical field. In particular, FARO Technologies, Inc. has produced systems for skeletal analysis known as METRECOM® and systems for use in surgical applications known as SURGICOM™. Electrogoniometer-type devices of the type embodied in the METRECOM and SURGICOM systems are disclosed in U.S. Pat. No. 4,760,851 (described above) and U.S. Pat. No. 5,305,203 issued Apr. 19, 1994 and U.S. Pat. No. 5,251,127 issued Oct. 5, 1993 all of which are assigned to the assignee hereof and incorporated herein by reference.
Problems of lower back pain are well-known, and it is believed that a significant contribution to such back problems can be attributed to improper sleeping position. Biomechanists and clinicians have determined that a sleeping position which allows the body to be in a neutral position is the one which causes the least stress on the various joints and more importantly the lower spine and pelvic area. Such a proper sleeping position is defined as the position in which the body centerline lies in a plane which is parallel to the ground, whereby the spine, pelvis, neck and lower legs are not required to rotate or bend with respect to each other in order to adapt to the sleeping surface (e.g., a mattress). Accordingly, a need exists for a method or a device which would allow individuals to sleep in this preferred sleeping position.
SUMMARY OF THE INVENTION
The above-discussed and other problems and deficiencies of the prior art are overcome or alleviated by the method and apparatus for measuring sleeping positions of the present invention. In accordance with the present invention, a method for measuring sleeping positions using a portable coordinate measuring machine is presented. The measured sleeping position information can be used to select or design a mattress which will result in a preferred sleeping position, whereby stresses on the individual's back and other muscles are minimized. The portable coordinate measuring machine (e.g., the CMM described in U.S. patent application Ser. No. 08/021,949) comprising a multijointed manually positionable measuring arm for accurately and easily measuring a plurality of points or landmarks of an individual.
The preferred mechanical measuring arm used in the CMM of this invention is generally comprised of a plurality of transfer housings (with each transfer housing comprising a joint and defining one degree of rotational freedom) and extension members attached to each other with adjacent transfer housings being disposed at right angles to define a movable ann having, in this example, five or six (at least two degrees) of freedom. In addition, each transfer casing includes visual and audio endstop indicators to protect against mechanical overload due to mechanical stressing.
The METRECOM system may be the preferred coordinate measuring machine for use with the method of the present invention, since the high accuracy of the coordinate measuring machine described in U.S. patent application Ser. No. 08/021,949 is not likely required.
In accordance with the method of the present invention, the 3-dimensional digitizer measures the vertical height of a point from the floor (or other level surface) or preferably the position of the point along an axis parallel to the floor. A number of body landmarks are measured so that the computer can determine the relative difference between the landmarks, whereby the body's (or individual's) center axis (or line) can be defined. From this information, a mattress can be designed or selected so that the individual's center line is maintained in a more or less parallel plane relative to the floor when the individual is in a sleep position. Thereby, eliminating the above-discussed problems related to improper sleeping positions.
The above-discussed and other features and advantages of the present invention will be appreciated and understood by those skilled in the art from the following detailed description and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
Referring to the drawings, wherein like elements are numbered alike in the several FIGURES:
FIG. 1 is a front diagrammatic view depicting the three dimensional measuring system of the present invention including a coordinate measuring machine, a controller box and a host computer;
FIG. 2 is a side elevation view depicting the host computer mounted on the serial box, which is in turn, mounted on a maneuverable arm;
FIG. 3 is a side elevation view of the three dimensional measuring system of the present invention mounted on a theodolite stand;
FIG. 4 is a rear elevation view of the CMM shown in FIG. 1;
FIG. 5 is a longitudinal view, partly in cross-section of the CMM of FIG. 1;
FIG. 6 is an exploded, side elevation view of a transfer housing used in the CMM of FIG. 1;
FIGS. 6A and 6B are views along the lines 6A--6A and 6B--6B, respectively, of FIG. 6;
FIG. 7 is a cross-sectional elevation view of two assembled, transversely orientated transfer housings;
FIG. 8 is an enlarged, side elevation view of a counterbalanced spring device used in the CMM of FIG. 1;
FIGS. 9A and 9B are top and bottom plan views depicting the handle/probe assembly of FIG. 1;
FIGS. 10A and 10B are respective side elevation views of a ball probe and a rounded probe;
FIG. 11 is an enlarged front view of the controller box of FIG. 1;
FIG. 12 is an enlarged rear view of the controller box of FIG. 1;
FIG. 13 is a schematic view of the electronic components for the three dimensional measuring system of FIG. 1;
FIG. 14 is a side elevational view of the theoretical optimum body position with a straight line drawn through specific landmarks as per an idealized upright posture; and
FIGS. 15 and 16 are views of a computer screen display showing examples of digitized landmark measurements defining the center axis of an individual relative to the floor in a selected preferred sleeping position.
FIG. 17 is an elevational view of a sleeping product having varying thicknesses for leveling purposes.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring first to FIG. 1, the three dimensional measuring system used in the present invention generally comprises a coordinate measuring machine (CMM) 10 composed of a manually operated multijointed arm 12 and a support base or post 14, a controller or serial box 16 and a host computer 18. It will be appreciated that CMM 10 electronically communicates with serial box 16 which, in turn, electronically communicates with host computer 18.
As will be discussed in more detail hereinafter, CMM 10 includes transducers (e.g., one transducer for each degree of freedom) which gather rotational positioning data and forward this basic data to serial box 16. Serial box 16 provides a reduction in the overall requirements of host computer 18 to handle certain complex calculations and provides certain preliminary data manipulations. As shown in FIG. 2, serial box 16 is intended to be positioned under the host computer 18 (such as the notebook computer shown in FIG. 2) and includes EEPROMS which contain data handling software, a microcomputer processor, a signal processing board and a number of indicator lights 20. As mentioned, basic transducer data is sent from CMM 10 to serial box 16. Serial box 16 then processes the raw transducer data on an ongoing basis and responds to the queries of the host computer with the desired three-dimensional positional or orientational information.
Preferably, all three components defining the three dimensional measuring system of this invention (e.g., CMM 10, serial box 16 and host computer 18) are mounted on either a fixed mounting surface using a rigid plate and/or a standard optical measurement instrument thread followed by mounting on a known and standard theodolite mobile stand such as shown at 22 in FIG. 3. Preferably, theodolite stand 22 comprises a part no. MWS750 manufactured by Brunson. Such a mobile stand is characterized by a stable rolling platform with an extendable vertical tower and with common attachments and locking mechanisms. As shown in FIGS. 2 and 3, support base 14 of CMM 10 is threaded or otherwise attached onto a vertical support member 24 of stand 22 while serial box 16/host 18 is supported on a shelf 26 pivotally connected at a first joint 28 to an arm 30 which is pivotally connected to a second joint 32. Connecting member 34 interconnects joint 32 to a swivel connection 36 attached to a cap 38 mounted over the top of member 24.
Referring now to FIGS. 1 and 4-9, CMM 10 will now be described in detail. As best shown in FIG. 5, CMM 10 comprises a base 14 connected to a first set of two transfer housings including a first transfer housing 40 which, in turn, is connected to a second transfer housing 42 (positioned transverse to housing 40). A first extension member 44 is rigidly attached to a second set of two transfer housings including a third transfer housing 46 transversely attached to a fourth transfer housing 48. First extension member 44 is positioned perpendicularly between transfer housings 42 and 46. A second extension member 50 is aligned with and rigidly attached to transfer housing 48. Rigid extension member 50 is rigidly attached to a third set of two transfer housings including a fifth transfer housing 52 transversely attached to a sixth transfer housing 54. Fifth transfer housing 54 has attached thereto a handle/probe assembly 56.
In general (and as will be discussed in more detail hereinafter), position sensing transducers are mounted in each of the six transfer housings 40, 42, 46, 48, 52 and 54. Each housing is comprised of bearing supports and transducer compartments which are made to then cylindrically attach to each other using 45° angled attachment screws (FIG. 6). At the base 14 is a counterbalanced spring device 60 for support of arm 12 in its standard vertical configuration (FIG. 8).
Turning now to FIGS. 6 and 7, a detailed description will be made of a transfer housing and its internal components. It will be appreciated that FIG. 6 is an exploded view of a transfer housing, while FIG. 7 shows an enlarged view of the transversely oriented and attached transfer housings (e.g., housings 46 and 48). Each housing includes an internal carrier 62 and an external casing 64. Mechanical stability between internal carrier 62 and external casing 64 is provided by two counter-positioned (e.g., oppositely disposed) conical roller bearings 66, 68 positioned to compress against their respective conical races, 70, 72. Conical races 70 and 72 are permanently affixed into the external transfer casing 64. Carrier 62 includes a shaft 122 extending therefrom and terminating at threading 74. Conical bearings 66, 69 are preferably made from hardened steel while races 70, 72 are also made from hardened steel.
During assembly of transfer casing 48, a compressional force is applied using a nut 73, which is tightened to a specific torque on threads 74, providing a prestressed bearing situation resulting in no motion other than axial rotation under typically applied loads. Because of the necessity of a low profiled or such an arm during manual handling and the attendant reduction in the overall stiffness, it is preferable and, in fact required in certain applications, to also install a thrust bearing 76 at the interface between carrier 62 and casing 64. Thrust bearing 76 provides further mechanical stiffening between carrier 62 and casing 64 of the transfer housing. Thrust bearing 76 comprises five elements including thrust adjustment ring 300, flat annular race 302, roller bearing and cage 304, annular race 306 and opposing thrust cover 308. Thrust bearing 76 is adjusted through a series of set screws 78 and provides for high bending stiffness. The transducer, (preferably an encoder 80 such as is available from Heidenhain under the designation Mini-Rod, part no. M-03600), is mounted to a universal mounting plate 82 for mounting into the transfer casing. Universal mounting plate 82 is important in satisfying possible component availability problems such that a change in manufacture of transducer 80 and, hence, the change in mounting screw configuration can be accommodated through modifications in the mounting plate 82. Mounting plate 82 is shown in FIG. 6A as a triangular shaped plate having rounded corners. FIG. 6A also depicts threaded members 88 and 90, a pin 86 and a coupler 84 (all of which are discussed hereinafter).
High accuracy rotational measurements using encoders 80 require that there should be no loads applied to the encoders and that motion of the transfer casing be accurately transmitted to the encoder despite small misalignments of the axis of the transfer casing and axis of the encoder. The angular transfer errors are well known to those skilled in the art from the published encoder literature. Communicating with encoder 80 is a coupler 84 such as is available from Rembrandt under the designation B1004R51R. An extension shaft 86 is utilized for ultimately connecting encoder 80 to the transfer casing 64. Shaft 86 is attached both to coupler 84 and to the end of carrier 62 at threading 74 using set screws 88, 90 (see FIG. 7). An electronic preamplifier board 92 is positioned in close proximity to encoder 80 and is mounted (via screws 94) on the inside of cap cover 96. Cap cover 96 is attached to casing 64 via screw 97. A transition housing 98 interconnects cap cover 96 to casing 64 via screw 97 and screws 100. Sealing of the transfer housing to the environment is accomplished at the joint using an O-ring groove 102 in which is mounted a standard rubber O-ring groove 104. A rotational endstop 106 (to be discussed hereinafter), is best shown in FIG. 6B and comprises a square shaped metal housing having an opening therethrough which is mounted onto casing 64 using bolt 108 threaded through the opening of the housing. Wires pass through grommets to stop abrasion over long term use are mounted on both carrier 62 and casing 64 at 110 and 112. A location pin 114 is received by a complimentary shaped recess 116 in carrier 62 for the purpose of maintaining relative orientation of two adjacent transfer casings.
Referring to FIG. 7, for environmental and other reasons, it is important that all wires be completely hidden from sight and, therefore, contained within the arm 12. FIG. 7 depicts two assembled transfer housings 46, 48 mounted perpendicularly to each other and demonstrating the passage of wires. It will be appreciated that during use of CMM 10, the encoder information from encoder 80 is passed to its processor board 92 through wire 118 which is then amplified and passed through the arm by machined passageways 120. Wire 118 then passes through a channel 120 in the shaft 122 of the internal carrier 62 of the transfer casing 46 and through a grommetted hole 124 at which time it passes into a large cavity 126 machined on the external casing 64 of transfer housing 46. Cavity 126 permits the coiling of the wire strands during rotation of the transfer casing and is configured so as not to produce any wire abrasion and a minimum of wire bending. However, because the wire limits the overall ability to fully rotate, an incomplete spherical groove 128 is created in which is positioned an endstop screw 130, which limits the full rotation, in this case to 330°. It will be appreciated that the pass through channel 120 and wire coiling cavities 122 are subsequently repeated in each transfer casing allowing the wires to progressively make their way down to the connector mounted at the base 14, resulting in no exposed wiring.
Turning now to FIG. 8, the construction of the aluminum arm as well as the various bearings and transducers results in an accumulated weight of approximately 10 to 15 pounds at the probe handle assembly 56 of CMM 10. Under normal circumstances, this would create a significant amount of fatigue during use and, hence, must be counterbalanced. Weight counterbalances are not preferred since they would significantly increase the overall weight of the device when being considered for transportability. Therefore, in a preferred embodiment counterbalancing is performed using counterbalance device 60 which comprises a torsional spring 132 housed in a plastic casing 134 and mounted at transfer housing 42 at base 14 for providing a lift for arm 12. Coiled torsional spring 132 can be mounted in a variety of positions affecting the overall pretension and, hence, may be usable on a variety of lengths and weights of arms 12. Similarly, due to the weight of arm 12 and the effect of the recoiled spring, significant shock loads may occur when repositioning the arm to the storage position. To prevent significant shocking of the arm upon retraction, air piston shock absorber 134 is also configured into plastic housing 142 of counterbalance spring device 60. This results in an absorption of the shock load and slow relaxation into the rest position. It will be appreciated that FIG. 8 depicts the shock absorber 134 in a depressed configuration.
In FIGS. 9A and 9B, top and bottom views of probe handle assembly 56 are shown. Probe handle assembly 56 is meant to be held as either a pencil or pistol grip and possesses two switches (items 150 and 152 in FIG. 9A) for data taking, a connector (item 154 in FIG. 9B) for the attachment of optional electronics and a threaded mount 156 for receiving a variety of probes. Because the CMM 19 is a manual measurement device, the user must be capable of taking a measurement and then confirming to CMM 10 whether the measurement is acceptable or not. This is accomplished through the use of the two switches 150, 152. The front switch 150 is used to trap the 3-dimensional data information and the back switch 152 confirms its acceptance and transmits it to the host computer 18. On the back of the switch enclosure 158 (housing 150, 152) is connector 154 which possesses a number of voltage lines and analog-to-digital converter lines for general attachment to a number of options such as a touch probe.
A variety of probes may be threaded to handle assembly 56. In FIG. 10A, hard 1/4 inch diameter ball probe 158 is shown while in FIG. 10B, a hard 1/4 inch rounded probe 160 is shown. Both probes 158, 160 are threadably mounted to mount 156 (using male threaded member 157), which in turn, is threadably mounted to probe housing 58. Mount 156 also includes a plurality of flat surfaces 159 for facilitating engagement and disengagement of the probes using a wrench.
Turning now to FIGS. 11 and 12, a description of the controller or serial box 16 now follows. FIG. 11 shows the front panel face 162 of the controller or serial box 16. Front panel 162 has eight lights including power indicator light 164, error condition light 166, and six lights 20, one for each of the six transducers (identified as items 1-6) located in each transfer housing. Upon powering up, power light 164 will indicate power to the arm 12. At that time, all six transducer lights will indicate the status of each of the six transducers. The transducers are preferably incremental digital optical encoders 80 and require referencing. However, the transducers may be analog devices. Hence, upon start up, each of the six joints (e.g., transfer housings) must be rotated to find the reference position at which time the six lights shall turn off.
During use, should any of the transducers approach its rotational endstop 106 from within 2 degrees, a light and an audible beep for that particular transducer indicates to the user that the user is too close to the end stop; and that the orientation of the arm should be readjusted for the current measurement. The serial box 16 will continue to measure but will not permit the trapping of the data until such endstop condition is removed. A typical situation where this endstop feature is necessary is the loss of a degree of freedom by the rotation of a particular transducer to its endstop limit and, hence, the applications of forces on the arm causing unmeasured deflections and inaccuracies in the measurement.
At any time during the measurement process, a variety of communication and calculation errors may occur. These are communicated to the user by a flashing of the error light and then a combination of lights of the six transducers indicating by code the particular error condition. It will be appreciated that front panel 162 may alternatively utilize an alphanumeric LCD panel giving alphanumeric error and endstop warnings.
Turning to FIG. 12, the rear panel 168 of serial box 16 includes a variety of standard PC connectors and switches including a reset button 170 which resets the microprocessor; an AC input fan 172 for air circulation; a connector 174 for a standard PC AT keyboard, connector 176 for an optional VGA board for monitoring of the internal operations of serial box 16, connector 178 for receiving the variety of signal lines for the CMM data, and connector 180 for the standard RS232 connector for the host 18.
Serial box 16 is responsible for monitoring the temperature of the CMM and in real time modifying the kinematics or mathematics describing its motion according to formulas describing the expansion and contraction of the various components due to changes in temperature. For this purpose, and in accordance with an important feature of this invention, a temperature monitoring board 182 (which includes a temperature transducer) is positioned at the location of the second joint 42 on the interior of a cover 184 (see FIGS. 4 and 5). CMM 10 is preferably constructed of aircraft grade aluminum externally and anodized. Preferably, the entire arm 12 is constructed of the same material except for the mounting screws which are stainless steel. The same material is used throughout in order to make uniform the expansion and contraction characteristics of arm 12 and make it more amenable to electronic compensation. More importantly, the extreme degree of stability required between all parts through the large temperature range requires that there be no differential thermal expansion between the parts. As mentioned, the temperature transducer 182 is preferably located at transfer housing 42 because it is believed that this location defines the area of highest mass and is therefore the last area to be stabilized after a large temperature fluctuation.
Referring now to FIG. 13, the overall electronic schematic layout for CMM 10 and serial box 16 is shown. Six encoders 80 are shown with each encoder having an amplifier board 92 located in close proximity to it for the minimization of noise on signal transfer. An option port 154 is shown which is a six pin connector available at the handle 56 for the attachment of a variety of options. Two control buttons 150 and 152 for indicating to serial box 16 the measurement process, are also shown.
The temperature transducer is associated with a temperature circuit board 182 which is also located in arm 12 as shown in FIG. 13. In accordance with still another important feature of this invention, the temperature board 182 comprises an EEPROM board. The EEPROM is a small computerized memory device (electrically erasable programmable read only memory) and is used to contain a variety of specific calibration and serial number data on the arm. This is a very important feature of this invention which permits high quality control of CMM 10 and importantly, precludes the inadvertent mixup of software and arms. This also means that the CMM arm 12 is a stand alone device not requiring specific calibration data to reside in controller box 16 which may need to be separately serviced and/or switched with other machines.
The electronic and pulse data from the arm electronics is then transmitted to a combined analog-to-digital converter/digital counting board 186 which is a paired set comprising a 12 bit analog to digital converter and a multi channel 16 bit digital counter. Board 186 is positioned on the standard buss of the controller box. The counting information is processed using the core module 188 (comprising a commercially available Intel 286 microprocessor such as a part number CMX-286-Q51 available from Ampro) and programs stored on an EEPROM also residing in the controller box. Subsequent data is then transmitted through the serial communication port 189.
The microprocessor-based serial box 16 permits preprocessing of calculations specific to CMM 10 without host level processing requirements. Typical examples of such preprocessor calculations include coordinate system transformations and outputting data in specific formats required for downloading to a variety of hosts and user programs.
The serial box is configured to communicate with a variety of host formats including PC, MSDOS, Windows, Unix, Apple, VME and others. Thus, the serial box processes the raw transducer data on an ongoing basis and responds to the information requests or polling of the host computer with the desired three dimensional positional or orientational information. The language of the serial box is in such a form that drivers or computer communication subroutines in microprocessor 188 are written in the language of the host computer so as to drive the serial port and communicate with CMM 10. This function is designated the "intelligent multi-protocol emulation and autoswitching" function and works as follows: A variety of host programs may be installed on the host computer. These host programs will poll the serial port with a variety of requests to which the serial box must respond. A number of protocols have been preprogrammed into the serial box to responds to polls or inquiries on the serial port for a variety of different, popular softwares. A polling request by a software requires a specific response. The serial box will receive the polling request, establish which protocol it belongs to, and respond in the appropriate manner. This allows transparent conmunication between CMM 10 and a wide variety of application software such as computer aided design and quality control softwares, e.g., AutoCad® from Autodesk, Inc., CADKEY® from Cadkey, Inc., and other CAD programs; as well as quality control programs such as GEOMET® from Geomet Systems, Inc. and Micromeasure III from Brown and Sharpe, Inc.
The three dimensional CMM of the present invention operates as follows. Upon power up, the microprocessor 188 in the serial box 16 undergoes start up self-checking procedures and supplies power through the instrument port to arm 12 of CMM 10. The microprocessor and software residing on EEPROM 182 determines that upon initial power up none of the encoders 80 have been initialized. Hence, the microprocessor 188 sends a signal to the display board lighting all the lights 20, indicating a need to be referenced. The user will then mechanically move the arm which will cause the transducers to individually scan their range, at which time a reference mark is passed. When the reference mark is passed, the digital counter board 186 responds by trapping its location and identifying to the front display board 20 that the transducer has been referenced and the light is extinguished. Once all transducers have been referenced, the system establishes serial communication with the host and waits for further instruction. Pressing of the front or back button of handle 56 will initiate a measurement process. Pressing the front button 150 will trap the current transducer readings. Pressing the back button 152 will indicate to the microprocessor that these values are to be translated into dimensional coordinates and issued through the serial port to the host 18. The host 18 and the serial box 16 will then continue to react to each other's serial line requests.
Subsequent to assembly of CMM 10, the device is optimized or calibrated in accordance with the method describe in U.S. patent application Ser. No. 08/021,949. Further, the CMM 10 is initialized in the same manner described in U.S. patent application Ser. No. 08/021,949.
While the above generally describes the coordinate measuring machine of U.S. patent application Ser. No. 08/021,949, such a high accuracy measuring device, may not be required. It may be preferred, from a cost standpoint, that the aforementioned METRECOM MODEL: IND-01 Coordinate Measuring Machine commercially available from FARO Technologies, Inc., Industrial Division, 125 Technology Park, Lake Mary, Fla. 32746 (assignee of the present invention) be employed. The METRECOM system performs the same functions as the above described system, however with reduced accuracy and at a substantial cost savings. The IND-01 model differs from the above described CMM in that an external processor is not used. An analog-to-digital interface board is preferably installed directly into host computer 18 with direct connection/communication with the transducers in the arm. However, an analog-to-digital converter could alternatively be housed in a separate box having a serial or parallel output. Further, the IND-01 model does not include temperature compensation or pre-amplifier boards at each of the joints. Also, ball bearings are used in place of the conical roller bearings, although each transfer casing has double bearings which are pre-assembled and stressed in the same manner.
A CMM (e.g., as described above with reference to U.S. patent application Ser. No. 08/021,949 or the METRECOM Model: IND-01) is used to measure body landmarks of an individual. It will be appreciated that, while a multi-axial rotational device as described above is preferred, a linear measurement type apparatus may suffice. For example, an electronic height gauge could be used for some of the measurements.
Prior to measuring these landmarks certain information regarding the individual's sleeping habits are entered into the computer. A preferred sleeping position is selected from the below list;
(1) Prone (face down),
(2) Supine (on the back),
(3) Fetal (curled on the side), or
(4) Fetal/Prone (upper body face down and legs curled on the side). Also, whether a pillow is use and the type of pillow used (i.e, firm or soft) is entered. Menus can be employed to enter the above and other information. Again, theoretically the optimum body position is one which allows a straight line to be drawn through specific landmarks as per an idealized upright posture, see FIG. 14. It will be appreciated, that it will not always be possible to touch (i.e., probe or measure) all relevant landmarks and certain assumptions may have to be made as a function of body types and proportions for typical individuals requiring measurement adjustments, referred to herein as Z-adjustments. Handle/probe assembly 56 (after having been initialized) is positioned at the following landmarks and these positioned are stored:
(1) top middle of the head (optional depending on pillow use),
(2) top left shoulder,
(3) top right shoulder,
(4) base of the spine,
(5) the highest point of the left knee,
(6) the highest point of the right knee,
(7) the highest point of the left ankle,
(8) the highest point of the right ankle,
(9) the front of the left hip bone, and
(10) the from of the right hip bone.
The aforememioned Z-adjustments are a function of pelvic (i.e., hip bone measurements), knee and ankle measurement and of the distance between various landmarks or bone length. It is sufficient for the present invention that any differences are to rounded to the nearest inch. A total of five offsets are to be determined at the head, shoulder, pelvis, knee and ankle. Alignment is defined as an index as follows:
ALIGNMENT INDEX=HEAD OFFSET+SHOULDER OFFSET+HIP OFFSET+KNEE OFFSET
with the ankle offset being the reference.
Z-offsets are calculated as follows:
ANKLE.sub.REF =(POSITION.sub.LEFT ANKLE (Z)+POSITION.sub.RIGHT ANKLE (Z))/2+ZADJUSTMENT.sub.ANKLE /2,
HEAD OFFSET=POSITION.sub.HEAD --ANKLE.sub.REF,
SHOULDER OFFSET=(POSITION.sub.LEFT SHOULDER (Z)+POSITION.sub.RIGHT SHOULDER (Z))/2-ANKLE.sub.REF,
HIP OFFSET=POSITION.sub.BASE OF SPINE --ANKLE.sub.REF, or HIP OFFSET=(POSITION.sub.LEFT HIP (Z)+POSITION.sub.RIGHT HIP (Z))/2+ZADJUSTMENT.sub.HIP -ANKLE.sub.REF,
KNEE OFFSET=(POSITION.sub.LEFT KNEE (Z)+POSITION.sub.RIGHT KNEE (Z))/2+ZADJUSTMENT.sub.KNEE /2--ANKLE.sub.REF.
The Z-adjustments (ZADJUSTMENT) are calculated as follows:
ZADJUSTMENT.sub.ANKLE =-K.sub.ANKLE *LENGTH.sub.HIP TO KNEE,
ZADJUSTMENT.sub.KNEE =-K.sub.KNEE *LENGTH.sub.HIP TO KNEE,
ZADJUSTMENT.sub.HIP =-K.sub.HIP *LENGTH.sub.HIP TO KNEE,
where K ANKLE , K KNEE and K HIP are proportions expected for different body types, for example, K ANKLE is the thickness of the ankle in the medial lateral direction or anterior posterior direction as a ratio to the length of the femur, the long bone from the hip to the knee. Alternatively, a body type may be selected before proceeding with measurements to provide extra precision in selection of the correct K values. Such selection could be made from a menu at the host computer. The hip (i.e., pelvis) to knee length has been found to be an excellent representation of overall bone size.
Once these landmarks have been digitized and the digitized measurements adjusted as described above the center axis of the individual is displayed relative to the floor (or a plane parallel thereto) on the computer screen. It will be appreciated that the digitized landmarks were taken while the individual was lying in the selected preferred sleeping position, see examples in FIGS. 15 and 16. A mattress is then selected which will provide the best leveling of the individuals center line in the desired sleep position. Information on a plurality of mattresses can be loaded into the computer and the computer can make this levelness determination, whereby the mattress with the most level body center line for the individual is selected, using the alignment index defined above. Thereby, eliminating many of the above-discussed problems related to improper sleeping positions.
Alternatively, a mattress or bed can be designed where mattress stiffness in the regions of the shoulders, pelvis, and feet (ankles) is varied or variable so as to result in a leveling of sleeping position. In will be appreciated that portions of a mattress can be elevated or lowered at various regions or can be manufactured with varying thicknesses over the length of a mattress to accomplish the same purpose.
While preferred embodiments have been shown and described, various modifications and substitutions may be made thereto without departing from the spirit and scope of the invention. Accordingly, it is to be understood that the present invention has been described by way of illustrations and not limitation. | A method for measuring sleeping positions using a portable coordinate measuring machine is presented. The measured sleeping position information can be used to select or design a mattress which will result in a preferred sleeping position, whereby stresses on the individual's back and other muscles are minimized. The portable coordinate measuring machine comprising a multijointed manually positionable measuring arm for accurately and easily measuring a plurality of points or landmarks of an individual. | 6 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of U.S. patent application Ser. No. 10/495,500, filed May 13, 2004, which issued as U.S. Pat. No. 7,034,227 on Apr. 25, 2006, and which claims the benefit of Provisional Application Ser. No. 60/404,688 filed Aug. 19, 2002, and priority to International PCT Application Serial No. PCT/US03/25867, filed Aug. 19, 2003.
TECHNICAL BACKGROUND
The disclosure relates to a conduit system adapted for containing and protecting various types of wiring laid alongside, beneath, or otherwise adjacent to railroad tracks.
BACKGROUND
Railroad lines provide an ideal location for the placement of various types of cabling. Included in this group are electrical cables and other types of communication cabling. However, because of the nature of the materials from which railway lines are constructed, it is inadvisable to simply bury a cable beneath a railroad line. The pressures and abrasive action of the ballast used to support railway lines quickly degrade any cables buried without protection. In addition, repairs to cabling may interfere with the travel of trains over the railway lines.
Various types of conduit have been provided for the protection of cables laid alongside or beneath rail lines. Examples include extruded plastic, pre-cast concrete, cast-in-place concrete, molded composite materials having random orientation of fiber-reinforcing strands therein, and steel. Concrete, both pre-cast and cast-in-place, is extremely heavy and therefore installation may be quite expensive. Extruded plastic cable troughs, both unreinforced and reinforced with randomly oriented fiber strands, have relatively low strengths and, accordingly, shorter life spans and reduced ability to withstand the rigors of installation adjacent a railway lines. Cast or molded thermoplastic materials having randomly oriented fibers tend to be somewhat stronger than unreinforced types of cabling trough, but are quite expensive. Steel cable trough can also be quite expensive. Accordingly, there is recognized a need for a cable trough for railway cabling that has high strength and is lightweight and durable and yet which is inexpensive.
These and other objectives and advantages will appear more fully from the following description, made in conjunction with the accompanying drawings wherein like reference characters refer to the same or similar parts throughout the several views.
SUMMARY OF THE DISCLOSURE
The cable trough disclosed herein embodies an elongate channel that has a bottom and a pair of sidewalls that extend upwardly therefrom in a generally parallel relationship with each other. A removable top is adapted to be placed onto the sidewalls and can be secured to the channel in order to enclose cables disposed within the channel. Preferably, both the channel and the top of the cable trough are formed of a thermosetting resin having contained therein generally uniformly longitudinally oriented reinforcing fibers. These materials are fabricated into the cable trough, preferably using a pultrusion process.
Respective lengths or sections of the channel from which the cable trough is made are connected to one another by one or more, and preferably three, connecting clips that are secured between the sidewalls and/or bottom of the respective sections in order to connect them to one another. The connecting clip has a central web with a first and second edge and a pair of stringers that are connected to the first and second edges. The stringers are spaced apart by the web and are generally parallel to one another. The stringers and the web together form a pair of diametrically opposed mouths that are adapted to clamp therein a sidewall or bottom of the channel or the cover of the cable trough. In general, the connecting clip has an “H”-shaped cross-section. One benefit to the use of this type of connecting clip is that no tools are required to assemble a run of the cable trough.
The cable trough is relatively simple to install. A method for installation of the cable trough begins with identifying the path where the cables must be run. A first and then a second or subsequent section of the cable trough will then be emplaced along the path along which the cable is to run in an end-to-end relationship. At least one of the connecting clips is installed between the respective ends of each subsequent section of cable trough in order to secure the sections to one another. Once the channel portion of the cable trough has been installed, the requisite cables are laid within the trough and the cable trough covers are placed onto the channel sections of the cable trough and removably secured thereto in order to protect the cables from the exterior environment.
It is to be understood that the cable trough may take many shapes and forms, including elongate straight sections, curved sections, T-connectors, and other variously shaped connectors and runs.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded cross-sectional perspective view of a typical cable trough illustrating the relationship between the channel of the trough and its cover.
FIGS. 2 a - 2 c illustrate a T-section, a 45° bend, and a 90° bend in the cable trough, respectively.
FIG. 3 illustrates an H-clip of the type used to assemble two sections of cable trough.
FIG. 4 illustrates a cross-sectional view of a cable trough according to another embodiment.
FIG. 5 illustrates a perspective view of the cable trough of FIG. 4 .
DETAILED DESCRIPTION
Although the disclosure hereof is detailed and exact to enable those skilled in the art to practice various embodiments, the physical embodiments herein disclosed merely exemplify the invention which may be embodied in other specific structures. While certain embodiments have been described, the details may be changed without departing from the invention, which is defined by the claims.
Cable trough is typically installed alongside railway lines, either above grade or below grade, depending on the application. Above-grade installations of cable trough may be made directly on the surface of the ballast that supports a railway line, or in an elevated position where the cable trough has been secured to, for example, the wall of a railway tunnel.
FIG. 1 illustrates a cross-section of a typical cable trough constructed and arranged according to one example embodiment. Note that any dimensions appearing in the figures are by way of illustration only and it is to be understood that the embodiments disclosed herein are not limited to those dimensions. The cable trough 10 essentially comprises a channel 12 having a top such as cover 14 . The channel comprises a pair of generally vertical sidewalls 16 extending upwardly from and secured to a bottom such as base plate 18 . Each of the sidewalls 16 has on an inner surface thereof an inwardly extending lip 20 that may be formed continuously along the sidewall 16 or in certain predetermined locations as desired. The lip 20 serves as a part of a closure mechanism that retains the cover 14 on the channel 12 once the cable trough 10 has been installed.
The cover 14 essentially comprises an elongate plate 22 that has a width and length that are commensurate in scope with those of the channel 12 . The plate 22 has a pair of channel members 24 that extend downwardly therefrom and which engage the upper edges of the respective sidewall 16 of the channel 12 . Note that the channel members 24 address both sides of the upper edge of the sidewalls 16 . In FIG. 1 the cover 14 and channel 12 are shown in their disassembled position.
When the cover 14 has been seated firmly onto the channel 12 , with the upper edges of the sidewalls 16 seated within the channel members 24 of the cover 14 , one or more connector bolts may be passed downwardly through the cover through countersunk bores 26 formed therein. The connector bolts (not shown) have a cam or other offset projection extending from a distal end thereof such that when the connector bolt is rotated, as by screwdriver or the like, to a closed position, the cam or projection will be positioned beneath the lip 20 of the sidewall 16 . When in its closed position, the connector bolts will secure the top 14 to the channel 12 to complete the cable trough 10 . As can be appreciated, cabling, whether electrical, mechanical or fiber optic, is laid in the channel 12 of the cable trough 10 before the cover 14 is placed thereon.
It should be understood that the cable trough 10 is not waterproof as such. Accordingly, in order to prevent the accumulation of water and ice inside the channel 12 of the cable trough 10 , one or more drain holes 15 may be formed through the bottom of the trough to allow water to exit the channel 12 .
FIGS. 2 a - 2 c illustrate various types of connectors that may be interposed between straight sections in order to run the cable trough 10 around corners and to create slightly more complex networks. FIG. 2 a illustrates a simple tee 30 . FIG. 2 b illustrates a 45° bend 32 and FIG. 2 c illustrates a 90° bend 34 . It is to be understood that the connectors illustrated in FIGS. 2 a - 2 c are exemplars only, and many more connectors useable with the cable trough 10 may be created for use therewith.
FIG. 3 is a schematic view of the cable trough 10 of the illustrating how two sections of the cable trough 10 are secured to one another. As can be seen in FIG. 3 , successive sections of cable trough 10 are laid end to end. One or more clips 40 are used to connect the respective bottom surfaces 18 and sidewalls 16 of the cable trough portions 10 . The clips 40 are generally “H” shaped in profile having a central web 42 that connects first and second stringers 44 and maintains them in a generally parallel relationship with one another. These stringers 44 are spaced apart or otherwise constructed and arranged to resiliently clamp the sidewalls 16 of the respective cable trough portions therebetween. It is preferred to utilize a single clip 40 for each sidewall 16 and bottom 18 in order to connect the successive portions of cable trough 10 . The assembly of the successive portions of cable trough 10 may be achieved without the use of tools, the clamping action of the clips 40 working in conjunction with the weight of ballast typically placed on or around the cable trough 10 to maintain the cable trough 10 in its assembled state.
The method of assembling cable trough 10 comprises the steps of emplacing a first portion of cable trough in a predetermined position and emplacing a second portion of cable trough 10 in the second predetermined position adjacent the first portion of cable trough such that the end portions of the cable trough are adjacent one another. The clips 40 are attached to the end of the first portion of cable trough 10 and the end of the second portion of cable trough is then inserted into the remaining free ends of the clips 40 to secure the two portions of cable trough to one another. Note that this process is essentially the same for connecting straight portions of cable trough 10 as for connecting straight portions to connectors, or connectors to connectors. Once the portions of channel 12 have been secured to one another and the desired cabling has been placed therein, complementary covers 14 are placed onto the channels 12 of the cable trough 10 and secured thereto using connector bolts passed through countersunk bores 26 in the cover 14 .
In order to achieve a suitable level of strength the channels 12 of the cable trough, and preferably the connectors as well, are produced using an extrusion method commonly referred to as pultrusion. Essentially, continuous strands of reinforcing fibers, typically glass, although other types of reinforcing fibers may be used, are coated or wetted with a heat-curable thermosetting polymeric resin and then pulled through a forming die. The forming die is heated so as to set and cure the resin in the desired shape. The benefit to using this pultrusion method is that the reinforcing fibers present within the sidewall 16 and bottom 18 of the channel, and also those reinforcing fibers present in the cover 14 , run longitudinally through these structures, thereby creating a much more rigid structure. The uniformly oriented reinforcing fibers in the cable trough 10 result in greater ultimate strength, rigidity, and lower deflections. This greater strength and rigidity enables the cable trough to last longer than typical prior art cable troughs made of cast concrete or molded or extruded thermoplastics having randomly oriented reinforcing fibers incorporated thereinto. The increased strength not only improves the cable trough's resistance to damage, but also results in a longer useful life for the cable trough 10 , thereby greatly reducing its effective cost.
Given the flexible nature of the pultrusion process used to produce the cable trough 10 , the geometry of the sidewalls 16 , bottom 18 and cover 14 may be easily changed. This flexibility in manufacturing allows the cable trough 10 to be adapted for varying situations very rapidly and inexpensively. And, because the longitudinal orientation of the reinforcing fibers in the cable trough structures, there is a near exponential increase in the loading capacity of the cable trough 10 per unit increase in the sidewall 16 thickness. This feature of the cable trough 10 allows relatively small changes in the geometry of the trough 10 to account for large variations in the manner in which the trough 10 may be used. This feature also allows this customization to be accomplished relatively inexpensively, as little extra material need be used to realize large increases in the strength of the trough 10 .
FIGS. 4 and 5 illustrate another embodiment of a cable trough 50 having a top, such as a cover 52 , which defines a channel 54 . The channel 54 is also defined by comprises a pair of generally vertical sidewalls 56 extending upwardly from and secured to a bottom, such as a base plate 58 . Each of the vertical sidewalls 56 has on an inner surface thereof an inwardly extending lip 60 that may be formed continuously along the sidewall 56 or in certain predetermined locations, as desired. The lip 60 serves as a part of a closure mechanism that retains the cover 52 on the channel 54 once the cable trough 50 has been installed.
The cover 52 essentially comprises an elongate plate 62 that has a width and length that are commensurate in scope with the length and width of the channel 54 . For example, in the particular embodiment illustrated in FIGS. 4 and 5 , the plate 62 is approximately 10 inches wide and 120 inches long. The plate 62 has a pair of channel members 64 that extend downwardly from the plate 62 and that engage upper edges of the sidewalls 56 . Note that the channel members 64 address both sides of the upper edge of the sidewalls 56 . In FIGS. 4 and 5 , the cover 52 and channel 54 are shown in an assembled position.
In the embodiment shown in FIGS. 4 and 5 , angled members 66 connect the sidewalls 56 and the bottom of the cable trough 50 , e.g., the base plate 58 . In the illustrated embodiment, each angled member 66 is positioned at an angle of approximately 72° relative to the base plate 58 and at an angle of approximately 18° relative to the respective sidewall 56 . These angles are not critical, however. For example, in another embodiment, each angled member 66 may be positioned at angles of approximately 45° with respect to both the base plate 58 and the respective sidewall 56 . The angled members 66 add rigidity to the structure of the cable trough 50 and may reduce or prevent deflection of the sidewalls 56 .
When the cover 52 has been seated firmly onto the channel 54 , with the upper edges of the sidewalls 56 seated within the channel members 64 of the cover 52 , one or more connector bolts may be passed downwardly through the cover through countersunk bores (not shown in FIGS. 4 and 5 ) formed therein. The connector bolts (not shown in FIGS. 4 and 5 ) have a cam or other offset projection extending from a distal end thereof such that when the connector bolt is rotated, as by screwdriver or the like, to a closed position, the cam or projection will be positioned beneath the lip 60 of the sidewall 56 . When in its closed position, the connector bolts will secure the top 52 to the channel 54 to complete the cable trough 50 . As can be appreciated by those of ordinary skill in the art, electrical, mechanical, fiber optic, or another type of cabling may be laid in the channel 54 of the cable trough 50 before the cover 52 is placed thereon.
It should be understood that the cable trough 50 is not waterproof as such. Accordingly, in order to prevent the accumulation of water and ice inside the channel 54 of the cable trough 50 , one or more drain holes (not shown in FIGS. 4 and 5 ) may be formed through the bottom of the trough to allow water to exit the channel 54 .
The foregoing is considered as illustrative only of the principles of various embodiments. Furthermore, 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. While certain embodiments have been described, the details may be changed without departing from the spirit and scope of the present invention, which is defined solely by the claims. | A cable trough for installing cables alongside a railway line or other right of way is described. The cable trough is constructed using longitudinally oriented reinforcing fibers coated with polymeric resin that generally aligns the reinforcing fibers with the length of the cable trough. One or more connector clips may be used to secure respective portions of the cable trough to one another. The cable trough is provided with a cover that may be removably secured to an elongate channel to protect the cables housed within the cable trough. Elbows, corners, tees, and other connectors may be provided to run the cable trough in any desired direction. A method of installing cables in a cable trough is also described. | 7 |
BACKGROUND OF THE INVENTION
This invention relates in general to the propagation of signal energy within solid material, such as detonation waves conducted through bulk explosives, and the effect thereon of shock waves propagated more rapidly through the bulk material.
The invention is more particularly applicable to solid explosives wherein shock waves are generated in longitudinal cavities or channels formed in the explosive material. Propagation of the shock waves at velocities higher than the detonation waves in the channels and the resulting increase in detonation velocity is known as the "channel effect", which is modified in accordance with the present invention.
In connection with explosives, it is already well known that propagation of self-sustaining detonation waves at a prescribed wave velocity is responsible for rapid consumption of the explosive material. Such self-sustained detonation waves are furthermore known to increase in velocity with the density of the explosive material through which the detonation wave is propagated.
It is also known in the art that the detonation wave velocity in a tubular or hollow type explosive is higher than that in a solid body explosive. The increase in magnitude of the detonation wave velocity beyond its otherwise established limits is caused by a shock wave generated in the channel of the tubular explosive, the shock wave being propagated through the channel passage at a velocity higher than that of the detonation wave in the annular portion of the explosive in surrounding relation to the channel. Such higher velocity shock wave in the channel compresses the solid particles of the explosive material, within the annular portion of the explosive body forwardly of the detonation wave, to locally increase explosive density with a corresponding increase in the self-sustained detonation wave velocity. The resulting detonation velocity approaches that of the explosive powder when fully compressed to crystal density. Such increase in the detonation velocity resulting from what is known as the "channel effect", is less for explosive charges of higher original density.
It is also known that the effective detonation wave velocity may be further increased beyond what is possible as a result of the aforementioned "channel effect", by periodic blockage of shock wave propagation through the channel passage by means of bulk material disposed between adjacent axial ends of a plurality of axially aligned cavities in a multiple-cavity type of tubular explosive. In such a multiple-cavity arrangement, reflection of the shock wave at the end of each cavity initiates the explosive material thereat to generate two new detonation waves respectively propagated forwardly and rearwardly while a new shock wave is generated in the following cavity after some delay. When the detonation wave propagating forwardly collides with the rearwardly directed detonation wave generated at the end of the cavity, pressure oscillations not present in continuous, open channel type cavity arrangements are produced. Nevertheless, the rate of explosive consumption is increased, corresponding to an increase in the average detonation wave velocity.
It is an important object of the present invention to provide a continuous open channel type of cavity arrangement in a solid explosive capable of increasing detonation to an ultra-high wave velocity greater than the increase in velocity heretofore achieved by periodic blockage of shock waves within multiple-cavity arrangements, and without the previous oscillations associated therewith.
In accordance with the foregoing object, it is a further object to exploit the ultra-high velocity effect to increase jet velocity in shaped charges, reduce the angle between detonation front and liner in such shaped charges and control wave profile in plane wave lenses.
SUMMARY OF THE INVENTION
In accordance with the present invention, propagation of shock waves in longitudinal cavities or channels formed in a solid bulk material of predetermined density increases detonation wave velocity beyond the limits heretofore imposed by explosive material density in traditional continuous, open channel and multiple-cavity arrangements by virtue of a novel configuration involving, according to certain embodiments, the threading or rifling of the internal passage wall surfaces of certain cavities. The resulting characteristics of the detonation wave propagated through the solid portions of the bulk material is unexpectedly smooth but with a significantly higher detonation wave velocity despite high original bulk density for explosive in powder form pressed to near crystal density.
According to of the invention, the novel cavity configuration involves a plurality of channel passages circumferentially spaced about a central cavity and extending generally in the axial passage direction. Plural shock waves propagated within the respective channel passages interact to produce a compounding of the aforementioned "channel effect" resulting in a further increase in detonation wave velocity, even with the cavity passages being smooth bored. Where one or more of the cavity passages is internally threaded or rifled as aforementioned the increase in detonation wave velocity is even greater.
In connection with embodiments utilizing internally threaded channels, the passage wall surfaces have a helical thread-shape. Where the explosive sensitivity is low, the threaded wall surfaces may be formed by a material of greater sensitivity than the body of the material through which the detonation wave is propagated. A higher detonation wave velocity may thereby be achieved without the pressure oscillations heretofore associated with shock wave blocking action and detonation collisions in a multiple cavity type of tubular explosive.
According to still other embodiments of the invention, the aforementioned compounding of the "channel effect" is applied to shaped charges, in order to increase jet velocity of the shaped charge.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
Other objects, advantages and novel features of the invention will become apparent from the following detailed description of the invention when considered in conjunction with the accompanying drawing wherein:
FIG. 1 is a side section view through an explosive charge with which the present invention is associated in accordance with one embodiment thereof;
FIG. 2 is a transverse section view taken through a plane indicated by section line 2--2 in FIG. 1.
FIG. 3 is a partial transverse section view illustrating a portion of an explosive charge embodying the present invention in accordance with another embodiment thereof;
FIG. 4 is a partial side section view taken substantially through a plane indicated by section line 4--4 in FIG. 3;
FIG. 5 is a side section view through a shaped charge type of explosive round embodying the present invention in accordance with yet another embodiment thereof; and
FIG. 6 is a transverse section view taken substantially through a plane indicated by section line 6--6 in FIG. 5.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Referring now to the drawing in detail, FIGS. 1 and 2 illustrate an explosive munition round, generally referred to by reference numeral 10 as a typical environment for the present invention. As shown, the round 10 has a generally cylindrical body of solid explosive material 12 of predetermined sensitivity and density, enclosed by a casing 14. An ignition detonator 16 projects into the body of explosive material 12 at one axial end. When energized, the detonator 16 initiates a detonation wave in the body of material 12 that propagates forwardly therethrough in a direction along its axis 18. The body of explosive material 12 may be fully consumed by a self-sustained energy wave having a detonation wave velocity dependent on the density of the explosive material, as already well known in the art.
According to the embodiment shown in FIGS. 1 and 2, a central cylindrical cavity 20 forms a hollow chamber within the body of explosive 12. The cavity 20 extends continuously along axis 18 from an inner end 21 thereof to an open exit end 22 as shown. The inner end 21 is spaced a distance (s) through the body of explsoive material 12 from the detonator 16. As already known in the art, in the absence of the circumferentially surrounding channels 24 within the body of explosvie material the products of detonation produce a shock wave in cavity 20 propagated at a higher velocity than the explosive detonation wave. The shock wave is propagated through the air initially filling cavity 20 and compresses the explosive material ahead of the detonation wave within the annular portion of the body of explosive material 12 surrounding the cavity 20. The localized increase in density of the explosive material resulting therefrom, correspondingly increases the average self-sustaining detonation velocity of the energy wave through the entire body of explosive material 12. The foregoing shock wave action is generally referred to as a "channel effect".
In accordance with the embodiment of the invention shown in FIGS. 1 and 2, the detonation velocity is further increased by the compounding of the "channel effect" resulting from a plurality of the channel passages or bores 24 formed within the body of explosive material 12 in a cross-sectionally annular arrangement surrounding central cavity 20. The channel passages 24 extend continuously to exit end 22, parallel to axis 18, from an axial start location spaced a shorter distance (d) from the detonator 16 than the distance(s) in order to establish an initial run distance (s-d) accommodating generation of additional shock waves produced within the respective channel passages 24. The additional shock waves in the channel passages locally increase the explosive density and detonation velocity in the bulk of explosive surrounding cavity 20. As a result, the velocity of the shock waves in cavity 20 further increase the overall detonation velocity in the explosive bulk surrounding cavity 20. Such compounding of the "channel effect" occurs whether or not the channel passages 24 are smooth or rifled.
According to yet another embodiment of the invention as depicted in FIGS. 3 and 4, the "channel effect" is modified to increase the detonation velocity even further by periodic partial blocking of the shock wave traveling through a channel passage 24'. Such partial blocking of the shock wave does not produce the pressure oscillations heretofore experienced from use of full blockage of a shock wave through a channel passage. More rapid detonation and higher shock wave velocities are thereby achieved, beyond the the capability of smooth continuous channel passages or fully interrupted channels. Partial interruption of shock wave propagation through the channel passage 24' extending through a body of explosive 34 as shown in FIGS. 3 and 4, occurs because the passage 24' has an internal helical screw thread type of surface 36. If the bulk of explosive is not sensitive enough, the helical surface may be coated or lined with a thin lining 38 of explosive material that is more sensitive than that of the surrounding body of explosive 34. The thread profile, height and pitch of surface 36 between impact portions 39 thereof as shown in FIG. 4, is designed to locally induce ignition of the explosive when the shock wave being propagated through channel passage 24' impacts the portions 39 of surface 36. A three dimensional wave interaction thereby occurs, much milder than the head-on wave collisions heretofore experienced in fully interrupted channels.
The increase in the denotation velocity is achieved without the pressure oscillations associated with multiple cavities in accordance with embodiments of the invention as hereinbefore described with respect to FIGS. 3 and 4. The embodiments described with respect to FIGS. 1 and 2, on the other hand, result in the compounding of the "channel effects" to also achieve higher detonation velocities. Such embodiments of the invention, respectively shown in FIGS. 1 and 4, embody novel features which may be utilized individually or in combination for shaped charges to increase the jet velocity in accordance with yet another embodiment of the invention as illustrated in FIGS. 5 and 6. As shown in FIG. 5, the shaped charge generally referred to by reference numeral 40 includes an explosive fill 42 enclosed by a cylindrical casing 44 in surrounding relation to a central conical cavity 48 extending inward from an exit end 46 of the shaped charge. The cavity 48 is lined by a conical liner 50 of uniform thickness. Within the body of explosive, several circumferentially spaced channel passage bores 52 are formed generally parallel to the axis 54 of the shaped charge 40. A detonator 56 and a booster/wave shaper 58 are embedded in the explosive fill 42 at its rear end. Another annular series of circumferentially spaced channel passages 60 are formed in the explosive fill spaced radially inwardly of the channel passages 52 at an angle to the axis 54. Each annular series of channel passages 52 and 60 are respectively interconnected at their inner ends by axially spaced annular connector passages 62 and 64. While the channel passages 52 are open at the exit end 46 of the charge 40 as shown in FIG. 5, the channel passages 60 terminate within the explosive fill adjacent the exit end forwardly of the apex 66 of the conical liner 50.
Connector passage 64 is axially spaced from booster/wave shaper 58 by distance (d2) to allow the detonation action an initial propagation distance for stabilization and attainment of coherent conditions, whereby the products of detonation in channels 60 are responsible for sustaining the shock waves therein. For correspondingly similar reasons, the connector passage 62 is axially spaced by distance (d 1 ) from shaper 58. The channel passages 52 and 60 are filled with air at atmospheric or higher pressure, or with other gases such as argon or xenon at possibly different pressures to provide higher shock temperatures capable of providing better ignition of the sensitive liner 50. The pressures, densities and other initial conditions within the channel passages 52 and 60 of each annular series are equalized by the connector passages 62 and 64 to insure symmetrical collapse of liner 50 in response to detonation of the charge 40 producing a higher jet velocity.
It will be apparent from the foregoing description that desired detonation velocity along a channel may be obtained by selective size control. Also, plane wave lenses may be produced by increasing the velocity adjacent the lateral surface of a cylindrical-shaped explosive charge having circumferentially spaced channels. In cylindrical-shaped explosives, detonation is usually slower adjacent the surface to produce a curved wave. By increasing the detonation velocity adjacent the surface in accordance with the present invention, a plane wave may be produced.
Other modifications and variations of the present invention are possible in light of the foregoing 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. | The detonation wave velocity in a solid explosive body of material, incred by the "channel effect", is further increased by compounding of the "channel effect" and/or by partial shock wave interruption by means of a threaded or rifled passage wall surface in a continuous, open channel arrangement. The high velocity detonation wave can be used to increase the jet velocity of shaped charges. | 5 |
RELATED APPLICATION
[0001] The present application claims priority of Italian Patent Application No. BO2006A 000786 filed Nov. 20, 2006, which is incorporated herein in its entirety by this reference.
FIELD OF THE INVENTION
[0002] The present invention relates to a wind generator. Specifically, the present invention finds advantageous, but not exclusive, application in the field of lighting streets, highways, etc., to which explicit reference will be made in the following description without loss in generality.
BACKGROUND OF THE INVENTION
[0003] It is known that supplying electricity to streetlamps, road signs, emergency telephones, etc. is very expensive because it requires an extensive distribution network constituted by buried electric cables, the installation of which is expensive both in terms of employed materials and due to the specialized manpower which is required.
[0004] In order to avoid the drawbacks due to the use of a centralized electric network for supplying electricity to streetlamps, during the past years streetlamps actuated, for example, by wind energy have been developed.
[0005] Furthermore, in order to attempt to limit at most the visual impact that the use of wind blades implies on the territory, streetlamps using at least one vertical axis impeller have been designed, the transverse volume dimensions of which are contained within the volume of the diameter of the post itself.
[0006] Not only; since obviously in normal conditions of operation, the impeller coupled to the generator produces electric energy all day long, during the daytime hours (i.e. when the streetlamp combined to the wind apparatus is not switched on) the produced energy may either be easily sent to the network and sold to an electrical energy marketing company, or used for other purposes. It is apparent that all the surplus energy which is not used for lighting by means of the streetlamp onto which the above-mentioned wind apparatus is mounted is sellable.
[0007] Moreover, these streetlamps running on wind energy may present powers which easily reach 1 kW.
[0008] Furthermore, because, as previously mentioned, the dimensions of the impeller blades are contained in the volume dimensions of a normal supporting post, the environmental impact of visual nature is very low, indeed, the presence of rotating elements may in this case be visually pleasant.
[0009] For example, some of these solutions have been described in GB 2 246 173 (TEMPLE) and in GB 2 344 382 (SANSONE ET AL.)
[0010] However, despite working in a fairly satisfactory manner, the apparatuses described in the aforesaid documents do not fully exploit the power of the wind which strikes the impeller because, as explained in greater detail below, a portion of the wind energy is lost, thus considerably decreasing the efficiency of the impeller itself and, consequently, also of the electric generator connected thereto.
SUMMARY OF THE INVENTION
[0011] It is therefore the main object of the present invention to make a wind apparatus which is free from the above-described drawbacks and which is, at the same time, easy and cost-effective to implement.
[0012] According to the present invention, a wind apparatus as claimed in the attached claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The present invention will now be described with reference to the accompanying drawings which illustrate two non-limitative embodiments thereof, wherein:
[0014] FIG. 1 shows a global view of a first embodiment of a wind apparatus according to the present invention;
[0015] FIG. 2 shows an enlarged detail of the wind apparatus of FIG. 1 ;
[0016] FIG. 3 shows a longitudinal section X-X of the first embodiment in FIG. 1 ; and
[0017] FIG. 4 is a three-dimensional illustration of some details belonging to a second embodiment of a wind apparatus object of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0018] In FIG. 1 , numeral 10 generically indicates, as a whole, a wind generating apparatus according to the present invention.
[0019] As shown in FIGS. 1-3 , in a first embodiment thereof, the apparatus 10 comprises a rod 11 (with longitudinal and vertical symmetry axis (A)) fixed to a base 12 . On the rod 11 , on the side opposite to the base 12 , there is provided a lamp (not shown in the accompanying figures) directly powered by the electric energy produced by a wind impeller 13 in concert with a wind generator 14 (see below).
[0020] The wind impeller 13 , in turn, comprises a hub 15 coaxial with the axis (A) of the rod 11 . Furthermore, the rod 11 is inside the hub 15 and a pair of bearings 16 , 17 onto which the weight of the entire impeller 13 is relieved, are keyed thereon. The bearings 16 , 17 allow the relative rotation of the impeller 13 itself with respect to the rod 11 .
[0021] A plurality of essentially tile-shaped blades 18 is integral with the hub 15 . Each tile presents a corresponding concave surface 18 a and a corresponding convex surface 18 b.
[0022] In embodiment shown in FIGS. 1-3 , the wind impeller 13 is completed by a plurality of horizontal reinforcement plates 19 , possibly integrally obtained with the hub 15 . Such horizontal plates 19 divide the blades 18 into vertical sections.
[0023] Furthermore, the lower portion of the hub 15 is provided with a flange 20 (essentially perpendicular to axis (A)), which, in use, rests on a thrust bearing assembly 21 by means of which the weight of the entire impeller 13 is relieved onto the base 12 ( FIG. 3 ).
[0024] In a known manner, the generator 14 is electrically connected to a battery (not shown) and/or to an electric line (not shown).
[0025] A rotor 14 a of the wind generator 14 is made integral with the lower end 15 a of the hub 15 , in a known manner, while a stator 14 b of the same wind generator 14 is accommodated in a cavity CAV provided in the base 12 .
[0026] In order to facilitate the assembly/disassembly of the wind generator 14 in/from the cavity CAV, the base 12 may be made in two portions 12 a , 12 b , reciprocally coupled in use by means of known systems and thus not shown.
[0027] As shown in FIG. 3 , the rod 11 , the lower portion of the hub 15 and the thrust bearing assembly 21 are inserted through a through hole FF made in the base 12 so as to allow the lower end 15 a of the hub 15 to extend into the cavity CAV.
[0028] Obviously, if the base 12 consists of two portions 12 a , 12 b , also the through hole FF may be made in two halves.
[0029] Furthermore, since the lower portion of the hub 15 and the flange 20 are nearly always rotating about the axis (A) (it is presumed that such apparatuses are installed in places which are mostly windy), in order to avoid dangers for bystanders, the lower part of the apparatus 10 is protected by a protective hedge 22 ( FIGS. 1 , 3 ), which, for example, may consists of two semi-cylindrical half shells (not expressly indicated in the accompanying figures) reciprocally coupled in a known manner.
[0030] Now, we will assume that the wind blows according to a direction shown by an arrow (W) ( FIG. 1 ).
[0031] In case the wind impeller 13 was in no way shielded, the wind (which blows according to (W)) would strike a first portion of the blades 18 (more in detail, the blades 18 which are approximately situated on the right-hand part of the apparatus 10 shown in FIG. 2 ) on their concave surfaces 18 a causing a rotation of the impeller about the axis (A) according to an arrow (R) ( FIG. 2 ); however, the wind would act also on the convex surfaces 18 b of a second portion of blades 18 (more in detail, the blades 18 which are approximately situated on the left-hand side of the apparatus 10 shown in FIG. 2 ).
[0032] The action on the second portion of blades 18 would be counter-productive for the purpose of electric energy production because it would counter-react the action of the wind on the first portion of blades 18 and, thus, would “slow down” the rotation of the wind impeller 13 about the axis (A) according to the arrow (R) causing a considerable waste of energy as a consequence.
[0033] Therefore, it has been inventively thought to shield the aforesaid second portion of blades 18 with an essentially semi-cylindrical-shaped wind screen hood 23 . Such wind screen hood 23 rests on the rod 11 by means of a thrust bearing 24 and, thus, is also adapted to rotate about the axis (A).
[0034] Furthermore, on a vertical edge (B) of the wind screen hood 23 there are provided two rudders 25 , 26 ( FIG. 1 ) which allow the orientation of the wind screen hood 23 itself according to the direction of the wind given by the arrow (W) so as to reach a position of balance. Indeed, since the action of the wind will also occur on them, such rudders 25 , 26 (in stationary wind conditions) will align with the direction of the wind itself, direction given by the arrow (W), as explained.
[0035] Therefore, the system will be configured as shown in FIGS. 1 , 2 in a condition of balance until the wind blows in the direction identified by the arrow (W). It is apparent that if the wind changes direction, the system will reposition itself in a new condition of balance.
[0036] For the optimal operation of the impeller 13 , the left-hand portion of the blades 18 shown in FIGS. 1 , 2 must be covered by the wind screen hood 23 so that no significant wind action occurs directly on such blades 18 .
[0037] Furthermore, since such second portion of blades 18 does not “hit” into the wind with its own convex surfaces 18 b (because they are “covered” by the wind screen hood 23 ), there will be no significant negative effect which would tend to slow down the wind impeller 13 in its rotation about the axis (A) according to the arrow (R).
[0038] In this manner, there is no loss of a part of energy as occurs instead in traditional wind apparatuses.
[0039] As previously mentioned, if the direction of the wind changes, the wind screen hood 23 will be oriented as a consequence according to the new direction.
[0040] In other words, the wind screen hood 23 , combined with the corresponding rudders 25 , 26 , forms a sort of “weather vane” or “wind sock” adapted to align in the same direction as the wind (direction indicated by the arrow (W)).
[0041] FIG. 4 shows a second embodiment of the invention in which the traditional blades 18 of the impeller 13 , which were previously illustrated with reference to FIGS. 1-3 , are replaced by a plurality of propeller segments 180 of an impeller 13 *.
[0042] For example, the propeller segment 180 * shown in FIG. 4 contemplates a first surface 180 *a and a second surface 180 *b.
[0043] For the previously explained reasons, the second surface 180 *b must be shielded by the wind screen hood 23 * with which two rudders 25 * and 26 * are integral. As the wind direction given by the arrow (W) changes, the position of the wind screen hood 23 * will also change with the implications which have been described with reference to the first embodiment shown referring to FIGS. 1-3 .
[0044] Obviously, a generator (not shown) of the previously seen type is associated to the impeller 13 *.
[0045] In a further embodiment (not shown), at least one portion of the wind screen hood is scroll-shaped to create an air inlet funnel, in which the air itself is compressed.
[0046] The main advantage of the apparatus according to the present invention is in that, by adopting a simple, essentially semi-cylindrical hood moved by the wind force itself by means of at least one rudder, either only the concave surface of the blades (first embodiment), or a particular surface of the propeller segments (second embodiment) are directly struck by the wind, while the surfaces which would “brake” the impeller when struck by the wind are shielded.
REFERENCE NUMBERS
[0000]
10 —wind apparatus
11 —rod
12 —base
12 a —portion (of the base 12 )
12 b —portion (of the base 12 )
13 —wind impeller
13 —wind impeller
14 —wind generator
14 a —rotor (of the wind generator 14 )
14 b —stator (of the wind generator 14 )
15 —hub (of the wind impeller 13 )
15 a —lower end (of the hub 15 )
16 —bearing
17 —bearing
18 —blade (of the wind impeller 13 )
18 a —concave surface (of the blade 18 )
18 b —convex surface (of the blade 18 )
19 —plate
20 —flange
21 —thrust bearing assembly
22 —protective hedge
23 —wind screen hood
24 —thrust bearing
25 —rudder
25 *—rudder
26 —rudder
26 *—rudder
180 —propeller segment
180 *—propeller segment
180 *a—first surface (of a propeller segment)
180 *b—second surface (of a propeller segment)
(A)—vertical axis (of rod 11 , impeller 13 and wind screen hood 23 )
(B)—edge
(CAV)—cavity
(FF)—through hole | A wind apparatus which specifically comprises an essentially semi-cylindrical-shaped wind screen hood adapted to rotate about a vertical axis. The wind screen hood is external to a wind impeller and is put into rotation (to reach a position of balance) by rudders actuated by the wind so as to cover a portion of a plurality of radial thrust elements according to the direction of the wind itself. | 5 |
BACKGROUND OF THE INVENTION
This invention relates to snow blowers and more particularly to mounting of the skid shoe on the auger housing of a snow blower.
It is customary to provide a skid shoe on the auger housing of a snowblower. The skid shoe maintains the auger housing at a preset height relative to the riding surface to prevent the auger housing from getting hung up on the riding surface due to abrupt changes in surface height. Conventionally, a skid shoe is mounted at a preset height. It would be advantageous, however, to be able to vary the height of the skid shoe to accommodate different riding surface characteristics.
SUMMARY OF THE INVENTION
It is an object of the present invention to present a skid shoe mounting assembly which is height-adjustable to accommodate varying riding surface conditions.
The skid shoe is comprised of a base section fixably mounted to a vertical strut. The base section extends generally longitudinally with vertically arced ends. The vertical strut is fixably mounted to the base section at one end and has a plurality of apertures and a slot arranged such that it can be mounted to the housing of a snow blower auger section in a plurality of locations. To accommodate the skid shoe, the auger housing sidewalls have an aperture and slot arranged in a manner to provide cooperative location with the apertures and slots of the skid shoe in a variety of locations. Each skid shoe location corresponds to a different relative elevation of the skid shoe base to the auger housing.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a snow blower.
FIG. 2 is a side view of the skid shoe positioned in front of the sidewall of the auger housing in accordance with the present invention.
FIGS. 3a, 3b and 3c are a schematic representation of the relative positions obtainable by the skid shoe.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, a snow blower generally indicated as 11 includes a frame 15 which has a motor 17 mounted thereto for driving an impeller 19 and auger 21 in a conventional manner. The auger 21 is comprised of a housing 23 including sidewalls 25 and an arched rear wall 27. The auger housing 27 rotatably maintains by any conventional means an auger blade 29.
Referring more particularly to FIG. 2, a skid shoe 31 is mounted to the auger sidewall 25. The skid shoe is comprised of a base 33 having a generally longitudinal extension with vertically arced ends. A generally vertically extending strut 35 is fixably mounted to the base at one end by any conventional means. The strut 35 has a first aperture 37 and a second aperture 39 located along a vertically symmetric center line 41 of the strut 35. At the upper end of the vertical strut 35 is located a vertical extending slot 43 offset from the center line 41 to one side. A third aperture 45 is located above the slot 43 and offset from the center line 41 in opposition to the slot 43. Each wall 25 contains at its lower end a generally vertically extending slot 47 directed along center line 41 and an aperture 51 located off-set to the center line 41.
Referring to FIGS. 3a, 3b and 3c, to mount a skid shoe 31 to either sidewall 25 the apertures 37, 39 and 45 and slot 43 of the strut 31 can be cooperatively aligned to the slot 47 and aperture 51 of the sidewall 25 and fixably secured there by a nut bolt assembly 53 and 57 in one of a plurality of arrangements. One of said arrangements aligns aperture 51 of a sidewall 25 to slot 43 of strut 35 and slot 47 of sidewall 25 to aperture 37 of strut 35.. A second arrangement aligns aperture 51 of sidewall 25 to the upper end of slot 43 of strut 35 and slot 47 of sidewall 25 to aperture 39 of strut 35. A third position is obtained by rotating the skid shoe 37 such that aperture 51 of the sidewall 25 is aligned to aperture 45 of the strut, and slot 47 of said wall 25 is aligned to aperture 39 of the strut. These embodiments allow the skid shoe to obtain one of the three relative height positions to the sidewall 25 of the snow blower 11.
The aforedescribed preferred embodiment should not be viewed as limiting. The scope of the present invention is defined by the appendix claims. | A skid shoe mounting arrangement detachably mounted to the side of the snow blower auger housing such that the skid shoe mounting assembly can be easily reassembled to a plurality of preset heights relative to said auger housing. | 4 |
REFERENCE TO RELATED APPLICATION
This application may be considered related to commonly owned and U.S. patent application Ser. No. 09/711,499, filed on Nov. 13, 2000, now U.S. Pat. No. 6,450,725, which is a continuation-in-part of U.S. patent application Ser. No. 09/482,995, now U.S. Pat. No. 6,322,327 B1, issued on Nov. 27, 2001, and to commonly owned U.S. patent application Ser. No. 10/199,777, entitled APPARATUS AND METHODS FOR SEPARATING SLURRIED MATERIAL, co-filed herewith and commonly owned U.S. patent application Ser. No. 10/199,764, entitled EXCAVATION SYSTEM EMPLOYING A JET PUMP, co-filed herewith.
FIELD OF THE INVENTION
This invention relates generally to hydraulic nonmechanical pumping devices for transferring material, and specifically, to jet pumps for moving solid, semi-solid and/or liquid materials, as well as related methods.
BACKGROUND
Our previous invention described in U.S. Pat. No. 6,322,327 B1 provides a jet pump with significantly increased vacuum efficiency, resulting in the ability to move greater amounts of solid or slurry materials without a proportionate increase in energy consumption. While that pump configuration has made a significant contribution in the field of pump efficiency and capabilities, the material being vacuumed or suctioned in that pump configuration typically is mixed with the motive fluid of the jet pump. This can present difficulties where the material being pumped might become volatile when placed in contact with the motive fluid or when the material being pumped is preferably be kept separate from the motive fluid for other reasons. Also, our previous developments still required significant volumes of motive fluid in many commercial scale pumping operations.
Thus, a need has continued to exist for a jet pump which does not require a large volume of motive fluid in commercial operations, and which allows a user to keep pumped material separate from the motive fluid of the jet pump.
SUMMARY OF THE INVENTION
The present invention meets these and other needs by providing, among other things, apparatus comprising:
(a) a jet pump in fluid communication with a passageway for a material to be suctioned, the jet pump being sized and configured to create a vacuum in the passageway when the jet pump is in use;
(b) a motive fluid pump sized and configured to supply a motive fluid to the jet pump; and
(c) a motive fluid reservoir downstream from the jet pump, the motive fluid reservoir being in fluid communication with the jet pump and the motive fluid pump so that during use the motive fluid pump recirculates at least a portion of the motive fluid from the motive fluid reservoir to the jet pump;
wherein the jet pump is comprised of a nozzle assembly which is sized and configured to (A) receive the motive fluid and a gas, and (B) eject the motive fluid as a liquid flow while feeding the gas into proximity with the periphery of the liquid flow. Preferably, the jet pump in apparatus of this invention is further comprised of a housing defining a suction chamber into which the nozzle assembly may eject the liquid flow, the housing further defining a suction inlet and a suction outlet; and an outlet pipe extending from the suction outlet away from the suction chamber, the outlet pipe being in fluid communication with the suction chamber and being disposed to receive the liquid flow; the outlet pipe defining at least a first inner diameter along a portion of its length and a second inner diameter along another portion of its length, the second inner diameter being less than the first inner diameter. It is particularly preferred in certain applications that the nozzle assembly extend into the suction chamber towards the suction outlet and into the imaginary line of flow of the suction pipe.
In another embodiment of the invention, the apparatus further comprises a material collection reservoir which is sized and configured to permit the formation of a vacuum therein. In this embodiment, the collection reservoir is intermediate to, and in fluid communication with, the passageway for the material to be suctioned and the jet pump. This collection reservoir allows material which is suctioned to be collected without mixing with or otherwise contacting the motive fluid of the jet pump.
Yet another embodiment of this invention provides a method of moving material from one location to another. The method comprises:
a. injecting a pressurized fluid into a nozzle assembly to produce a flow of pressurized fluid,
b. providing a gas to the nozzle assembly to surround the flow of pressurized fluid with the gas,
c. directing the flow of pressurized fluid surrounded by the gas into a suction chamber which defines both an inlet in fluid communication with a collection reservoir and an outlet in fluid communication with an outlet pipe, the outlet pipe defining a venturi-like inner surface, and directing the flow of pressurized fluid surrounded by the gas into the outlet pipe to produce a vacuum in the collection reservoir,
d. suctioning the material to be moved into the collection reservoir using the vacuum produced in step (c.), and
e. recirculating at least a portion of the pressurized fluid directed into the outlet pipe back into the nozzle assembly.
In a preferred embodiment of this invention, the material to be moved is liquid material from a slurry comprised of a mixture of solid material and liquid material. The suctioning of step (d.) is carried out after placing the collection reservoir in fluid communication with a slurry container and equipped with a filter so that, when a vacuum is created in the collection reservoir, a vacuum is created in the slurry container and liquid material from slurry within the slurry container is suctioned through the filter and into the collection reservoir while solid material remains in the slurry container. This preferred embodiment thus enables the removal of liquid from the slurry without mixing or otherwise bringing together the separated liquid material with the motive fluid of the jet pump. In another preferred embodiment of this invention, the method further comprises the step of controlling the flow rate of the gas into the nozzle assembly to thereby control the level of vacuum produced in the suction chamber.
These and other embodiments, advantages, and features of this invention will be apparent from the following description, accompanying drawings and appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partial cross-sectional, side view of a preferred embodiment of the present invention.
FIG. 2 is a side view of another preferred embodiment of the present invention.
FIG. 3 is an enlarged view in cross-section of the jet pump component of the device of FIG. 1 .
In each of the above figures, like numerals or letters are used to refer to like or functionally like parts among the several figures.
DETAILED DESCRIPTION OF THE INVENTION
It will now be appreciated that the re-circulation of motive fluid for the jet pump component in apparatus of this invention coupled with a collection reservoir intermediate in series to the targeted material to be suctioned enables vacuum collection of the material to be moved into the collection reservoir without moving parts contacting the material and without the material contacting motive fluid of the jet pump. Thus solids, liquids, gases and all mixtures or two or more of those which are subject to being moved by a vacuum can be moved, collected and/or separated without vacuum pump contact, and the jet pump driving the vacuum is self-contained in that it only requires a fixed amount of motive fluid to operate. When using the preferred jet pumps of this invention, the foregoing can be accomplished without pump cavitation so as to maintain a stable level of vacuum during pump operation regardless of the material being suctioned.
Turning now to the drawings, FIG. 1 illustrates one preferred embodiment of this invention. There, a re-circulating jet pump apparatus is shown to include a jet pump 10 , a pipe 12 which defines a passageway in fluid communication with pump 10 , a motive fluid pump 14 , a motive fluid reservoir 16 , and a heat exchanger 46 . Pump 14 is an electrical centrifugal pump controlled at an electrical control panel 2 . Pump 14 forces motive fluid, e.g., liquid water or another inert fluid, into a pipe loop 11 which feeds the pressurized motive fluid into a nozzle assembly (see FIG. 3) of jet pump 10 . A pressure gauge P is provided to allow monitoring of the motive fluid pressure. Loop 11 places the re-circulating motive fluid in thermal communication with heat exchanger 46 by directing the motive fluid through exchanger 46 to remove accumulated heat from the motive fluid during its re-circulation.
The motive fluid reservoir 16 further comprises a drain valve 8 , a breather valve 18 and an exhaust port 19 . Valve 18 and port 19 exhaust gas built up in reservoir 16 during use of the vacuum created by jet pump 10 , in order to maintain a level of motive fluid in reservoir 16 sufficient to feed a pipe 15 at the lower portion of reservoir 16 . Pipe 15 in turn feeds motive fluid to motive fluid pump 14 . Reservoir 16 further comprises vertical baffles 4 and 6 for diverting the flow of a mixture of motive fluid and gas suctioned into and expelled out of jet pump 10 . By diverting the flow in this way, baffles 4 and 6 facilitate the separation of liquid from gas within reservoir 16 to minimize gas in the motive fluid exiting reservoir 16 at pipe 15 . This in turn minimizes the amount of gas fed into pump 14 . While this configuration of the motive fluid reservoir is preferred, other reservoir configurations or labyrinth-like structures may be employed so long as the configuration minimizes the amount of gas transferred from the motive fluid reservoir to the motive fluid pump.
As seen in another preferred embodiment illustrated in FIG. 2, the apparatus of FIG. 1 is placed in fluid communication with a material collection reservoir 50 . Collection reservoir 50 defines a collection reservoir inlet 52 through which suctioned material enters reservoir 50 . In the particular embodiment depicted, the material enters inlet 52 from a slurry container T which is in fluid communication with reservoir 50 through inlet 52 and is lined with a filter F. As a vacuum is created in reservoir 50 , the fluid communication between reservoir 50 and container T causes a vacuum to be formed in container T to draw liquid material from slurry therein through filter F and into material collection reservoir 50 . This particular de-watering configuration is more particularly described in our co-filed and commonly owned U.S. patent application Ser. No. 10/199,777, which is fully incorporated herein by reference. A collection reservoir outlet 54 is connected to pipe 12 to place the interior of reservoir 50 in fluid communication with the passageway defined by pipe 12 . A discharge port 56 at a lower portion of reservoir 50 may be closed to allow suctioned material which enters reservoir 50 to accumulate, or opened to drain reservoir 50 of suctioned material. Draining through port 56 can be facilitated during jet pump operation by placing discharge port 56 of reservoir 50 in fluid communication with another vacuum pump (not shown) to pull accumulated material from the lower portion of reservoir 50 . Collection reservoir 50 should be constructed in such a way that it structurally withstands the vacuum produced by the pump(s) with which it is in fluid communication during operation of the apparatus.
In the preferred embodiments depicted, the jet pump is configured in accordance with our previously developed jet pump described in commonly-owned U.S. Pat. No. 6,322,327 B1 and in our co-pending and commonly-owned U.S. patent application Ser. No. 09/711,499, both of which are entirely incorporated herein by reference. FIG. 3 illustrates in cross-section jet pump 10 of FIGS. 1 and 2. Jet pump 10 includes nozzle assembly 307 , which in turn is comprised of a constricted throat 301 formed by fluid nozzle 201 , an air injection nozzle 202 which forms a nozzle opening 303 , and a nozzle housing 203 . Nozzle housing 203 is a flanged member which is attached to and maintains the proper position of fluid nozzle 201 adjacent to air injection nozzle 202 . Air intake 211 is a passage through nozzle housing 203 . In the embodiment depicted, a single air intake 211 is shown although a plurality of intakes also may be provided. A gas conduit in the form of an air hose 204 allows a gas to enter jet pump 10 through intake 211 . The gas enters the nozzle assembly through intake 211 and an aperture 304 in nozzle 202 , then into an annular air gap 302 to form an air bearing around fluid flow ejected from nozzle 201 as the gas passing through gap 302 between the tip of nozzle 201 and the upstream side of nozzle 202 . The amount of gas allowed into jet pump 10 is controlled by a valve V which includes a gauge G (FIG. 1 ). By using valve V to control the level of gas entering jet pump 10 , it is possible to increase or decrease the level of vacuum produced by jet pump 10 .
Water or other motive fluid from loop pipe 11 passes through fluid nozzle 201 and air injection nozzle 202 of nozzle assembly 307 and into a housing 200 which defines a suction chamber 205 , a suction inlet 210 and a suction outlet 220 . In suction chamber 205 , the fluid in the form of a liquid flow combines with gas or gaseous material entering from pipe 12 through inlet 210 , and the combined stream enters an outlet pipe 207 through outlet 220 , pipe 207 being comprised of an outlet pipe segment 207 a which is detachable from the apparatus and which itself comprises a concentric wear segment in the form of a venturi target tube 206 . The combined stream then passes through target tube 206 into outlet pipe 207 and into motive fluid reservoir 16 .
Although not depicted in these drawings and typically less important when the material being suctioned does not include solid material, the nozzle assembly 307 , and in particular the downstream end of air injection nozzle 202 may be extended into suction chamber 205 and into an imaginary line of flow of material from pipe 12 through suction inlet 210 to increase the vacuum created by jet pump 10 . This feature is more particularly described in the previously referenced U.S. Pat. No. 6,322,327 B1 and U.S. patent application Ser. No. 09/711,499.
Outlet pipe 207 defines a first inner diameter Q, and target tube 206 defines a second inner diameter R which is less than inner diameter Q. It should be appreciated that outlet pipes of this invention may also be fabricated without a target tube but with a non-uniform inner surface so as to define a narrowing passage providing a venturi-like effect to the material exiting the suction chamber through the outlet pipe.
The gas employed in the jet pump component of preferred embodiments of this invention will preferably be under no more than atmospheric pressure, to reduce risk of operations and cost. The gas preferably will be an inert gas, e.g., nitrogen or argon, when the liquid or other material being pumped could be volatile in the presence of certain atmospheric gases, e.g., oxygen. When such volatility is not an issue, the gas employed will be most conveniently atmospheric air.
Typically, as depicted, the motive fluid pump is an electrically powered centrifugal pump or the like. However, the motive fluid pump alternatively may be any pump that is otherwise compatible with the motive fluid being pumped and is otherwise capable of causing the motive fluid to re-circulate back into the jet pump sufficiently to cause the jet pump to form a vacuum. The motive fluid of this invention may be any fluid which is capable of being used in the jet pump to create a vacuum. Typically, the motive fluid will be liquid water or some other aqueous liquid solution, but the motive fluid also may be a gas or another liquid if the circumstances of use dictate that water is less preferred as the motive fluid. Preferably, the motive fluid is inert to the material being moved or suctioned, to reduce hazardous condition risks in the event that the motive fluid comes into contact with the suctioned material.
The heat exchanger in preferred embodiments of this invention may be any device which reduces the temperature of the motive fluid of the jet pump, and its location along the re-circulation path of the motive fluid may vary. The heat exchanger may, for example, be a set of copper coils located along the piping which extends from the motive fluid pump to the nozzle assembly of the jet pump. Or, it could be located within or attached to the motive fluid reservoir. The location and configuration of the heat exchanger may vary as long as the heat exchanger reduces the temperature of the motive fluid during use.
While it is understood that at least one preferred jet pump described herein is characterized by certain component features, the foregoing description of specific embodiments can be readily adapted for various applications without departing from the general concept or spirit of this invention. Thus, for example, the inner surface of the outlet pipe (which provides the venturi effect feature of the outlet pipe) alternatively can be defined by the pipe itself, rather than a detachable wear plate. These and other adaptions and modifications are intended to be comprehended within the range of equivalents of the presently disclosed embodiments. Also, while specific embodiments have been described above, several other applications and embodiments of the presently described invention may be contemplated in view of this disclosure. Thus, for example, while the accompanying drawings illustrate the pumping system of this invention as used for separating liquid material from a slurry, the system may be used for virtually any application in which liquids, solids as agglomerate or particulate matter, or a slurry comprised of a mixture of liquid and solid material, must be separated or moved from one location to another. The system also may be employed to remove liquids from such slurry mixtures, thereby permitting solid particulate matter to be rapidly separated from the liquid and dried, if desired. In each of the above examples, small batch operations as well as large commercial batch, semi-continuous and continuous operations are possible using pumping methods and systems of this invention. The present invention can be used in any application requiring significant suction effect of solid material in a liquid or gaseous environment. The invention can also be used for suction in gaseous or liquid environments without solids present, and maintain a significant suction effect. Thus, as noted extensively herein, the invention can also be used in closed loop de-watering applications to remove excess water or moisture from material.
The dimensions of the various component parts of, the pressure under which motive fluid is fed to the jet pump of, and the level of vacuum produced by, devices of this invention may vary depending upon the circumstances in which the device will be employed, so long as the dimensions, pressures and vacuum permit the apparatus to function as described. Except where specifically noted otherwise herein, the component parts may be fabricated from a wide variety of materials, the selection of which will depend again upon the circumstances in which the device will be employed. Preferably, metals, metal alloys or resilient plastics, for example, will be employed to insure that points of mechanical contact or abrasive wear in the systems and pumps will be resilient enough to withstand the forces placed upon them during pump operation.
It also should be appreciated that virtually any material which can be suctioned or vacuumed can serve as the material to be moved in the practice of this invention. Thus, for example, agricultural products, liquid products or side-products, liquid waste, slurries of waste and mixtures of liquids and solids can all be suctioned using the apparatus and method of this invention.
Each and every patent or printed publication referred to above is incorporated herein by reference to the fullest extent permitted as a matter of law.
This invention is susceptible to considerable variation in its practice. Therefore, the foregoing description is not intended to limit, and should not be construed as limiting, the invention to the particular exemplifications presented hereinabove. Rather, what is intended to be covered is as set forth in the ensuing claims and the equivalents thereof permitted as a matter of law. | A recirculating liquid jet pump for moving a wide variety of materials is described. The pump is preferably equipped with an intermediate collection reservoir enabling the placement of material to be suctioned into the collection reservoir without bringing together the material to be suctioned with the motive fluid of the liquid jet pump. The collection reservoir may also be connected to a separate container for de-watering solid-liquid mixtures to enable mixture liquid to be separated from the solids without bringing the separated liquid into contact with the motive fluid of the jet pump and without the use of excessive amounts of jet pump motive fluid. | 5 |
FIELD OF THE INVENTION
[0001] This invention relates to integrated circuits, and particularly to minimizing depth of Boolean integrated circuits.
BACKGROUND OF THE INVENTION
[0002] One important problem in integrated circuit (IC) design is the minimization of the delay in the circuits. In ICs, Boolean circuits comprise trees to carry out certain Boolean functions. Typically, the Boolean circuits are created from a library of Boolean elements such as two-input AND and OR elements (cells) and NOT (inverter) elements or cells. The delay of Boolean circuits can ordinarily be minimized by minimizing the depth of the Boolean circuit.
[0003] The maximal number of cells that lie on any path from any input of a Boolean circuit to the output of the Boolean circuit is called a depth of a Boolean circuit. Each cell along the path adds one to the depth of the circuit. Thus, a tree or subtree having a path containing eight cells has a depth of 8. The delay of a Boolean circuit increases with its depth.
[0004] Considerable attention has been given to minimizing depth of Boolean circuits. Much of the attention has been directed at certain classes of Boolean functions (such as comparators, adders, subtractors, multipliers, etc), and to the development of techniques that allow fabricating Boolean circuits with small depth and small number of cells. In the present case, consideration is given to the special classes of Boolean circuits that perform the following functions:
f 0 ( x 1 ,x 2 , . . . ,x n )= x 1 ( x 2 ( x 3 ( x 4 ( . . . ))))
f 1 ( x 1 ,x 2 , . . . ,x n )= x ( x 2 ( x 3 ( x 4 ( . . . )))).
[0005] The above functions are important because they are included in many arithmetic operations, such as addition, subtraction, and comparison. A fast hardware evaluation of these functions has been developed based on the presumption that all inputs x 1 , x 2 , . . . , x n of functions f 0 and f 1 have the same arrival depth when functions f 0 and f 1 are a part of adders and comparators.
[0006] Functions f 0 and f 1 are used in several methods of synthesis Boolean circuits other than special arithmetical operations, for example a Boolean function y determined by the RTL-Verilog code:
y=0;
if ( A 1) y= 1;
if ( A 2) y= 0;
if ( A 3) y= 1;
if ( A 4) y= 0;
if ( A 5) y= 1;
if ( A n) y= 0.
[0007] It is clear that y=ƒ 1 (Ã 1 ,A n-1 , . . . ,A 1 ). Consequently, functions f 0 and f 1 can be used during the synthesis of Boolean circuits to evaluate Boolean functions determined by some programming languages.
[0008] Variables A 1 , A 2 , . . . , A n can be either single variables or comprehensive expressions that are evaluated by different Boolean circuits. These variables often have the different arrival depths. Because the values of variables A 1 , A 2 , . . . , A n are evaluated by the different Boolean circuits whose depths are optimized separate from each other, a need exists for a more universal method of rapid reduction of the depth of functions f 0 and f 1 for various sets of arrival depths of inputs A 1 , A 2 , . . . , A n .
SUMMARY OF THE INVENTION
[0009] The present invention is directed to a process of fabricating Boolean circuits of minimal depth functions having different input arrival depths.
[0010] In one embodiment, Boolean circuits are designed with minimal depth. The depth of an existing circuit is calculated, the Boolean circuit being composed of cells arranged in a tree to perform a Boolean function. Those subtrees having a non-regular root cell is balanced, wherein a non-regular cell is one having a number of children other than one or having one child of a type different from the root cell. The cells are iteratively transformed parent and/or grandparent cells until the depth of the circuit not reduced between two successive iterations. The resulting circuit design is then output.
[0011] The subtrees are balanced by constructing a new subtree connected to the nets that are leaves to the tree, or by creating a new cell connected to two leaves that are nets with minimal depth and thereupon constructing a new subtree connected to the leaves.
[0012] If a parent cell to a selected cell has two or more children or is a type different from that of the selected cell, the subtree may be adjusted so that the parent cell is the same type as its child and has more than one child. Adjustment of the subtree can be accomplished by balancing the subtree to make the parent cell the same type as the selected cell (if the parent and selected cells were of different types), or by creating a new cell as parent to the selected cell (if the parent cell had more than one child cell).
[0013] The adjustment of the subtree by creating a new parent cell can be accomplished by creating a new cell as a duplicate of the parent cell, and connecting the selected cell to the new parent cell. The adjustment of the subtree by balancing the subtree can be accomplished by creating new parent cells of the same type as the selected cell, and a selected new cell of the same type as the original parent cell. Each new parent cell is connected to the other parent cell and to a respective grandparent cell of the original parent cell. The selected new cell is connected to new parent cells. The subtrees containing the new parent cells are then balanced.
[0014] In another embodiment of the present invention, a computer readable code is provided to cause a computer to perform the processes of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] [0015]FIGS. 1 and 2 are diagrams of Boolean circuits useful in explaining certain of the expressions used herein.
[0016] [0016]FIG. 3 is a flowchart of the steps of the process of optimizing depth of Boolean circuits in accordance with a preferred embodiment of the present invention.
[0017] FIGS. 4 - 7 are flowcharts of certain subprocesses used in the process illustrated in FIG. 3.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0018] In the present invention, inputs x 1 ,x 2 , . . . ,x n have respective arrival depths expressed as non-negative integer numbers d 1 ,d 2 , . . . ,d n . This is different from the case where d 1 =d 2 = . . . =d n =0.
[0019] [0019]FIG. 1 illustrates a Boolean circuit with inputs X 1 ,X 2 , . . . ,X 6 and output y. There are 3 two-input cells of the type OR2: A,B,D, and 4 two-input cells of type AND2: C,E,F,G. For ease of explanation, the names of the nets are the same as the names of their respective driver cells, so net A is connected to the output of cell A; net B is connected to the output of cell B, etc.
[0020] A cell U is connected to a cell V (or input x i ) if one of inputs of cell U is connected to the net that is driven by the cell V (or input x i ). In such case, cell U is a child of cell V (or input x i ), and cell V (or input x i ) is a parent of cell U. In the example of FIG. 1, cell A is connected to inputs X 1 and X 2 and cell F is connected to cells D and E. Thus, cell F is a child of cells D and E and cells D and E are parents to cell F.
[0021] P 0 (U) and P 1 (U) are the parents of the cell U. The depth d is recursively defined for each cell and each net of the Boolean circuit. For each input x 1 assume d(x i )=d 1 . The depth d(U) for each cell U and the net U connected to the output of cell U is defined as 1 plus the maximum depth of the parent with the largest depth. Hence, depth d(U) can be written as d(U)=max(d(P 0 (U)),d(P 1 (U)))+1. In the example,
d ( A )=max(d(x 0 ), d ( x 1 ))+1, and
d ( F )=max( d ( D ), d ( E ))+1.
[0022] Using this recursive definition, the depth of all the cells can be calculated. If d 1 =d 2 = . . . d 6 =0,
d ( A )= d ( B )= d ( C )=1
d ( D )= d ( E )=2
d ( F )=3
d ( G )=4
[0023] Hence, the depth of the Boolean circuit is the depth of the net to which its output connected. Thus, the depth of the Boolean circuit shown in FIG. 1 is d(G)=4.
[0024] Cells are ordered in “topological order” if they are ordered by depth in ascending order; cells are ordered in “back topological order” if they are ordered by depth in descending order. In the example the order A, B, C, D, E, F, G is a topological order.
[0025] A cell U is called “dis-balanced” if d(P 0 (U))≠d(P 1 (U)). In the example there are two dis-balanced cells: E and G.
[0026] A cell U is a called a “regular” cell if it has only one child and this child is of the same type (AND2 or OR2) as the type of the cell U. In the example there are four regular cells: B, C, E and F. A “non-regular cell” is one having a number of children other than one, or a single child of a different type. Thus, cell A is a non-regular cell because it has two children, cell D is a non-regular cell because its child is a different type from cell D, and cell G is a non-regular cell because it has no children.
[0027] For each non-regular cell U a uniform subtree D(U) fragment of the Boolean circuit is determined recursively:
[0028] 1) U ε D(U);
[0029] 2) if the cell V ε D(U) and cell P 1 (V), i=0, 1, is a regular cell, it implies that P 1 (V) ε D(U);
[0030] 3) the uniform subtree D(U) also contains all nets connected to any input of any cell V ε D(U).
[0031] [0031]FIG. 2 illustrates the uniform subtrees D(A), D(D) and D(G) of the three non-regular cells shown in FIG. 1. The non-regular cell U is the root of the uniform subtree D(U). Each Boolean circuit consisting of OR2 and AND2 cells can be presented as the union of uniform subtrees created for all non-regular cells. Thus each cell V of the Boolean circuit belongs to one of its uniform subtrees, and the root of the uniform subtree that contains cell V is cell R(V).
[0032] Finally, two cells U and V are considered duplicates if they are connected to the same cells and they are of the same type.
[0033] [0033]FIG. 3 is a flowchart of the process of the present invention. The process begins at step 100 with the Boolean circuit determined by the expression x 1 (x 2 (x 3 (x 4 ( . . . )))) for function f 0 (x 1 , x 2 , . . . ,x n ) and by the expression x 1 (x 2 (x 3 (x 4 ( . . . )))) for function f 1 (x 1 ,x 2 , . . . ,x n ). The Boolean circuit description, such as in Verilog code, is input to the process at step 100 . In accordance with the invention equivalent transformations will be applied to the starting Boolean circuit to reduce the depth of the resulting circuit. Because only equivalent transformations are employed, the evaluation of the Boolean function f k (x 1 ,x 2 , . . . ,x n ), where k=0,1, by the resulting Boolean circuit is the same as the evaluation of the function by the starting Boolean circuit.
[0034] At step 102 , the CALCULATE DEPTH procedure is run. The CALCULATE DEPTH procedure examines all the cells in the topological order. The depth of each regular cell is calculated as the maximum of the depth of parents plus one. A BALANCE SUBTREE transformation is applied to non-regular cells U at step 104 . The BALANCE SUBTREE transformation is described in detail in connection with FIG. 4.
[0035] At step 106 , the cells are examined in back topological order. The PROCESS TRANSFORMATION procedure is applied to each cell U. The PROCESS TRANSFORMATION procedure is described in greater detail in connection with FIG. 5.
[0036] At step 108 , the REMOVE DUMMY procedure is applied. Dummy cells may have existed in the starting Boolean circuit, or created as part of one or both of steps 104 or 106 . To remove dummy cells, all cells are examined in the topological order. If both parents of the cell are the same the cell is removed, and all the children of this cell are reconnected to the parent cells.
[0037] At step 110 , the CALCULATE DEPTH procedure, described in step 102 , is re-run. If the depth of the circuit was reduced during steps 106 - 110 , the process loops back to step 106 at step 112 . Otherwise, the process continues to step 114 where a REMOVE DUPLICATES AND DUMMY procedure is run. In this procedure, all cells are examined in the topological order. If the cell has a duplicate cell, the cell is removed and all the children of the cell are reconnected to the duplicate. If both parents of the cell are the same, the cell is removed and all children of the cell are reconnected to the parent cells.
[0038] Finally, the process ends at step 116 with the output of the resulting Boolean circuit.
[0039] [0039]FIG. 4 is a flowchart of the BALANCE SUBTREE transformation used at steps 104 (FIG. 3), 408 (FIG. 6) and 504 (FIG. 7). If at step 200 the cell U of the Boolean circuit is a regular cell, no action is necessary and the transformation ends. If, at step 200 , cell U is a non-regular cell the uniform subtree D=D(U) is used to construct a new uniform subtree D_NEW and replace the uniform subtree D with the new subtree D_NEW so that the children of the cell U become connected to the root cell of the subtree D_NEW. Both subtrees D and D_NEW have the same number of cells but the depth of the root cell of the subtree D_NEW can be less than the depth of the cell U.
[0040] The process of constructing the subtree D_NEW starts as step 202 . Let A={a 1 ,a 2 , . . . ,a m }, where m≧2, be a set of nets that are the leaves of the subtree D and let s 1 ,s 2 ,. . . ,s m be the depths of these nets. For example, the uniform subtree D(D) shown in FIG. 2 has 3 leaves: A, X 3 , X 4 with depths 1, 0, 0 respectively. Subtree D_NEW is defined recursively.
[0041] At step 202 , a determination is made as to whether m=2 or m>2 (recall, m is the number of nets that are leaves to the subtree). If at step 202 m=2, subtree D_NEW is established at step 204 and consists of one cell connected to nets a 1 and a 2 . The type of this cell is the same as cell U.
[0042] If at step 202 m>2, the process continues to step 206 to chose leaves a 1 ε A and a j ε A with minimal possible depths s 1 and s j . At step 208 , cell V is created connected to nets a 1 and a 2 with the same type as cell U. Net V is connected to the output of the cell V and s=max(s 1 ,s j )+1 is the depth of the cell V. Subtree D_NEW is constructed at step 210 for the set of leaves {V,a 1 ,a 2 , . . . ,a m }\{a 1 ,a j }. This set has one less net than the set A={a 1 ,a 2 , . . . ,a m }.
[0043] [0043]FIG. 5 is a flowchart of the PROCESS TRANSFORMATION procedure used at step 106 (FIG. 3). The process begins at step 300 with the examination of the parents of cell U. If, at step 300 , both parents of cell U have already been examined, the process ends at step 326 . Otherwise, the process advances to step 302 to consider parent V of cell U. At step 302 , if d(V)<d(U)−1 then the process returns to step 300 to consider the other parent W. At step 304 , if parent V is an input to the Boolean circuit, the process returns to step 300 to consider the other parent W. If at step 306 , cell U and parent cell V are not the same type, the process loops to step 318 . Otherwise, if at step 308 cell U is the only child of parent cell V, the process returns to step 300 to consider the other parent W. If cell U is not the only child of cell V (i.e., parent cell V is a non-regular cell), the process advances to step 310 where the uniform subtree D(R(U)) is searched to find dis-balanced cells Z. If subtree D(R(U)) contains no dis-balanced cells Z, the process returns to step 300 to consider the other parent W. Otherwise the dis-balanced cell Z with maximal possible depth d(Z) is selected at step 312 . If at step 314 the depth of cell Z is not greater than the minimum depth of either parent plus 2 , namely that d(Z)≦min(d(P 0 (V)),d(P 1 (V)))+2, then the process returns to step 300 , otherwise the MOVE transformation, more fully described in connection with FIG. 7, is applied to cells U and V at step 316 and the process advances to step 326 .
[0044] If, at step 306 , cells U and V are of different types, the process continues to step 318 . At step 318 , the other parent cell W of cell U is considered (as opposed to parent cell V). Cells W 1 and W 2 are the parents of cell V and grandparents to cell U. At step 318 , if both cells W 1 and W 2 are of the same type as the type of the cell V then the process returns to step 300 . Otherwise, at step 320 parameter k is defined. More particularly, k is 0 if cells W, U, W 1 , W 2 are of the same type. Otherwise, k=1. At step 322 , if d(W)>d(U)−2−k, then the process returns to step 300 . Otherwise at step 324 the DISTRIBUTE transformation, more fully described in connection with FIG. 6, is applied to cells U and V and the process ends at step 326 .
[0045] Steps 306 and 308 effectively identify if parent cell V is a non-regular cell. Recall, one form of non-regular cell is one with more than one child or is of a different type than its child. Step 306 identifies if cell V is a non-regular cell because it is a different type from cell U, and the transformation of FIG. 6 is performed (if cell V's parent cells W 1 and W 2 are not the same type as cell V) to distribute and balance the subtree to make cell V a regular cell. Step 308 identifies if cell V is a non-regular cell because it has more than one child, and the MOVE transformation of FIG. 7 is performed to change cell V to a regular cells by creating a new cell V 1 to be parent to cell U.
[0046] In FIG. 6, cell V is a parent of cell U and cells U and V are of different types, i.e., cell U is an AND 2 cell and cell V is an OR 2 cell, or vice versa. W is the second parent of cell U, and W 1 and W 2 are the parents of cell V. At step 400 , new cell NEW_V 1 is created and connected to cells W 1 and W and new cell NEW_V 2 is created and connected to cells W 2 and W. Both new cells NEW_V 1 and NEW_V 2 are of the same type as cell U. At step 402 , a new cell NEW_U is created connected to cells NEW_V 1 and NEW_V 2 . Cell NEW_U is of the same type as cell V. At step 404 , new cell NEW_U replaces cell U so that the children of the cell U become connected to the cell NEW_U instead of to cell U. At step 406 , cell V is removed if the cell V had only one child U. At step 408 BALANCE SUBTREE transformation is applied to cells NEW_V 1 and NEW_V 2 .
[0047] The DISTRIBUTE transformation increases the number of cells of the Boolean circuit by 2 , except where a cell is removed at step 406 in which case the transformation increases the number of cell by 1 . The transformation is an equivalent transformation because cell U is replaced with an equivalent cell NEW_U.
[0048] [0048]FIG. 7 is a flow chart of the MOVE transformation used at step 316 (FIG. 5). Cell V is a parent of cell U and the cells U and V are of the same types. Cell V is a non-regular cell and thus has more than one child. At step 500 , a new cell V 1 is created as a duplicate of the cell V. At step 502 , cell U is connected to the cell V 1 instead of to cell V. At step 504 , the transformation BALANCE SUBTREE transformation is performed on the subtree D(R(U)). Note that the MOVE-transformation increases the number of cells, but the depth of the circuit may actually be reduced by the BALANCE SUBTREE transformation, as previously described.
[0049] As previously stated, inputs x 1 ,x 2 , . . . ,x n have respective arrival depths expressed as non-negative integer numbers d 1 ,d 2 , . . . ,d n . In the present case, the arrival depths do not need to be equal (it is not necessary that d 1 =d 2 = . . . =d n =0). Thus, the present invention provides for the more general case of providing an optimally minimal depth Boolean circuit for performing the functions
f 0 ( x 1 ,x 2 , . . . ,x n )= x 1 ( x 2 ( x 3 ( x 4 ( . . . )))) and
f 1 ( x 1 ,x 2 , . . . ,x n )= x 1 ( x 2 ( x 3 ( x 4 ( . . . )))),
[0050] where the arrival depths of each input x 1 ,x 2 , . . . ,x n are not the same. It also applies to the special case where d 1 =d 2 = . . . =d n =0. Experiments demonstrate that where the input arrival depths are equal and n≦64, a Boolean circuit obtained by the present invention has a depth no greater than one more, and in some cases the same, as one obtained by prior techniques specifically directed to equal input arrival depths.
[0051] In preferred embodiments, the invention is carried out in a computer, with a memory medium, such as a recording disk of a disk drive, having a computer readable program therein containing computer readable program code that carries out the computer processes of the invention. The stating Boolean circuit may be represented in RTL-Verilog code and input as data to the computer. The computer, operating under control of the computer readable program, and particularly the computer readable program code on the disk, executes the code and performs the process steps of the invention, thus supplying an output in the form of an RTL-Verilog code describing the resulting Boolean circuit with minimal depth.
[0052] Although the present invention has been described with reference to preferred embodiments, workers skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the invention. | Boolean circuits are designed with minimal depth by calculating the depth of an existing circuit. Those subtrees having a non-regular root cell (i.e., cells having other than one child or having a child of a type different from the cell) are balanced by constructing a new subtree. The cells are then iteratively transformed with parent and/or grandparent cells to reduce the depth of the circuit. The transformation may include balancing the subtree to make the parent cell the same type as the selected cell, or by creating a new cell as parent to the selected cell. | 6 |
FEDERALLY SPONSORED RESEARCH
[0001] This invention was made with government support under grant No. R24EY12893-01, awarded by the National Institutes of Health. The government has certain rights in the invention.
FIELD OF THE INVENTION
[0002] This invention relates to an electrode array or flexible circuit, electronics package and a method of bonding a flexible circuit or electrode array to an integrated circuit or electronics package.
BACKGROUND OF THE INVENTION
[0003] Arrays of electrodes for neural stimulation are commonly used for a variety of purposes. Some examples include U.S. Pat. No. 3,699,970 to Brindley, which describes an array of cortical electrodes for visual stimulation. Each electrode is attached to a separate inductive coil for signal and power. U.S. Pat. No. 4,573,481 to Bullara describes a helical electrode to be wrapped around an individual nerve fiber. U.S. Pat. No. 4,837,049 to Byers describes spike electrodes for neural stimulation. Each spike electrode pierces neural tissue for better electrical contact. U.S. Pat. No. 5,215,088 to Norman describes an array of spike electrodes for cortical stimulation. U.S. Pat. No. 5,109,844 to de Juan describes a flat electrode array placed against the retina for visual stimulation. U.S. Pat. No. 5,935,155 to Humayun describes a retinal prosthesis for use with a flat retinal array.
[0004] Packaging of a biomedical device intended for implantation in the eye, and more specifically for physical contact with the retina, presents a unique interconnection challenge. The consistency of the retina is comparable to that of wet tissue paper and the biological media inside the eye is a corrosive saline liquid environment.
[0005] Thus, the device to be placed against the retina, in addition to being comprised of biocompatible, electrochemically stable materials, must appropriately conform to the curvature of the eye, being sufficiently flexible and gentle in contact with the retina to avoid tissue damage, as discussed by Schneider, et al. It is also desirable that this device, an electrode array, provides a maximum density of stimulation electrodes. A commonly accepted design for an electrode array is a very thin, flexible conductor cable. It is possible to fabricate a suitable electrode array using discrete wires, but with this approach, a high number of stimulation electrodes cannot be achieved without sacrificing cable flexibility (to a maximum of about 16 electrodes).
[0006] A lithographically fabricated thin film flex circuit electrode array overcomes such limitations. A thin film flex circuit electrode array can be made as thin as 10 um (<0.0005 inches) while accommodating about 60 electrodes in a single circuit routing layer. The flex circuit electrode array is essentially a passive conductor ribbon that is an array of electrode pads, on one end, that contact the retina and on the other end an array of bond pads that must individually mate electrically and mechanically to the electrical contacts of a hermetically sealed electronics package. These contacts may emerge on the outside of the hermetic package as an array of protruding pins or as vias flush to a package surface. A suitable interconnection method must not only serve as the interface between the two components, but must also provide electrical insulation between neighboring pathways and mechanical fastening between the two components.
[0007] Many methods exist in the electronics industry for attaching an integrated circuit to a flexible circuit. Commonly used methods include wire-bonding, anisotropic-conductive films, and “flip-chip” bumping. However, none of these methods results in a biocompatible connection. Common materials used in these connections are tin-lead solder, indium and gold. Each of these materials has limitations on its use as an implant. Lead is a known neurotoxin. Indium corrodes when placed in a saline environment. Gold, although relatively inert and biocompatible, migrates in a saline solution, when electric current is passed through it, resulting in unreliable connections.
[0008] In many implantable devices, the package contacts are feedthrough pins to which discrete wires are welded and subsequently encapsulated with polymer materials. Such is the case in heart pacemaker and cochlear implant devices. Flexible circuits are not commonly used, if at all, as external components of proven implant designs. The inventor is unaware of prior art describing the welding of contacts to flex circuits.
[0009] Attachment by gold ball bumping has been demonstrated by the Fraunhofer group (Beutel, et al.) to rivet a flex circuit onto an integrated circuit. A robust bond can be achieved in this way. However, encapsulation proves difficult to effectively implement with this method. Because the gap between the chip and the flex circuit is not uniform, underfill with epoxy is not practical. Thus, electrical insulation cannot be achieved with conventional underfill technology. Further, as briefly discussed earlier, gold, while biocompatible, is not completely stable under the conditions present in an implant device since it “dissolves” by electromigration when implanted in living tissue and subject to an electric current (see Pourbaix).
[0010] Widespread use of flexible circuits can be found in high volume consumer electronics and automotive applications, such as stereos. These applications are not constrained by a biological environment. Component assembly onto flex circuits is commonly achieved by solder attachment. These flex circuits are also much more robust and bulkier than a typical implantable device. The standard flex circuit on the market is no less than 0.002 inches in total thickness. The trace metalization is etched copper foil, rather than thin film metal. Chip-scale package (CSP) assembly onto these flex circuits is done in ball-grid array (BGA) format, which uses solder balls attached to input-output contacts on the package base as the interconnect structures. The CSP is aligned to a corresponding metal pad array on the flex circuit and subjected to a solder reflow to create the interconnection. A metallurgical interconnect is achieved by solder wetting. The CSP assembly is then underfilled with an epoxy material to insulate the solder bumps and to provide a pre-load force from the shrinkage of the epoxy.
[0011] Direct chip attach methods are referred to as chip-on-flex (COF) and chip-on-board (COB). There have been some assemblies that utilize gold wirebonding to interconnect bare, integrated circuits to flexible circuits. The flipchip process is becoming a reliable interconnect method. Flipchip technology originates from IBM's Controlled Collapse Chip Connection (C 4 ) process, which evolved to solder reflow technique. Flipchip enables minimization of the package footprint, saving valuable space on the circuit, since it does not require a fan out of wirebonds. While there are a variety of flipchip configurations available, solder ball attach is the most common method of forming an interconnect. A less developed approach to flipchip bonding is the use of conductive adhesive, such as epoxy or polyimide, bumps to replace solder balls. These bumps are typically silver-filled epoxy or polyimide, although electrically conductive particulate of select biocompatible metal, such as platinum, iridium, titanium, platinum alloys, iridium alloys, or titanium alloys in dust, flake, or powder form, may alternatively be used. This method does not achieve a metallurgical bond, but relies on adhesion. Polymer bump flip chip also requires underfill encapsulation. Conceivably, polymer bump attachment could be used on a chip scale package as well. COB flipchip attach can also be achieved by using gold stud bumps, as an alternative to solder balls. The gold bumps of the chip are bonded to gold contacts on the hard substrate by heat and pressure. A recent development in chip-to-package attachment was introduced by Intel Corporation as Bumpless Build Up Layer (BBUL) technology. In this approach, the package is grown (built up) around the die rather than assembling the die into a pre-made package. BBUL presents numerous advantages in reliability and performance over flipchip.
[0012] Known techniques for bonding an electronic package to a flex circuit do not result in a hermetic package that is suitable for implantation in living tissue. Therefore, it is desired to have a method of attaching a rigid substrate to a flexible circuit that ensures that the bonded electronic package and flex circuit will function for long-term implant applications in living tissue.
SUMMARY OF THE INVENTION
[0013] An implantable electronic device comprising a hermetic electronics control unit, a first thin film flexible electrically insulating substrate; an electrically conducting metal layer deposited on the first insulating layer in electrical contact with the electronics control unit; a second thin film flexible electrically insulating substrate deposited on the electrically conducting metal layer; and a second flexible electrically insulating substrate defining holes that expose the electrically conducting metal layer.
[0014] A method of making an implantable electronic device comprising depositing a release coat on a hybrid substrate, depositing a first flexible electrically insulating substrate on the release coat; depositing an electrically conducting metal layer on the first flexible electrically insulating substrate, depositing a second flexible electrically insulating substrate on the metal layer, cutting said hybrid substrate to distinguish a carrier portion of said hybrid substrate, removing said release coat, removing at least a portion of said first flexible electrically insulating substrate from said carrier; creating voids in one of said flexible electrically insulating substrates to said metal layer creating a pattern of electrodes; bonding a microelectronics assembly to said hybrid substrate, and covering said microelectronics assembly with a hermetically sealed header.
[0015] The novel features of the invention are set forth with particularity in the appended claims. The invention will be best understood from the following description when read in conjunction with the accompanying drawings.
OBJECTS OF THE INVENTION
[0016] It is an object of the invention to provide a hermetic, biocompatible electronics package that is attached to a flexible circuit.
[0017] It is an object of the invention to attach a hermetically sealed electronics package to a flexible circuit for implantation in living tissue.
[0018] It is an object of the invention to attach a hermetically sealed electronics package to a flexible circuit for implantation in living tissue to transmit electrical signals to living tissue, such as the retina.
[0019] It is an object of the invention to provide a hermetic, biocompatible electronics package that is attached directly to a rigid substrate.
[0020] Other objects, advantages and novel features of the present invention will become apparent from the following detailed description of the invention when considered in conjunction with the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] [0021]FIG. 1 illustrates a perspective cutaway view of an eye containing a flexible circuit electrode array.
[0022] [0022]FIG. 2 is a side view of an electronics package.
[0023] [0023]FIG. 3 illustrates a cutaway side view of an electronics package.
[0024] [0024]FIG. 4 is a top view of a flex circuit without the electronics package.
[0025] [0025]FIG. 5 presents a side view of a flex circuit with the electronics package.
[0026] [0026]FIG. 6 is a side view of a flex circuit that is bonded with adhesive to a hybrid substrate.
[0027] [0027]FIG. 7 is a series of illustrations of a flexible circuit being bonded using conductive metal pads to a hybrid substrate.
[0028] [0028]FIG. 8 is a series of illustrations of weld staple bonding of a flexible circuit to a hybrid substrate.
[0029] [0029]FIG. 9 is a sequence of steps illustrating tail-latch interconnect bonding of a flexible circuit to a hybrid substrate.
[0030] [0030]FIG. 10 is a sequence of steps illustrating formation of an integrated interconnect by vapor deposition.
[0031] [0031]FIG. 11 is a side view of a flexible circuit bonded to a rigid array.
[0032] [0032]FIG. 12 is a side view of an electronics control unit bonded to a rigid array.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0033] The following description is the best mode presently contemplated for carrying out the invention. This description is not to be taken in a limiting sense, but is made merely for describing the general principles of the invention. The scope of the invention should be determined with reference to the claims.
[0034] The present invention provides a flexible circuit electronics package and a method of bonding a flexible circuit to a hermetic integrated circuit which is useful for a number of application, including implantation in living tissue as a neural interface, such as a retinal electrode array or an electrical sensor. The tissue paper thin flexible circuit 18 , FIG. 1, transmits electrical signals to the eye 2 by means of electrodes, that are located in a stimulating electrode array 10 , that are in contact with the retina 14 . It is obvious that in addition to a stimulating electrode array or sensing electrode, the electrodes may be contacts connecting to remote electrodes. FIG. 1 illustrates the electronics control unit 20 in a perspective cutaway view of an eye 2 containing a flexible circuit electrode array 18 . The electronics control unit 20 is hermetically sealed. The electronics control unit 20 may be a hermetic ceramic case with electronics inside, or it may be a hermetically sealed integrated circuit, or any other environmentally sealed electronics package. The stimulating electrode array 10 is implanted on the retina 14 . Flexible circuit ribbon 24 connects the stimulating electrode array 10 to the electronics control unit 20 . The flexible circuit ribbon 24 preferably passes through the sclera 16 of the eye 2 at incision 12 . Another embodiment of the invention is the flexible circuit ribbon 24 replaced by alternative means of electrical interconnection, such as fine wires or thin cable. The lens 4 of the eye 2 is located opposite the retina 14 . A coil 28 , which detects electronic signals such as of images or to charge the electronics control unit 20 power supply, located outside the eye 2 , near the lens 4 , is connected to the electronics control unit 20 by wire 30 .
[0035] [0035]FIG. 2 illustrates a side view of the hermetic electronics control unit 20 and the input/output contacts 22 that are located on the bottom of the unit 20 . The input/output contacts 22 are bonded in the completed assembly to the flexible circuit 18 . Thick film pad 23 is formed by known thick film technology, such as silk screening or plating. The pad 23 facilitates attachment of wire 30 , and is preferably comprised of a biocompatible material such as platinum, iridium, or alloys thereof, and is preferably comprised of platinum paste. Wire 30 is preferably bonded to pad 23 by welding.
[0036] [0036]FIG. 3 illustrates a cutaway side view of the hermetic electronics control unit 20 . The microelectronics assembly 48 is mounted on the hybrid substrate 44 . Vias 46 pass through the substrate 44 to input/output contacts 22 . Electrical signals arrive by wire 30 and exit the electronics control unit 20 by input/output contacts 22 .
[0037] A top view of the flexible circuit 18 is illustrated in FIG. 4. Electrical signals from the electronics control unit 20 (see FIG. 3) pass into bond pads 32 , which are mounted in bond pad end 33 . Flexible electrically insulating substrate 38 , is preferably comprised of polyimide. The signals pass from the bond pads 32 along traces 34 , which pass along flexible circuit ribbon 24 to the stimulating electrode array 10 . The array 10 contains the electrodes 36 , which are implanted to make electrical contact with the retina 14 of the eye 2 , illustrated in FIG. 1. An alternative bed of nails embodiment for the electrodes 36 is disclosed by Byers, et al. in U.S. Pat. No. 4,837,049.
[0038] In FIG. 5, the hermetic electronics control unit 20 is illustrated mounted to flexible circuit 18 . In order to assure electrical continuity between the electronics control unit 20 and the flexible circuit 18 , the electrical control unit 20 must be intimately bonded to the flexible circuit 18 on the bond pad end 33 . A cutaway of the electronics control unit 20 (FIG. 5) illustrates a bonded connection 42 . The flexible electrically insulating substrate 38 is very thin and flexible and is able to conform to the curvature of the retina 14 (FIG. 1), when implanted thereon.
[0039] Methods of bonding the flexible insulating substrate 18 to the hermetic electronics control unit 20 are discussed next.
[0040] Platinum Conductor in Polymer Adhesive
[0041] A preferred embodiment of the invention, illustrated in FIG. 6, shows the method of bonding the hybrid substrate 244 to the flexible circuit 218 using electrically conductive adhesive 281 , such as a polymer, which may include polystyrene, epoxy, or polyimide, which contains electrically conductive particulate of select biocompatible metal, such as platinum, iridium, titanium, platinum alloys, iridium alloys, or titanium alloys in dust, flake, or powder form.
[0042] In FIG. 6, step a, the hybrid substrate 244 , which may alternatively be an integrated circuit or electronic array, and the input/output contacts 222 are prepared for bonding by placing conductive adhesive 281 on the input/output contacts 222 . The rigid integrated circuit 244 is preferably comprised of a ceramic, such as alumina or silicon. In step b, the flexible circuit 218 is preferably prepared for bonding to the hybrid substrate 244 by placing conductive adhesive 281 on bond pads 232 . Alternatively, the adhesive may be coated with an electrically conductive biocompatible metal. The flexible circuit 218 contains the flexible electrically insulating substrate 238 , which is preferably comprised of polyimide. The bond pads 232 are preferably comprised of an electrically conductive material that is biocompatible when implanted in living tissue, and are preferably platinum or a platinum alloy, such as platinum-iridium.
[0043] [0043]FIG. 6, step c illustrates the cross-sectional view A-A of step b. The conductive adhesive 281 is shown in contact with and resting on the bond pads 232 . Step d shows the hybrid substrate 244 in position to be bonded to the flexible circuit 218 . The conductive adhesive 281 provides an electrical path between the input/output contacts 222 and the bond pads 232 . Step c illustrates the completed bonded assembly wherein the flexible circuit 218 is bonded to the hybrid substrate 144 , thereby providing a path for electrical signals to pass to the living tissue from the electronics control unit (not illustrated). The assembly has been electrically isolated and hermetically sealed with adhesive underfill 280 , which is preferably epoxy.
[0044] Studbump Bonding
[0045] [0045]FIG. 7 illustrates the steps of an alternative embodiment to bond the hybrid substrate 244 to flexible circuit 218 by studbumping the hybrid substrate 244 and flexible electrically insulating substrate 238 prior to bonding the two components together by a combination of heat and/or pressure, such as ultrasonic energy. In step a, the hybrid substrate 244 is prepared for bonding by forming a studbump 260 on the input/output contacts 222 . The studbump is formed by known methods and is preferably comprised of an electrically conductive material that is biocompatible when implanted in living tissue if exposed to a saline environment. It is preferably comprised of metal, preferably biocompatible metal, or gold or of gold alloys. If gold is selected, then it must be protected with a water resistant adhesive or underfill 280 .
[0046] Alternatively, the studbump 260 may be comprised of an insulating material, such as an adhesive or a polymer, which is coated with an electrically conductive coating of a material that is biocompatible and stable when implanted in living tissue, while an electric current is passed through the studbump 260 . One such material coating may preferably be platinum or alloys of platinum, such as platinum-iridium, where the coating may be deposited by vapor deposition, such as by ion-beam assisted deposition, or electrochemical means.
[0047] [0047]FIG. 7, step b presents the flexible circuit 218 , which comprises the flexible electrically insulating substrate 238 and bond pads 232 . The flexible circuit 218 is prepared for bonding by the plating bond pads 232 with an electrically conductive material that is biocompatible when implanted in living tissue, such as with a coating of platinum or a platinum alloy. Studbumps 260 are then formed on the plated pad 270 by known methods. Step c illustrates cross-section A-A of step b, wherein the flexible circuit 218 is ready to be mated with the hybrid substrate 244 .
[0048] [0048]FIG. 7, step d illustrates the assembly of hybrid substrate 244 flipped and ready to be bonded to flexible circuit 218 . Prior to bonding, the studbumps 260 on either side may be flattened by known techniques such as coining. Pressure is applied to urge the mated studbumps 260 together as heat is applied to cause the studbumps to bond by a diffusion or a melting process. The bond may preferably be achieved by thermosonic or thermocompression bonding, yielding a strong, electrically conductive bonded connection 242 , as illustrated in step e. An example of a thermosonic bonding method is ultrasound. The bonded assembly is completed by placing an adhesive underfill 280 between the flexible circuit 218 and the hybrid substrate 244 , also increasing the strength of the bonded assembly and electrically isolating each bonded connection. The adhesive underfill 280 is preferably epoxy.
[0049] Weld Staple Interconnect
[0050] [0050]FIG. 8 illustrates the steps of a further alternative embodiment to bond the hybrid substrate 44 to flexible circuit 18 by weld staple bonding the substrate 244 and flexible electrically insulating substrate 38 together. In step a, a top view of the flexible circuit 18 is shown. Flexible circuit 18 is comprised of flexible electrically insulating substrate 38 , which is preferably polyimide, and bond pads 32 having a through hole 58 therethrough each bond pad 32 and through the top and bottom surfaces of flexible circuit 18 . The bond pads 32 are comprised of an electrically conductive and biocompatible material which is stable when implanted in living tissue, and which is preferably platinum or a platinum alloy, such as platinum-iridium.
[0051] [0051]FIG. 8, step b presents section A-A, which is shown in the illustration of step a. The through holes 58 pass completely through each bond pad 58 , preferably in the center of the bond pad 58 . They are preferably formed by plasma etching. The bond pads 58 are not covered on the top surface of flexible circuit 18 by flexible electrically insulating substrate 38 , thereby creating bond pad voids 56 .
[0052] [0052]FIG. 8, step c shows the side view of hybrid substrate 44 with input/output contacts 22 on one surface thereof. The hybrid substrate 44 is positioned, in step d, to be bonded to the flexible circuit 18 by placing the parts together such that the input/output contacts 22 are aligned with the bond pads 32 . Then wire 52 , which is preferably a wire, but may equally well be a ribbon or sheet of weldable material, that is also preferably electrically conductive and biocompatible when implanted in living tissue, is attached to input/output contact 22 and bond pad 32 to bond each aligned pair together. The wire 52 is preferably comprised of platinum, or alloys of platinum, such as platinum-iridium. The bond is preferably formed by welding using the parallel gap welder 50 , which moves up and down to force the wire 52 into the through hole 58 and into contact with input/output contact 22 . This process is repeated for each aligned set of input/output contacts 22 and bond pads 32 , as shown in step e.
[0053] The weld staple interconnect bonding process is completed, as shown in step f, by cutting the wire 54 , leaving each aligned set of input/output contacts 22 and bond pads 32 electrically connected and mechanically bonded together by staple 54 .
[0054] Tail-Latch Interconnect
[0055] [0055]FIG. 9 illustrates yet another embodiment for attaching the hybrid substrate 244 to a flexible circuit 218 by using a tail-ball 282 component, as shown in step a. The hybrid substrate 244 is preferably comprised of a ceramic material, such as alumina or silicon. In one embodiment, a wire, preferably made of platinum or another electrically conductive, biocompatible material, is fabricated to have a ball on one end, like the preferred tail-ball 282 illustrated in step a. The tail-ball 282 has tail 284 attached thereto, as shown in the side view of step a. The tail-ball 282 is aligned with input/output contact 222 on hybrid substrate 244 , in preparation to being bonded to flexible circuit 218 , illustrated in step b.
[0056] The top view of step b illustrates flexible electrically insulating substrate 238 , which is preferably comprised of polyimide, having the through hole 237 passing completely thorough the thickness and aligned with the tail 284 . The bond pads 232 are exposed on both the top and bottom surfaces of the flexible circuit 218 , by voids 234 , enabling electrical contact to be made with input/output contacts 222 of the hybrid substrate 244 . The voids are preferably formed by plasma etching.
[0057] The side view of FIG. 9, step c, which illustrates the section A-A of step b, shows the hybrid substrate 244 in position to be bonded to and aligned with flexible circuit 218 . The tails 284 are each placed in through hole 237 . Pressure is applied and the tail-balls 282 are placed in intimate contact with bond pads 232 and input/output contacts 222 . Step c illustrates that each of the tails 284 is bent to make contact with the bond pads 232 . The bonding process is completed by bonding, preferably by welding, each of the tails 284 , bond pads 232 , tail-balls 282 , and input/output contacts 222 together, thus forming a mechanical and electrical bond. Locking wire 262 is an optional addition to assure that physical contact is achieved in the bonded component. The process is completed by underfilling the gap with an electrically insulating and biocompatible material (not illustrated), such as epoxy.
[0058] Integrated Interconnect by Vapor Deposition
[0059] [0059]FIG. 10 illustrates a further alternative embodiment to creating a flexible circuit that is electrically and adhesively bonded to a hermetic rigid electronics package. In this approach, the flexible circuit is fabricated directly on the rigid substrate. Step a shows the hybrid substrate 44 , which is preferably a ceramic having a total thickness of about 0.012 inches, such as alumina or silicon, with patterned vias 46 therethrough. The vias 46 are preferably comprised of frit containing platinum.
[0060] In step b, the routing 35 is patterned on one side of the hybrid substrate 44 by known techniques, such as photolithography or masked deposition. It is equally possible to form routing 35 on both sides of the substrate 44 . The hybrid substrate 44 has an inside surface 45 and an outside surface 49 . The routing 35 will carry electrical signals from the integrated circuit, that is to be added, to the vias 46 , and ultimately will stimulate the retina (not illustrated). The routing 35 is patterned by know processes, such as by masking during deposition or by post-deposition photolithography. The routing 35 is comprised of a biocompatible, electrically conductive, patternable material, such at platinum.
[0061] Step c illustrates formation of the release coat 47 on the outside surface 49 of the hybrid substrate 44 . The release coat 47 is deposited by known techniques, such as physical vapor deposition. The release coat 47 is removable by know processes such as etching. It is preferably comprised of an etchable material, such as aluminum.
[0062] Step d illustrates the formation of the traces 34 on the outside surface 49 of the hybrid substrate 44 . The traces 34 are deposited by a known process, such as physical vapor deposition or ion-beam assisted deposition. They may be patterned by a known process, such as by masking during deposition or by post-deposition photolithography. The traces 34 are comprised of an electrically conductive, biocompatible material, such as platinum, platinum alloys, such as platinum-iridium, or titanium-platinum. The traces 34 conduct electrical signals along the flexible circuit 18 and to the stimulating electrode array 10 , which were previously discussed and are illustrated in FIG. 4.
[0063] Step e illustrates formation of the flexible electrically insulating substrate 38 by known techniques, preferably liquid precursor spinning. The flexible electrically insulating substrate 38 is preferably comprised of polyimide. The flexible electrically insulating substrate electrically insulates the traces 34 . It is also biocompatible when implanted in living tissue. The coating is about 5 microns thick. The liquid precursor is spun coated over the traces 34 and the entire outside surface 49 of the hybrid substrate 44 , thereby forming the flexible electrically insulating substrate 38 . The spun coating is cured by known techniques.
[0064] Step f illustrates the formation of voids in the flexible electrically insulating substrate 38 thereby revealing the traces 34 . The flexible electrically insulating substrate is preferably patterned by known techniques, such as photolithography with etching.
[0065] Step g illustrates the rivets 51 having been formed over and in intimate contact with traces 34 . The rivets 51 are formed by known processes, and are preferably formed by electrochemical deposition of a biocompatible, electrically conductive material, such as platinum or platinum alloys, such at platinum-iridium.
[0066] Step h illustrates formation of the metal layer 53 over the rivets 51 in a controlled pattern, preferably by photolithographic methods, on the outside surface 49 . The rivets 51 and the metal layer 53 are in intimate electrical contact. The metal layer 53 may be deposited by known techniques, such as physical vapor deposition, over the entire surface followed by photolithographic patterning, or it may be deposited by masked deposition. The metal layer 53 is formed of an electrically conductive, biocompatible material, which in a preferred embodiment is platinum. The patterned metal layer 53 forms traces 34 and electrodes 36 , which conduct electrical signals from the electronics control unit 20 and the electrodes 36 (see FIGS. 4 and 5).
[0067] Step i illustrates the flexible electrically insulating substrate 38 applied over, the outside surface 49 of the rigid substrate 44 , as in step e. The flexible electrically insulating substrate 38 covers the rivets 51 and the metal layer 53 .
[0068] Step j illustrates the hybrid substrate 44 having been cut by known means, preferably by a laser or, in an alternative embodiment, by a diamond wheel, thereby creating cut 55 . The portion of hybrid substrate 44 that will be removed is called the carrier 60 .
[0069] The flexible electrically insulating substrate 38 is patterned by known methods, such as photolithographic patterning, or it may be deposited by masked deposition, to yield voids that define the electrodes 36 . The electrodes 36 transmit electrical signals directly to the retina of the implanted eye (see FIG. 4)
[0070] Step k illustrates flexible circuit 18 attached to the hybrid substrate 44 . The carrier 60 is removed by utilizing release coat 47 . In a preferred embodiment, release coat 47 is etched by known means to release carrier 60 , leaving behind flexible circuit 18 .
[0071] Step I illustrates the implantable electronic device of a flexible circuit 18 and an intimately bonded hermetic electronics control unit 20 . The electronics control unit 20 , which contains the microelectronics assembly 48 , is hermetically sealed with header 62 bonded to rigid circuit substrate 44 . The header 62 is comprised of a material that is biocompatible when implanted in living tissue and that is capable of being hermetically sealed to protect the integrated circuit electronics from the environment.
[0072] [0072]FIG. 11 illustrates an electronics control unit 320 attached to flexible electrically insulating substrate 338 , which is preferably comprised of polyimide, by bonded connections 342 . The electronics control unit 320 is preferably a hermetically sealed integrated circuit, although in an alternative embodiment it may be a hermetically sealed hybrid assembly. Bonded connections 342 are preferably conductive adhesive, although they may alternatively be solder bumps. The bond area is underfilled with an adhesive 380 . Rigid stimulating electrode array 310 is attached to the flexible electrically insulating substrate 338 by bonded connections 342 .
[0073] [0073]FIG. 12 illustrates an electronics control unit 320 attached to rigid stimulating electrode array 310 by bonded connections 342 . The bond area is then underfilled with an adhesive 380 , preferably epoxy. Bonded connections 342 are preferably conductive adhesive, although they may alternatively be solder bumps.
[0074] Accordingly, what has been shown is an improved flexible circuit with an electronics control unit attached thereto, which is suitable for implantation in living tissue and to transmit electrical impulses to the living tissue. Obviously, many modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that, within the scope of the appended claims, the invention may be practiced other than as specifically described. | The invention is directed to a method of bonding a hermetically sealed electronics package to an electrode or a flexible circuit and the resulting electronics package, that is suitable for implantation in living tissue, such as for a retinal or cortical electrode array to enable restoration of sight to certain non-sighted individuals. The hermetically sealed electronics package is directly bonded to the flex circuit or electrode by one of several methods, including attachment by an electrically conductive adhesive, such as epoxy or polyimide, containing platinum metal flake in biocompatible glue; diffusion bonding of platinum bumps covered by an insulating layer; thermal welding of wire staples; or an integrated interconnect fabrication. The resulting electronic device is biocompatible and is suitable for long-term implantation in living tissue. | 8 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to an electronic device and, more in particular, it relates to an electronic device having a connector for electrical connection with outside typically represented by an engine control unit (also abbreviated as ECU, hereinafter).
[0003] 2. Description of the Related Art
[0004] Usually, electronic devices are subjected to heat cycle test before shipping. In particular, since the temperature in the vehicle changes greatly depending on on-off of an engine or change of circumstantial temperature, an electronic control device mounted on an automobile such as ECU is required to have a specification capable of withstanding to temperature cycles for a wide temperature region (usually, from −40 to 120° C.: based on the General Rules of Environmental Testing Methods for Automotive Electronic Equipment; JASO D001-94, established by Society of Automotive Engineers of Japan, Inc).
[0005] For such a temperature range, printed circuit boards having glass epoxy base member (described simply as FR4-type board, hereinafter) have been used generally for electronic circuits board since they are inexpensive.
[0006] An epoxy resin as a base member (a material utilized for the base member) of the FR4-type board has a glass transition temperature (also abbreviated as Tg, hereinafter) of about 125° C. which is soft and flexible particularly at high temperature. In ECU using such FR4-type board, the ECU is electrically connected with an external circuit as follows. At first, an opening is formed to an aluminum diecast for securing an electronic circuit board mounted with ECU. The electronic circuit board and the aluminum diecast are secured by fitting a connector main body having pin (for example, plural pins) into the opening of the aluminum die cast (base member formed with the pin). Then, pins for the connector (also referred as connector pins, hereinafter) are inserted into through holes extending through the electronic circuit board (FR4-type board). Then, the through holes and the pin are connected by soldering (such connection form is also referred as through hole connection, hereinafter).
[0007] FIG. 9 shows the cross sectional structural view of an existent (conventional) printed circuit board ECU.
[0008] A “continuous through hole” described in this specification is characterized, for example, by having an opening formed by being extended between main surfaces on both sides of the electronic circuit board, into which a member being inserted into or penetrating the electronic substrate is fitted. In other words, the continuous through hole, in view of essential feature that it is formed as an opening passing through the electronic board in the direction of the thickness, is distinguished from a so-called “usual through hole” with a main purpose of electrical connection between a plurality of conductive layers formed in the electronic board (isolated from each other in the direction of the thickness of the electronic board) in this specification.
[0009] The prior art concerning the connector (connector device) described above includes JP-A No. 6-76887 that discloses a reinforced structure for a pin portion by resin filling in a connector device.
SUMMARY OF THE INVENTION
[0010] Since ECU has recently tended to be located nearer to an engine, the specification for the upper limit of the temperature range has tended to be higher in the temperature cycle test for a wider temperature range (for example, −55 to 150° C.). For use in such temperature range, not a usual FR4-type board, but a board made of ceramics such as alumina is used. Since the ceramic substrate cannot be formed with continuous through hole, through hole connection with the external circuit described above is impossible and the connector terminal and the pad on the board are practically connected to by the wire-bonding method.
[0011] However, the wire bonding connection involves a problem of taking much manufacturing time along with increase of the number of terminals. Further, a need for ECU made of a printed circuit board is greater than the ceramic board for reduction in the cost of the ECU module.
[0012] In a case where the FR4-type board should be used or tested in a temperature circumstance as severe as −55 to 150° C., cracking destruction toward the inside of the board is caused at the end of the solder resist or at the end of the wirings on the surface of the board after several hundreds cycles. Since the insulation property of the board is deteriorated when such cracking destruction is caused, it cannot be said that sufficient reliability is provided.
[0013] High heat resistant board (also abbreviated as FR4.5-type board, hereinafter) of high Tg have been recently developed by board manufacturers. Those having Tg of about 150° C. to 180° C. have been developed generally although not yet popularized so much. In the use of FR4.5-type board, the board itself is not destroyed even when used for test in a severe temperature circumstance of −55 to 150° C.
[0014] Then, the present inventors have trially manufactured ECU as an automobile electronic device using an FR4.5-type board constituted with a base member having Tg in excess of 150° C.
[0015] As a result of actually manufacturing the ECU with the FR4.5-type board, it has been found that solder crackings are often caused in the solder connection portion at a relatively high probability. In particular, it has been found that large crackings are formed in the through hole connection portion described above (a portion in which a pin is inserted to the through hole), resulting in the deterioration of the connection reliability.
[0016] This is considered to be attributable to the followings:
[0017] A. A resin of high glass transition temperature Tg is rigid in view of the characteristics of a base member formed therewith.
[0018] B. Since the linear expansion coefficient of the connector resin is larger than that of an aluminum casing to which the connector main body is fitted, large warping deformation is developed to the casing during the temperature cycle test.
[0019] C. Stresses and/or strains are concentrated between the pin and the through hole of the board due to the difference of the linear expansion coefficient between the board and the connector resin.
[0020] The present invention intends to provide an automobile electronic device such as ECU using a circuit board constituted with a base member (a material used for that) having Tg exceeding 150° C.
[0021] For avoiding solder crackings, the present inventors have devised the following means.
[0022] At first, since the trigger of crackings in the through hole connection portion occurs at the surface of the solder connection portion, the portion is covered with other reinforcement member (e.g. a reinforcement material) for moderating stress concentration to the surface.
[0023] It is necessary that the cover member be an insulating member so as to keep insulation between adjacent pins.
[0024] Further, in view of the moldability, it is desirable that the member used for the cover member has a viscosity during coating and has a hardness comparable with or higher than that of the solder after setting. Accordingly, an epoxy series resin is effective to be used for the cover member for instance.
[0025] Coating of the member to the through hole solder connection portion on both surfaces of the circuit board is most effective but coating only for the single side is also effective.
[0026] Further, since requirement is not severe uniformly for the solder connection portion of all pins but the extent of stress concentration may sometimes differ locally such as on the outer side (or inside depending on the situation) of the connector, coating may be applied selectively in such a case.
[0027] Coating the rear side of the board (that is, the side thereof opposing to the aluminum casing to which the connector is fitted) with the resin may be performed by using a syringe having a long top end, or by injecting the resin into a through hole formed at the circuit board for resin injection using a syringe having a fine top end.
[0028] In JP-A No. 6-76887, a pin portion is reinforced by filling a resin in a connector device. However, the structure has a feature of providing a disk-shaped capacitor and a shield plate to the connector pin, with an aim of reinforcing connection therewith, and it does not describe in view of the reinforcement of the solder connection portion with the board.
[0029] It is also effective to decrease the rigidity of the connector pin.
[0030] While the pin diameter at the outside of the connector can not be changed optionally due to the restriction of the connection connector from the outside, the diameter for a portion in through hole connection with the board may be decreased.
[0031] When the diameter of the pin is changed inside the connector resin, the pin withdrawing strength can be improved.
[0032] In the same manner, to reduce the rigidity of the pin, it is also effective to bend the pin between the board through hole connection portion and the connector resin. It is more effective to bend the pin in the direction relatively away from the center of the circuit board.
[0033] It is also effective to enlarge a distance (space) between the board through hole connection portion and the connector resin.
[0034] In general, most of electronic parts are mounted on the surface of the board (the board surface) not facing the aluminum casing to which the connector is fitted (also referred as board surface A, hereinafter). In particular, a tall part, for example, an electrolytic capacitor is mounted on the board surface A in order to make the structure and the manufacture of the casing more simply. In a case where the distance (space) between the board through hole connection portion and the connector resin is enlarged while mounting such a part on the board surface A as it is, a larger inner volume is necessary for ECU.
[0035] However, since the external size of ECU is often designated by car manufacturers, it can not simply increase the inner volume of ECU.
[0036] Then, a tall part such as an electrolytic capacitor is mounted on the board surface opposing to the aluminum casing to which the connector is fitted (also referred as board surface B, hereinafter).
[0037] With such a structure, the distance between the board through hole connection portion and the connector resin can be enlarged without increasing the inner volume of ECU, and crackings in the solder through connection portion can be avoided.
[0038] According to the invention, electric connection reliability of an electronic device using a board having a through hole in which a resin having a glass transition temperature in excess of 150° C. is used as a base member can be improved.
BRIEF DESCRIPTION OF THE DRAWINGS
[0039] FIG. 1 is a cross sectional view of an electronic device;
[0040] FIG. 2 is a perspective view of an ECU module;
[0041] FIG. 3 is a cross sectional view of an electronic device;
[0042] FIG. 4 is a cross sectional view of an electronic device;
[0043] FIG. 5 is a cross sectional view of an electronic device;
[0044] FIG. 6 is a cross sectional view of an electronic device;
[0045] FIG. 7 is a cross sectional view of an electronic device;
[0046] FIG. 8 is a cross sectional view of an electronic device; and
[0047] FIG. 9 is a cross sectional view of an existent (conventional) electronic device.
DETAILED DESCRIPTION
[0048] FIG. 2 shows a perspective view of an engine control unit (ECU) module with a lid being detached as an example of an electronic device according to the present invention.
[0049] The ECU module includes an aluminum casing 1 (lid is not illustrated) formed with a connector 3 for input/output of signals relative to the external side, a circuit board 5 mounted on the aluminum casing 1 , a semiconductor package 9 mounted on the circuit board 5 , and silicone gel filling the inside of the casing 1 .
[0050] In this embodiment, connector pins 15 are inserted into continuous through holes in the circuit board 5 and applied with solder connection, to thereby provide connection between the board and a connector.
[0051] While the silicone gel needs not always be used, it is filled with a view point of improving the reliability in this embodiment.
[0052] FIG. 1 is a cross sectional view for FIG. 2 . In FIG. 1 , wall members (side walls) surrounding the circuit board 5 of the aluminum casing (metal casing) 1 shown in FIG. 2 and a lid covering the portion above the side wall members of the metal casing 1 which is not illustrated in FIG. 2 are not shown and they are not illustrated also in cross sectional views referred to hereinafter.
[0053] The semiconductor package 13 is connected to the circuit board 5 with solder by the die-bonding method and electrically connected by way of bonding wires 25 to a circuit layer (pad) 23 .
[0054] The circuit board 5 is a circuit board having a resin (insulating) layer and a circuit layer 7 . On the circuit board 5 , electronic parts 9 and 11 in addition to the semiconductor package 13 are mounted by soldering and the semiconductor package is mounted by BGA (Ball Grid Array).
[0055] The connector includes a resin main body 3 and pins 15 in which 60 pins each having a diameter of about 0.6 mm are planted. Such two connectors are fitted into the openings of the aluminum casing. The circuit board 5 is formed with continuous through holes 21 larger than the pin size (about 1.3 mm diameter) in conformity with the number of pins and the pattern for the pin pitch, etc. of the connector pins 15 . The continuous through hole is applied with electroless Cu plating, Ni plating, and gold plating successively. The pins 15 are inserted into the continuous through holes 21 to establish electrical connection with the solder 19 . A reinforcement resin film of epoxy series 17 is formed so as to cover the solder 19 .
[0056] While the reinforcement member 17 is made of an epoxy series resin in this embodiment, it may be an inorganic series adhesive. Non-conductive member is easy to handle with since it does not cause short-circuit even when coated so as to cover the adjacent pins entirely.
[0057] FIG. 3 and FIG. 4 show embodiments in which reinforcing resins 17 and 29 are formed so as to cover the through hole solder connection portion not only for the board surface A but also the board surface B, that is, on both surfaces of the board.
[0058] Then, a production process for ECU modules of FIGS. 1 to 4 is to be described.
[0059] At first, the production process for the board 5 is described. As an insulating resin layer, a prepreg (i.e. preimpregnation) of highly heat resistant epoxy resin (FR4.5-type) is used. The prepreg is a member formed by dipping a sheet of glass fiber or the like into resin and coating the sheet with the resin. As the wiring layer, usual copper foil and copper plating are used. Wiring layers and insulation layers are laminated each by the required number and pressed, and apertures for continuous through holes are extended through by drilling. Wirings for the surface layer, pads for solder BGA connection and through hole inner wall member are formed by plating. Plating was formed by applying copper plating, nickel plating and further gold plating. While plating may be applied only by copper plating, nickel plating and gold plating are applied desirably for solder connection and for preventing oxidation of the surface.
[0060] Then, an aluminum casing 1 having two holes to which the connector can be inserted is manufactured by casting. The casing has protrusions for positioning the board or threaded holes for fixing the board.
[0061] Then, the connector 3 having the pins 15 is fitted into the aluminum casing 1 . Both of them are bonded by adhesives. Electronic parts 9 , 11 , and 13 are put to reflow soldering at 250° C. by means of Sn 3 Ag 0.5 Cu solder 27 at 250° C. and mounted to the board 5 . The board 5 is positioned such that the pins 15 are inserted into the continuous through holes and they conform with the threaded holes of the casing and then fixed by screws. The back surface of the board is partially secured by adhesives. The continuous through holes 21 and the connector pins 15 are solder connected with Sn 3 Ag 0.5 Cu solder so as to establish electrical connection between them. This connection is conducted by a spot flow method of blowing a molten solder partially. This allows for solder connection of the continuous through hole with no substantial re-melting of solder connection portions for other electronic parts on the board. Further, a liquid epoxy series resin is coated so as to cover the through hole connection portion and cured for 30 min at 150° C.
[0062] In the example shown in FIG. 3 , the liquid epoxy resin is charged in a syringe, and coated so as to cover the soldered surface of the through hole connection portion on the board surface B by an elongate nozzle and then cured under the same conditions as described above.
[0063] In example shown in FIG. 4 , the circuit board 5 is formed with one or more of separate continuous through holes 31 in addition to the continuous through holes for insertion of connector pin, a nozzle is inserted on the side of the board surface A and an epoxy resin 29 is injected to the board surface B. As shown in FIG. 4 , a ridge is disposed to the connector main body resin to such an extent as reaching the surface of the board surface B so that the epoxy series resin can be saved. By saving the epoxy resin in the portion, the soldering surface of the through hole connection portion on the side of the board surface B can be covered with the epoxy series resin.
[0064] In embodiment shown in FIG. 5 , the diameter of the pin in the through hole connection portion is made smaller than the diameter of the pin in other portion in order to lower the rigidity of the pin 33 . The pin diameter on the outer side of the connector 33 can not be changed freely in view of the restriction of the connection connector from the outside. The pin withdrawing strength can be improved when the diameter is changed inside the connector resin 3 .
[0065] FIG. 6 shows an embodiment of bending pins 35 between the board through hole connection portion and the connector resin 3 in order to lower the pin rigidity. It is more effect to bend the pin 35 in the direction relative away from the center of the board 5 .
[0066] FIG. 7 is an example of enlarging the distance (space) between the board through hole connection portion and the connector resin. Most of electronic parts are generally mounted on the board surface A (one surface while not opposed to the casing in board main surface.). A tall part, for example, an electrolytic capacitor is mounted on the board surface A in order to make the structure of the casing and the manufacture thereof more simply. In a case where the distance between the board through hole connection portion and the connector resin is enlarged while mounting such a part on the board surface A as it is, a larger inner volume of ECU is necessary. However, since the external size, etc. of ECU is often designated by car manufacturers, the ECU inner volume can not be increased simply. In view of the above, a tall part such as an electrolytic capacitor 37 is mounted on the board surface B (other surface while opposed to the casing in board main surface.). In such a structure, the distance (space) between the board through hole connection portion and the connector resin can be enlarged without increasing the inner volume of ECU, to avoid crackings in the solder through hole connection portion.
[0067] An electronic device shown in FIG. 8 differs from the existent electronic device shown in FIG. 9 by forming the metal casing 1 so as to produce a plurality of cavities in the inside of the member of the metal or the alloy (for instance, aluminum and alloy including this), though it has the section structure that looks like the existent electronic device. The metal casing 1 formed like this can discharge the heat accumulated in connector resin 3 by the surface area's increasing. As a result, it becomes difficult for the connector pin 15 to be destroyed because the thermal expansion of connector resin 3 is suppressed and brought close to that of printed circuit board 5 . The metal casing 1 of FIG. 8 formed with the porous aluminum etc. is thick formed compared with other embodiments to secure the strength. This thickness may be adjusted to 80% or more of the thickness of the connector resin 3 . The metal casing 1 may be produced by forming holes or hollows with the drill and the milling machine in the main surface by using board member of metal or alloy that has a usual density, instead of producing the metal casing 1 shown in FIG. 8 with the metal or the alloy of the porous quality.
[0068] While we have shown and described several embodiments in accordance with the present invention, it is understood that the same is not limited thereto but is susceptible of numerous changes and modifications as known to those skilled in the art, and we therefore do not wish to be limited to the details shown and described herein but intend to cover all such changes and modifications as are encompassed by the scope of the appended claims. | An electronic device comprises a circuit board which has a through hole and uses a resin with a glass transition temperature exceeding 150° C. as a base member, a metal casing which has an opening, and a connector which is fitted to the opening of the metal casing in which a pin of the connector is inserted into the through hole, the pin and the through hole are connected with a conductive member, and a reinforcement member for securing the connector and the board is further provided on the conductive member, thereby improving the reliability of the electronic device. | 8 |
BACKGROUND OF THE INVENTION
Field of the Invention
The invention lies in the semiconductor technology and manufacturing field. More specifically, the invention relates to a mask for projecting a structure pattern onto a semiconductor substrate in an exposure unit. The exposure unit has a minimum resolution limit defining a minimum attainable lateral extent for a structure pattern element which is to be projected onto the semiconductor substrate.
Structures are formed on a semiconductor substrate usually by means of projection of a structure pattern from a mask onto the semiconductor substrate. This is done via a lens system in an exposure unit. In order to ensure the quality of a mapping operation and the functionality of the integrated circuit which is to be produced, the process involves prescribing a tolerance by which the lateral extent of the structure formed on the semiconductor substrate may differ from that on the projected mask or design master taking into account a reduction factor for the mapping.
Free parameters available when carrying out a projection in an exposure unit are, by way of example, the exposure dose and the setting of a focus value for the lens system in question. Generally, what is obtained is a number of combinations for the two aforementioned exposure parameters, for which a difference, which can be measured using a microscope, for example, is smaller than the prescribed tolerance value. A two-dimensional range for the combinations which satisfy such a condition is also called a process window.
For a fixed exposure dose, a range of admissible focus values for the exposure is available as a section through this process window. This range, which is also referred to as the depth of field, ideally has a large extent. This is because, firstly, with a large number of preliminary processes, a complicated surface topography may already have been produced on the semiconductor substrate by forming a corresponding number of levels in a circuit. Accordingly, it must be possible to carry out mapping at various levels, but in one mapping operation, in each case with high definition.
Secondly, by way of example, lens aberrations over the image plane of the semiconductor substrate bring about a distribution of differences in the local focus value with respect to a mean value for the focus. The differences (defocus) cannot be corrected without adversely affecting the other regions in the image plane.
Modern techniques for improving the resolution for projection, “lithographic resolution enhancement techniques”, equally result in a disadvantageous reduction in the depth-of-field range if they are intended to be used to transfer structure elements in the neighborhood of the resolution limit of the exposure unit to the image plane. These techniques include, by way of example, the use of off-axis illumination (OAI) or the use of half-tone phase masks.
Since reducing the resolution limit is aimed particularly at projecting particularly dense structures, as in memory production, for example, the problem of the depth-of-field range being too small arises particularly for structure elements which are arranged on the substrate in isolated fashion. This is because lens aberrations and the respective illumination setting used, for example off-axis illumination or particular aperture shapes, have different effects on densely arranged and isolated structure elements.
As a solution, various other techniques have been proposed, among which, by way of example, the alternating phase masks can be mentioned which, on account of their properties, have only an insignificant influence on the depth-of-field range in relation to the isolated structures. However, they are very complex to produce and usually require double exposures, which signifies a considerable increase in the expense of the overall production process.
Another solution is to carry out double exposure for respective dense structures and for the isolated structure elements in the peripheral region. This results in an increased cost outlay and possibly in a reduction in quality on account of additional alignment to be carried out during exposure.
Another solution involves arranging “sublithographic structures” (subresolution assist features (SRAF)) in the immediate surroundings of the isolated structure elements on the mask. These sublithographic structure elements have a lateral extent which is smaller than the minimum lateral extent which can be attained with the exposure unit. They are thus not mapped on the semiconductor substrate under normal exposure conditions. Their proximity to the isolated structure means that the sublithographic structure element delivers a light and phase contribution to the mapping of the isolated structure, however, similarly to the way in which this would bring about adjacent structure elements within a dense structure configuration, for example. The sublithographic structure elements therefore simulate a dense structure configuration around the isolated structure element.
One drawback of this solution is that the allocation and dimensioning of these sublithographic structure elements as auxiliary structures for isolated structure elements require complicated computation methods to be carried out taking into account the circuit's design rules. The design rules include conditions which need to be used to match the position and distances of structure elements to one another over a plurality of circuit levels. Another drawback is the increased sensitivity to the “mask error enhancement factor” (MEF), which describes a nonlinear, very acutely increasing relationship between the difference in the lateral extents of structures on the mask and the order of magnitude of the difference in the lateral extent of the same structures on the semiconductor substrate actually in the region of the resolution limit, i.e. the minimum lateral extent which can be obtained by the exposure unit. Yet another drawback is the significant reduction in the resolution with which structures are produced on the mask in binary form. The small extent of the sublithographic structure elements means that this resolution needs to be chosen to be particularly small, which significantly increases the writing time and hence the cost outlay for producing the mask.
SUMMARY OF THE INVENTION
It is accordingly an object of the invention to provide a mask for projecting a structural pattern onto a semiconductor substrate which overcomes the above-mentioned disadvantages of the heretofore-known devices and methods of this general type and which specifies a mask that increases the depth-offield range for projecting a mask onto a semiconductor substrate as compared with conventional masks or phase masks. It is also an object of the present invention to improve the size accuracy of a mapping operation for structure elements in dense structure configurations and also isolated structure elements during projection onto the semiconductor substrate.
With the foregoing and other objects in view there is provided, in accordance with the invention, a mask for projecting a structure pattern onto a semiconductor substrate in an exposure unit, the exposure unit having a minimum resolution limit for projecting the structure pattern onto the semiconductor substrate. The mask has the following features:
a substrate;
at least one raised first structure element on the substrate, the first structure element having a lateral extent amounting to at least the minimum resolution limit;
a configuration of raised second structure elements, the second structure elements:
being disposed in a vicinity of the first structure element on the substrate and arranged in a matrix with a row spacing and a column spacing; having a substantially identical shape and size; and having a respective lateral extent less than the minimum resolution limit, so that the structure configuration cannot be transferred to a photosensitive resist layer formed on the semiconductor substrate.
In other words, the above object is achieved with a mask for projecting a structure pattern onto a semiconductor substrate in an exposure unit, the exposure unit having a minimum resolution limit for a structure pattern element projected onto the semiconductor substrate, comprising substrate, at least one raised first structure element on the substrate, which has a lateral extent which is at least the minimum lateral extent which can be attained by the exposure unit, an arrangement of second raised structure elements, which are arranged in an area surrounding the at least one first structure element on the substrate in the form of a matrix with a row spacing and a column spacing, whose shape and size are essentially identical to one another, and which have a respective lateral extent which is less than the minimum lateral extent which can be attained by the exposure unit.
With the above and other objects in view there is also provided, in accordance with the invention, a mask blank for producing the above-outlined mask. The mask blank includes the following:
a substrate;
a first layer having a matrix configuration of structure elements on the substrate; and
a second opaque or semitransparent layer for forming first structure elements on the mask disposed above the first layer.
In other words, the object is also achieved by a mask blank for producing the mask. The mask blank comprises a substrate, a first layer with a matrix-like arrangement of structure elements which are arranged on the substrate, a second opaque or semitransparent layer for forming first structure elements on the mask, which is arranged above the first layer with the filling material.
The minimal resolution limit of the exposure unit corresponds in this case to a minimum lateral extent which can be attained for a structure pattern element projected onto the semiconductor substrate on a mask.
In line with one advantageous refinement, a filling material is arranged in the interspaces in the matrix-like arrangement.
Furthermore, the objects of the invention are also achieved method for producing the mask from the mask blank and by utilizing the mask blank to produce the mask.
In line with the present invention, the area surrounding a preferably isolated structure element with a lateral extent situated above the resolution limit of the exposure system is provided with a matrix-like arrangement of sublithographic structure elements. The resolution limit of the projection system corresponds to the minimum lateral extent which can be attained for structures on the semiconductor substrate using the exposure unit. This is dependent on the properties of the exposure unit, particularly the exposure settings, the wavelength used for the structuring light or particle beam (electron, ion, EUV, UV and visual beam), the lens system, and also on the properties of the mask and of the semiconductor substrate, particularly on the photosensitive resist used.
The sublithographic structure elements have a lateral extent which is smaller than the minimum lateral extent which can be attained using the exposure unit on the semiconductor substrate. The matrix-like structure configuration is thus not formed on the semiconductor substrate as such. The matrix comprises a number of structure elements which are arranged in rows and columns. The structure elements in the rows and columns are at a fixed distance from one another. That is to say that each row in the matrix is at the same distance from a row which is adjacent to it, and each column is at a second distance from a column which is adjacent to it. It is not necessary for the directions of the rows and columns to be at right angles to one another in each case.
The coverage density of the structure configuration is preferably small enough for full exposure over a large area to be produced on the semiconductor substrate at the appropriate position in the photosensitive layer when a positive resist is used.
The shape and size of the sublithographic structure elements are each essentially identical to one another. Provision is also made for the invention to involve sublithographic structure elements with a first shape and a second shape being arranged alternately in a column. The same applies to the rows in the matrix-like structure configurations. As one alternative, such an arrangement can be regarded for the purposes of the invention as two nested matrix-like inventive structure configurations. As another alternative, two adjacent structure elements with different shapes and with a sublithographic lateral extent can be regarded as a respective assembled, inventive, sublithographic structure element and are arranged in enlarged rows and/or columns of a matrix.
The sublithographic structure elements can be respectively connected to one another, for example to form a grid comprising crossing lines. In this case, the crossover points between the lines can be regarded as sublithographic structure elements, for example.
The sublithographic structure elements can be in the form of opaque or semitransparent layer structures.
The advantageous effect of the present invention can be explained in that the periodic pattern, which is arranged over a large area in an area surrounding a structure element arranged so as to be isolated on the substrate, modulates the Fourier transform for the structure pattern on the mask, which pattern is produced particularly at the diaphragm level of the lens system, such that the presence of dense structures producing mapping on the semiconductor substrate is simulated.
Although these portions are not mapped on the semiconductor substrate by the lens system, the structure configuration over a large area advantageously supplies contributions to mapping the structure element arranged in isolated fashion. The isolated structures and the sublithographic structures can be both transparent structures in an opaque or semitransparent surrounding area and opaque or semitransparent structures in a transparent surrounding area.
In line with one advantageous refinement of the present invention, each of the structure elements of the matrix-like structure configuration is situated outside a distance from the structure element arranged in an isolated fashion, which means that the structures of the matrix-like arrangement are not connected to the isolated structure.
Other features which are considered as characteristic for the invention are set forth in the appended claims.
Although the invention is illustrated and described herein as embodied in a mask for projecting a structure pattern onto a semiconductor substrate, it is nevertheless not intended to be limited to the details shown, since various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims.
The construction and method of operation of the invention, however, together with additional objects and advantages thereof will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view of a detail from a mask with an opaque or semitransparent structure element which is surrounded by a configuration of sublithographic structure elements according to the invention;
FIGS. 2A–2D are sectional views illustrating sequential process steps for producing the mask according to the invention from a mask blank with a separate layer set up specifically for the configuration of sublithographic structure elements; and
FIGS. 3A and 3B are plan view of examples of structure elements from which the matrix-like structure configuration of sublithographic elements is assembled.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the figures of the drawing in detail and first, particularly, to FIG. 1 thereof, there is shown a first exemplary embodiment of a mask in accordance with the invention. The figure shows a detail from the surface of the mask with an isolated, opaque or semitransparent structure element 7 which has a planar “pad” structure (top right in FIG. 1 ) and an “antenna” structure connected thereto (on the left in FIG. 1 ). The resolution limit, i.e. the minimum lateral extent 40 of a structure element which can be attained on the substrate using the exposure unit used in this case, is 0.13 μm in this example. The left-hand side of FIG. 1 shows a ruler with a 0.1 μm resolution which shows the sizes in relation to the wafer. The actual sizes on the mask are therefore a factor of 4 or 5 larger.
The regions on the substrate 1 which are not taken up by the structure element 7 in the detail shown have structure elements 3 which are grouped into a matrix-like arrangement 20 of structure elements 3 with rows and columns. The structure elements 3 have a square shape with a lateral extent 42 (cf. FIG. 3A ) of 0.05 μm. The period 41 of the configuration of structure elements, i.e. the distance between grid points in the matrix, is 0.17 μm. The structure elements 3 are therefore not resolved on the semiconductor wafer by the projection system.
The structure element 7 , which produces isolated mapping on the semiconductor substrate, taking into account the lack of mapping for the structure elements 3 , is completely surrounded by the configuration of structure elements 3 (shown only partly in FIG. 1 ). In the immediate surroundings of the structure element 7 , a region 10 on the transparent substrate 1 is left free of structure elements 3 in the configuration 20 . The region 10 has an extent of 0.075 μm.
FIG. 3A shows an enlarged illustration of the structure elements 3 shown in FIG. 1 in a square embodiment. The exact shape and size can be chosen as desired, however, remembering to observe the conditions cited at the outset. Another exemplary embodiment is outlined in FIG. 3 b . In this case, the sublithographic structure elements 3 are made up of four narrow lines put together to form a square.
The lateral extent 42 which governs any mapping on the semiconductor substrate can be regarded as a cross section of one of the four lines in a square structure element 3 . An extent from line to line over the transparent interspace inside the square can therefore, in line with the invention, be situated entirely above the minimum lateral extent 40 which can be obtained by the exposure unit on the semiconductor substrate. A crucial factor is that a lateral extent 42 needs to be present in the structure element 3 , below which lateral extent the minimum lateral extent 40 which can be attained by the exposure unit on a semiconductor substrate exists, with the result that the structure element 3 or the entire structure configuration 20 is not formed on the semiconductor substrate.
In line with an exemplary embodiment for producing the mask shown in FIG. 1 , an optimum shape or size for the structure element 3 is first obtained by means of simulation or experiment, i.e. by means of test exposures. At the same time, the optimum distance between the structure configuration 20 in question and the isolated structure element 7 is also determined, which is chosen to be constant at all edges of the structure element in a preferred embodiment. In the same way, the orientations and distances for the columns and rows in the matrix of the structure configuration 20 need to be determined.
In another step, suitable software is used to integrate the structure configurations 20 into the layout data for the circuit which is to be produced. If the aim is to fill up those regions of the surface of the substrate 1 which are left free of isolated structure elements 7 with structure configurations over the entire area, then the filling process starts in the layout data close to the edges of the isolated structure elements 7 . Starting from these in each case, geometric conflicts, for example the situation that, with two structure configurations impinging on one another, space is available on the surface only for half a column spacing, are solved by virtue of jumps in the respective arrangements, where possible in the center between two isolated structure elements 7 . As a result, the distance between these discontinuities and the structure elements 7 is chosen at the maximum.
Accordingly, optionally OPC structures are added to the layout or OPCs are integrated onto the structure elements 7 , taking into account the presence of the structure configurations 20 . With layout data in such a form, a mask writer, such as an electron beam writing unit or a laser writing unit, can now be used to produce the mask. In a similar manner to with conventional masks, inspection and, if appropriate, repairs are carried out using sublithographic auxiliary structure elements.
The advantage in the case of this exemplary embodiment is the automatic addition of a sublithographic structure element 3 having the same respective shape, size, distance under criteria which are objective and can therefore be used for use in a software programmer. The homogeneity of the structure configurations 20 from the filling process means that mask inspection is also much easier than, by way of example, in the case of individually assigned auxiliary structures, such as scatter bars, which are often classified as faults.
Another advantage is that a given design for structure configurations 20 satisfies a large number of different settings for the illumination of the mask such that they can each be used for the same mask. The result of this is increased flexibility for the illumination.
The increased, more homogeneous density of coverage on the mask also gives rise to advantages for etching processes which need to be performed on the mask when producing it.
Another exemplary embodiment for producing the inventive mask is shown in FIG. 2 . In this case, a special mask blank is provided, as illustrated in the cross-sectional profile in FIG. 2A . Arranged on a substrate 1 is a first layer 2 which comprises a full-area structure configuration 20 of sublithographic structure elements 3 . The structure elements 3 comprise molybdenum silicide as a material. When the structures are exposed, they are semitransparent to irradiated light.
The interspaces 4 in the first layer 2 are filled with an oxide and/or a nitride, so that the first layer 2 has a planar surface. Generally, however, a nonplanar surface is also entirely possible. Instead of the oxide and/or nitride, another material can also be selected which can be removed selectively with respect to the molybdenum silicide. Ideally, the filling material has similar optical properties to the material in the first layer—but with a higher etching selectivity toward the layer, so that the filling material can easily be removed without impairing the first layer.
A further layer 5 is disposed on the first layer 2 . The further layer 5 is formed of molybdenum silicide, and a chromium layer 6 is disposed on the layer 5 . This mask blank is used to produce a half-tone phase mask as described below.
FIG. 2B shows the formation of a region or frame, which is free of structure elements 3 , in the immediate surroundings of the positions 30 of the isolated structure elements 7 which are to be formed in a subsequent step. This involves the successive removal of the chromium layer 6 , of the further layer comprising molybdenum silicide and of the second layer with the filling material and the structure elements 3 in the region 10 by means of etching.
FIG. 2C shows, as the next step, the removal of the chromium layer 6 , of the further layer 5 comprising molybdenum silicide and of the filling material in the interspaces 4 in order to form the raised structure elements 7 . The structure elements 3 situated outside the regions 10 are now not removed any more, however. They form the inventive structure configuration 20 , which has a matrix shape for the structure elements 3 .
FIG. 2D shows the step for forming the half-tone phase mask by etching the thin chromium layer on the structure elements 7 . Like the sublithographic structure elements 3 , the isolated structure elements 7 are now in a semitransparent form. The step of chromium etching can be carried out using a mask, which means that further structure elements 7 exist which are opaque. It should be particularly emphasized that, in line with this exemplary embodiment, further sublithographic structure elements 3 , which remain unused, are situated in the first layer, hidden beneath the structure elements 7 . | A mask is configured for projecting a structure pattern onto a semiconductor substrate in an exposure unit. The exposure unit has a minimum resolution limit for projecting the structure pattern onto the semiconductor substrate. The mask has a substrate, at least one raised first structure element on the substrate which has a lateral extent which is at least the minimum lateral extent that can be attained by the exposure unit, a configuration second raised structure elements which are arranged in an area surrounding the at least one first structure element on the substrate in the form of a matrix with a row spacing and a column spacing, whose shape and size are essentially identical to one another, and which have a respective lateral extent that is less than the minimum resolution limit of the exposure unit. | 6 |
FIELD OF THE INVENTION
[0001] The present invention relates to a method of, and apparatus for, forming an article from at least one shape defining fluid impermeable interior member and at least one external skin. The present invention also relates to an article produced in accordance with the method or by the apparatus.
BACKGROUND OF THE INVENTION
[0002] It is known to produce structurally strong articles having load bearing capabilities by encapsulating inherently weak materials, such as expanded polystyrene (EPS), with one or more layers of a thermoplastic sheet material, such as APET (amorphous polyethylene terphalate) using the ARMACEL (Trade Mark) process.
[0003] The process is described in the applicant's International Patent Application No. PCT/AU95/00100 entitled: “A Method and Apparatus for Forming Structural Articles” (WO 95/23682) and International Patent Application No. PCT/AU96/00541 entitled: “Layered Structural Article” (WO 97/09166) and International Patent Application No. PCT/AU00/00250 entitled “Improved Method of Forming Structural Articles” (WO 00/59709), the relevant disclosure of each being incorporated herein by cross-reference. These documents disclose numerous other material suitable for the core and the thermoplastics sheet.
[0004] The ARMACEL process will now briefly be described with reference to FIGS. 1 to 4 . FIG. 1 shows a block shaped core 20 of essentially air or fluid permeable material, such as EPS. The core 20 is placed above a base plate 22 which primarily functions to support the core 20 and has a series of small holes 24 therethrough. Overlying the core 20 is a sheet 26 of thermoplastic material such as APET, the periphery of which is clamped by means of a clamp 28 . The clamp 28 extends all the way around the periphery of the core 20 in order to provide an effective seal together with the base plate 22 .
[0005] The sheet 26 is heated by means of a heater (not shown but disclosed in the abovementioned specifications) until it is at least soft or plastically deformable and is then moved relatively towards the core 20 while clamped by clamp 28 . The relative movement is accomplished by either moving the clamp 28 downwardly in the direction of arrow A, or moving the base plate 22 and core 20 upwardly in the direction of arrow B, or both. The air or gas located between the sheet 26 and the base plate 22 is drawn through the core 20 and the sheet 26 is conformed to the shape of the core 20 . As the core 20 is fluid permeable, the air which is located between the sheet 26 and the core 20 is able to pass through the core 20 and out the holes 24 in the base plate 22 , as indicated by arrows 30 .
[0006] The removal of the air or gas can be brought about by applying a reduced pressure or vacuum to the holes 24 , by applying a positive pressure to the upper side of the sheet 26 , or by both methods simultaneously. The pressure difference is applied for a sufficient length of time for the sheet 26 to cool, or be cooled, and thereby adopt a final position which is conformed to the shape of the core 20 and which binds the sheet 26 and the core 20 together by the creation of tensional forces in all directions in the sheet 26 . After the release of the clamp 28 , edges 29 of the sheet 26 can be trimmed adjacent the periphery of the core 20 .
[0007] FIG. 2 shows the product of the above process after trimming and inversion. The sheet 26 effectively renders the core 20 fluid impermeable. The coated side 32 is then punctured so as to form a series of apertures 34 to render it fluid permeable again. The process of FIG. 1 is then repeated, as shown in FIG. 3 , and the air between upper sheet 36 and the core 20 passes through the fluid permeable core 20 and thereafter through the apertures 34 in the lower sheet in similar fashion to that previously described.
[0008] FIG. 4 diagrammatically illustrates the situation that occurs if the above process is used in conjunction with a fluid impermeable core 38 . In this case, when a sheet 37 and the core 38 are brought together the air between the two is unable to pass through the core 38 as it is fluid impermeable and is trapped to form a bubble like space 39 , preventing the sheet 37 from engaging the major surface 38 a of the core 38 . The relative movement of the core 38 towards the sheet 37 can also create an air current which partially “balloons” the sheet 37 , which exacerbates the problem. This is a particular problem when the core has a large surface area or when the movement is performed quickly. A similar situation occurs when attempting to coat the second side of a coated fluid permeable core 20 , such as that shown in FIG. 2 , without the apertures 34 .
[0009] The invention disclosed in WO 00/59709 is an attempt to overcome the problem explained herein in relation to FIG. 4 . In WO 00/59709 the article to be encapsulated is provided with relatively large grooves or channels which assist in removal of the air or gas between the impermeable body or core 38 and the sheet 37 . Even so, not all of the air or gas is removed as illustrated in FIG. 4 of WO 00/59709. This can have consequence when the entrapped air or gas is heated since the heated air or gas expands and therefore exerts a force on the underlying body.
[0010] Prior art searches conducted since the priority date have disclosed PCT/AU98/00957 McCORMACK entitled “Vacuum Press for Pressing Thermoplastic Membrane onto an Article” and published under WO 99/25515. This specification seeks to overcome the abovementioned problems by evacuating the air or gas lying to both sides of the heated plastics sheet. Then, when the-heated plastics sheet is judged to be sufficiently soft, air at atmospheric pressure is introduced above the sheet to drive the heated sheet into contact with the article to be coated. The disclosure is to maintain both the object 10 to be coated level (by being supported by the flat base of the chamber 7 ) and to maintain sheet 11 level whilst heating (by maintaining the sheet 11 at the height of the emitter 26 and transducer 24 ). Thus there is no disclosure of inclining of the sheet 11 relative to the object 10 .
OBJECT OF THE INVENTION
[0011] It is an object of the present invention to substantially overcome, or at least ameliorate, some of the above difficulties with the prior art and, in particular, to provide methods of forming articles having at least one shape defining fluid impervious interior members and at least one external skin.
SUMMARY OF THE INVENTION
[0012] Accordingly, in a first aspect, the present invention discloses a method of forming an article having load bearing capabilities from at least one shape defining fluid impermeable interior member and at least one external skin, said method comprising the steps of:—
[0000] (i) heating a thermoformable sheet intended to form the external skin,
[0000] (ii) disposing a major surface of the member(s) at an inclined angle relative to the sheet,
[0000] (iii) moving said heated sheet relative to said member(s) to bring the heated sheet into substantially point or line contact with the surface of the member(s),
[0013] (iv) applying a fluid pressure differential between the side of said sheet remote from the member(s) and the side of the member(s) remote from said sheet and continuing the relative movement between the sheet and the member(s), to progressively move the point or line contact front between the sheet and the member(s) across the surface thereby expelling any gas present between the sheet and the surface of the major surface and conforming the sheet to the shape of the major surface and mutually engaging the sheet and the member(s),and
[0000] (v) maintaining said fluid pressure differential until said thermoformable sheet has cooled, whereupon tensional forces arise in the sheet in all directions
[0014] In an embodiment, the major surface(s) of the member(s) is/are disposed at approximately 90° to the sheet and the contact front moves in a substantially vertical direction along the surface(s). In a variation of this embodiment, when the member(s) has/have a pair of parallel or upwardly converging surfaces, the sheet is applied to both the surfaces simultaneously.
[0015] In another embodiment, the surface is inclined at an angle less than 40°, most preferably about 20°.
[0016] In a further embodiment, a contact finger is used to deform the heated sheet into a V or cone shape having an apex contacting the major surface(s) of the member(s) thereby dividing the sheet into two regions each disposed at the inclined angle to the surface of the interior member(s), whereby subsequent relative movement between the sheet and the surface progressively moves a contact front for each region of the sheet across the major surface(s).
[0017] In a second aspect, the present invention discloses an apparatus for forming an article having load bearing capabilities from at least one shape defining fluid impermeable interior member and at least one external skin, said apparatus comprising:—
a sheet holding device to hold a sheet of thermoformable plastics material at least a pair of opposite edges thereof; inclining means to dispose a major surface of said member(s) at an inclined angle relative to said sheet; translation means to move the member relative to the sheet holding device to move the sheet and the surface together; heating means to heat a thermoformable plastic sheet held in said sheet holding device to at last partially soften said sheet; pressure differential means to create a pressure differential between the sheet and the member(s) to conform the sheet to the member(s), wherein the translation means move the heated sheet into substantially point or line contact the with said major surface of the member(s) and thereafter progressively moves the point or line contact front between the sheet and the member(s) across the major surface thereby expelling any gas present between the sheet and the major surface; and maintaining said pressure differential until said thermoformable sheet has cooled, whereupon tensional forces arise in the sheet in all directions.
[0024] In a third aspect, the present invention discloses an article coated by the above method and/or apparatus.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] Preferred embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings in which;
[0026] FIG. 1 is a cross-sectional view of a prior art method of forming an article from a fluid permeable member and an external skin;
[0027] FIG. 2 is an inverted cross-sectional side view of the article formed in FIG. 1 ;
[0028] FIG. 3 is an article shown in FIG. 2 being coated with a further external skin in accordance with the prior art method of FIG. 1 ;
[0029] FIG. 4 is a cross-sectional side view of a prior art method of forming an article from a fluid impervious member and an external skin;
[0030] FIG. 5 is a cross-sectional side view of the initial stages of a method of forming an article from a fluid impervious member and an external skin in accordance with a first embodiment of the invention;
[0031] FIG. 6 is a cross-sectional side view of a subsequent stage of the method shown in FIG. 5 ;
[0032] FIG. 7 is a cross-sectional inverted side view of the article formed in FIGS. 5 and 6 being coated with a further external coating in accordance with the method of FIGS. 5 and 6 ;
[0033] FIG. 8 is a cross-sectional side view of the initial stages of a method of forming an article from a fluid impervious member and an external skin in accordance with a second embodiment of the invention;
[0034] FIG. 9 is a cross-sectional side view of the article shown in FIG. 8 during the coating process;
[0035] FIG. 10 is a cross-sectional side view of the article shown in FIG. 8 after the coating process;
[0036] FIG. 11 is a cross-sectional side view of the initial stages of a method of forming an article from a fluid member and an external skin in accordance with a third embodiment of the invention;
[0037] FIG. 12 is a cross-sectional side view of the initial stage of a method of forming an article from a fluid impermeable member and an external skin in accordance with a fourth embodiment of the invention.
[0038] FIG. 13 is a view similar to FIG. 7 but showing the member mounted on a pedestal, and
[0039] FIG. 14 is a perspective view of a core member containing a plurality of shallow incisions.
DETAILED DESCRIPTION
[0040] Referring to FIGS. 5 to 7 , there is shown a method of forming an article having load bearing capabilities according to a first embodiment of the invention. FIG. 5 shows a core 40 of essentially fluid impermeable material, such as metal, glass or dense wood.
[0041] The core 40 is placed above a base plate 22 which primarily functions to support the core 40 and has a series of small holes 24 therethrough. Overlying the core 40 is a first sheet 26 of APET, the periphery of which is clamped by means of a peripheral clamp 28 .
[0042] The sheet 26 is heated by means of a heater (not shown but disclosed in the abovementioned specifications) until it is at least soft or plastically deformable and is then moved relative to the core 40 whilst clamped by the clamp 28 . The relative movement is accomplished by moving the clamp 28 downwardly in the direction of arrow C (as shown in FIG. 5 ) or moving the base plate 22 and core 40 upwardly in the direction of arrow D, or both.
[0043] As the sheet 26 and base plate 22 are drawn towards each other a pressure differential is created between the sheet 26 , core 40 and base 22 drawing air or gas located from between sheet 26 and core 40 as to form the sheet 26 to the shape of the core 40 .
[0044] As best shown in FIG. 5 , the side surfaces 41 of the core 40 are disposed at an angle of approximately 90 degrees to the sheet 26 and two line contact fronts, each indicated as X, are formed between the (major) side surfaces 41 of the core 40 and the sheet 26 . As the sheet clamp 28 is moved relative to the core 40 , the fronts XX move in a substantially vertical direction along the side surfaces 41 of the core 40 . The progressive movement of the contact fronts across the side surfaces 41 simultaneously expels any air present between the sheet 26 and the side surfaces 41 of the core 40 and then allows the sheet 26 to conform to the shape of the core 40 . This air removal process advantageously obviates the need for the interior member to be fluid permeable, as air or gas is not required to pass through same.
[0045] After the side surfaces 41 of the core 40 have been fully covered by the sheet 26 , the pressure differential is maintained for a sufficient length of time for the sheet 26 to cool, or be cooled, and thereby adopt a final position which is conformed to the shape of the core 40 . This binds the sheet 26 and the core 40 together and creates tensional forces in all directions of the sheet 26 .
[0046] After the release of the clamp 28 , edges 42 of the sheet 26 are trimmed at the periphery of the core 40 . In this embodiment it will be appreciated that the peripheral clamp 28 extends all the way around the periphery of the core 40 in order to provide an effective seal together with the base plate 22 .
[0047] FIG. 7 shows the product of the above process after trimming and inversion. The process is then repeated, as shown in FIG. 7 , and the air or gas between second sheet 46 and the core 40 is evacuated in a similar fashion to that previously described.
[0048] The process as shown in FIG. 7 can also be used with a permeable core, that has been rendered impermeable by coating, without requiring the apertures 34 described with reference to FIG. 3 . Ass a consequence, a second coat of sheet thermoplastic material can be applied to a core which has previously been fully encapsulated with a prior coat of sheet thermoplastic material.
[0049] The bubble 39 shown in FIG. 4 is not formed against the (minor) top surface 43 as the sheet 26 effectively makes instantaneous contact with all of the top surface 43 . Preferably the top surface 43 can be tilted slightly so that one edge thereof contacts the sheet 26 before the opposite edge. Further, the small surface area of the top surface 43 does not create the air current described above with reference to FIG. 4 .
[0050] FIGS. 8 to 10 show a similar process to that shown in FIGS. 5 to 7 except a major surface 51 of a fluid impervious core 50 is inclined at an angle less than 40 degrees to the sheet 26 . As the sheet 26 and base plate 22 are moved toward each other a line contact front, in this case indicated by YY, between the sheet 26 and the core 50 progressively moves down the surface 51 of the core 50 . This progressively expels the air or gas between the sheet 26 and the surface 51 and allows the sheet 26 to conform to the core 50 . After release of the clamp 28 , the edges 53 of the sheet are trimmed at the periphery of the core 50 . The product can then be inverted and the process repeated as previously described.
[0051] FIG. 11 shows a similar process to that shown in FIGS. 8 to 10 except that the inclination of the sheet relative to the core is created by a contact finger 55 which is used to deform the heated sheet 26 into a V or cone-shape having an apex 57 contacting a major surface 62 of a fluid impervious core 60 . This divides the sheet 26 into two regions each disposed at an inclined angle to the major surface 62 of the core 60 , each having a line contact front indicated by ZZ. The core 60 , as in all of the other embodiments, is placed above a base plate 22 which primarily functions to support the core 60 and has a series of small holes 24 therethrough. Upon the application of a fluid pressure differential between the sheet 26 and the core 60 and relative movement between the sheet 26 and the surface 62 , the contact fronts ZZ for each respective region of the sheet 26 progressively move across the surface 62 . This expels any air or gas present between the sheet 26 and the surface 62 of the core 60 and allows the sheet 26 to conform to the shape of the core 60 . The edges of the sheet (not shown) are then trimmed so as to have the same periphery as the core. Then the core is inverted and the process repeated.
[0052] FIG. 12 shows a method of forming an article having load bearing capabilities according to a further embodiment of the invention. As was described with reference to prior art FIG. 4 , as the sheet 26 and base plate 22 are moved towards each other, and the pressure differential is applied, the air or gas between the sheet 26 and top surface 61 is trapped between the edges of the core 60 , because it is fluid impermeable, thereby creating a bubble-like space 65 . To expel this air or gas and allow sheet 26 to conform to core 60 , one or more tubes 70 are inserted through one of the holes 24 in base plate 22 . Each tube lies alongside the core 60 allowing fluid communication between the major surfaces 60 a and 60 b of the core 60 . A vacuum is then applied to the tube(s) 70 to remove the air or gas present in the space 65 between the sheet 26 and the core 60 which allows the sheet 26 to conform to the core 60 . As with earlier embodiments, the pressure differential is maintained until the sheet 26 has cooled, thereby creating tensional forces in the sheet 26 in all directions. In the trimming process, the tube(s) 70 which are encapsulated below the sheet 26 can be removed by trimming the sheet 26 at the upper edges 63 of the core 60 . Then the core 60 can be inverted and the process of FIGS. 8-10 used to coat the remaining surfaces of the core 60 . This technique finds particular application in coating a body having one surface which is difficult to coat but having its remaining surfaces easy to coat.
[0053] Turning now to FIG. 13 , the encapsulation of a two part core 70 having individual core members 70 A and 70 B is illustrated. As in FIG. 7 , the core 70 has previously been coated on its top and sides by a sheet 26 of thermoplastic material. The sheet 26 is trimmed and the core members 70 A and 70 B inverted and placed on a pedestal 71 which is in turn supported by the base plate 22 .
[0054] Then a second sheet 76 is applied as in FIG. 7 . However, because of the pedestal 71 , the second sheet 76 is drawn around the lower edges of the core 70 as seen in FIG. 13 . The sheet 76 is trimmed to allow the release of the pedestal. As the trimmed sheet 76 envelopes the lower edge of the core 70 as seen in FIG. 13 , this provides an exceptionally strong bond for the sheet 76 .
[0055] Turning now to FIG. 14 , a still further embodiment is illustrated in which a block shaped core 80 is provided with a series of score lines or incisions 81 . These are illustrated in a greatly magnified form in order to be visible at all in the drawing. The incisions 81 essentially constitute scratches in the surface of the core 80 . These provide channels which allow the air or gas between core 80 and the sheet 26 to escape but are essentially invisible in the finished article. It is not necessary that the incisions 81 be as regularly spaced or as uniformly deep as is illustrated in FIG. 14 .
[0056] The primary advantage of the invention is it extends the use of the ARMACEL process to relatively high strength, and fluid impervious or substantially impervious, materials such as metal, glass or dense wood.
[0057] The foregoing describes only some embodiments of the present invention and modifications, obvious to those skilled in the art can be made thereto without departing from the scope of the present invention. For example, the core can be fabricated from one, two, or multiple parts.
[0058] The term “comprising” (and its grammatical variations) as used herein is used in the inclusive sense of “having” or “including” and not in the exclusive sense of “consisting only of”. | The present invention discloses a method and apparatus to permit the ARMACEL process (known per se from WO 95/23682, WO/09166 and WO 00/59709) to be used without entrapping gas or air between a heated plastics sheet ( 26 ) and an impervious core ( 40, 50, 60, 70 ). The core ( 40, 50, 60, 70 ) is inclined relative to the sheet ( 26 ) by either maintaining the sheet ( 26 ) level and inclining the core ( 40, 50, 70 ) or by maintaining the core ( 60 ) level and depressing the sheet ( 26 ) to incline same. Apparatus is also disclosed including and inclined perforated base plate ( 22 ), a contact finger ( 55 ) and a pedestal ( 71 ). | 1 |
This is a Continuation of application Ser. No. 08/351,565 filed on Dec. 7, 1994, now abandoned which in turn is a continuation of application Ser. No. 07/925,966 filed on Aug. 5, 1992, now abandoned which is in turn a continuation-in-part of application Ser. No. 07/717,982 filed Jun. 20, 1991, now abandoned.
BACKGROUND OF THE INVENTION
The present invention relates to a headbox or breastbox for a papermaking machine, and particularly to means for adjusting the pulp density or concentration of the pulp suspension over the working width of the headbox or the machine width. One such headbox is known from Federal Republic of Germany Patent 35 14 554 equivalent to U.S. Pat. No. 4,888,094. Such a headbox is intended to make the pulp suspension uniform over the entire cross machine width of the pulp outlet from the headbox. At the downstream end of the flow path of the suspension, it should be made uniform in front of the discharge or outlet slot from the headbox. The uniformity sought is such that both the density of the pulp, that is, the weight of fiber content per unit volume, and the orientation of the fibers in the pulp, are constant over the width of the pulp outlet from the headbox. Both of these qualities are important prerequisites for the finished paper being produced by the papermaking machine, in order to have a proper weight per unit area profile over the entire cross machine width so called basis weight cross profile of the web and so that the paper lies flat and does not tend to curl.
During operation of the papermaking machine, numerous disturbing factors interfere with the satisfaction of the two uniformity requirements. These factors include temperature variations, pressure variations and manufacturing tolerances in the headbox and in the pulp suspension, for example.
The above noted German patent is concerned with solving the same problems as are noted above, which are also the problems to be solved by the present invention. That patent recognizes that it is important both to maintain the density of the fibers in the pulp suspension over the width of the pulp outlet and also to control the fiber orientation so that, if it is possible, no transverse flow will occur in the outlet channel. The German patent proposes that the density of the pulp suspension be changed locally, that is that the density of the pulp suspension be changed at given places across the machine width, as required. However, the patent does not provide what is believed by the present inventors to be the best solution to this problem.
It is also known to vary the width of the discharge slot, that is, the height of the outlet opening at the discharge slot. One way to do that is by the use of threaded spindles for swinging or bending one lip, and particularly, the upper lip that defines the discharge slot. For instance, see Federal Republic of Germany Patent 29 42 966, corresponding to U.S. Pat. No. 4,326,916, or Federal Republic of Germany Published Application OS 35 35 849. This adjustment of the width of the discharge slot enables local variation of the throughput of the suspension. At the same time, however, the direction of suspension flow is also locally affected, which affects the orientation of the fibers in the suspension. The local narrowing of the outlet slot causes a different flow direction in the fibers at the narrowed places of the slot than along the remainder of the discharge slot. Although the density of the pulp can be made uniform over the width of the pulp outlet by the so-called displacement control, the fiber orientation, which may have been good, is undesirably again disturbed. Although the inventors have recognized that the last two above noted German patent applications proceed fundamentally in the correct direction, nonetheless, they do not appear to be able to control independently the two parameters of the density of the pulp and the fiber orientation.
SUMMARY OF THE INVENTION
It is an object of the invention to provide a headbox or breastbox which enables independent control of each of the parameters of the basis weight cross profile suspension and the fiber orientation cross profile in the pulp suspension in a practical and reliable manner.
The concept of the invention involves sectionalizing the headbox into individual sections across the machine width, which is an already known design, and also to feed individually controllable, partial streams or section streams of the pulp suspension to the individual sections of the headbox. The operating parameters of each individual one of the partial streams, particularly their throughput, pulp density and fiber quality, can be individually adjusted without adjusting any of the parameters of the other partial streams or along with adjusting those parameters in the other partial streams differently. Each of the section streams feeds a respective separate section of the headbox. Each of the section streams is preferably conducted separately through the headbox, and the streams are combined with each other only toward the outlet nozzle from the headbox.
Each section stream is formed by bringing together two separate streams for that section, of which at least one stream, in some embodiments, and in other embodiments, both streams, have their above noted parameters controlled. Depending upon the mixture ratio, pulp concentration and the flow rate of these control streams, the nature of each of the section streams in each individual section can be very precisely established.
The headbox of the present invention distributes pulp suspension over the working width of the papermaking machine and ejects the suspension into the inlet slot or nip of a web forming section, for example.
The headbox includes a pulp suspension guide device through which pass a plurality of holes or channels that define the channels and that extend from the upstream to the downstream sides of the headbox. The holes or channels are in a selected array across the width of the headbox. There is a discharge nozzle also extending across the width of the machine with a discharge or outlet slot for distributing the pulp suspension. The discharge nozzle is shaped such that mixing of the pulp suspension from the respective channels of the pulp suspension guide is prevented.
Upstream of the headbox in the pulp suspension flow path are located means for adjusting the pulp density of the pulp suspension over the working width of the machine. The individual sections of the headbox are formed by partitions which divide the headbox into individual separate sections over the cross machine width. Each individual section has at least one feed line channel or hole for feeding through it a partial stream or section stream of the pulp suspension.
A mixer is arranged upstream of or in front of the feed line of the headbox. In one embodiment, the mixer has at least two connections for introducing respective parameter controlled suspension streams, having predetermined operating parameters, such as throughput, pulp density and fiber quality. In other embodiments, fewer than or only one of the connections and its suspension stream is controlled. But through merely that control, the final mixed output from the discharge slot is controlled.
Other objects and features of the present invention will become apparent form the following description of preferred embodiments of the invention considered in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1a schematically illustrates one pulp suspension control apparatus, and shows means for mixing flows that are supplied to individual sections of the headbox;
FIG. 1b illustrates an alternate pulp suspension control apparatus;
FIG. 2a is a side elevational cross-sectional view through one individual section of a first embodiment of a headbox, with a plurality of individual pulp flow channels through it;
FIG. 2b is a plan cross-sectional view of the headbox of FIG. 2a showing individual headbox sections and showing a plurality of channels through the headbox arrayed across the width of the machine and in each of the individual headbox sections;
FIG. 3a illustrates a second headbox embodiment like that in FIG. 2a and 2b and schematically depicts the suspension flow from the mixer which delivers parameter controlled suspension to the common section of the headbox;
FIG. 3b is an end view of the common section of FIG. 3a, seen in the direction of arrow A in FIG. 3a, showing individual deliveries of mixed suspension to the mixer for subsequent delivery to the headbox;
FIG. 3c is a view in the same direction as FIG. 3b, showing a partitioned common section embodiment for individual deliveries of mixed suspension to the suspension guide;
FIG. 4a is a side elevational cross-sectional view through a third embodiment of a headbox, where the individual sections are narrowed channels through the headbox and there are a plurality of those channels in each section, which are arrayed vertically across the headbox;
FIG. 4b is a plan cross-sectional partial view of the headbox of FIG. 4a;
FIG. 4c is an alternate fourth embodiment of the headbox of FIG. 4b, wherein the common section has individual partitioned sections, each for transmitting to the suspension guide a respective mixture of pulp suspension;
FIG. 5a is a side elevational cross-sectional view of a fifth embodiment of a headbox and mixer, showing two longitudinally spaced areas of partial channel sections in the headbox;
FIG. 5b is a plan cross-sectional view of the headbox of FIG. 5a, showing the individual sections of the common section across the width of the headbox;
FIG. 6a is a side elevational cross-sectional view of a sixth embodiment of a headbox and mixer combination, wherein the mixer is fed with a premixed partial stream which is mixed with a conventional supply of pulp suspension;
FIG. 6b is an enlarged detail of FIG. 6a;
FIG. 6c is a rear view of the mixer of FIG. 6a, showing the suspension or material feed to the mixer;
FIG. 7 is a side elevational cross-sectional view of a seventh embodiment of a headbox and mixer combination where the mixed partial streams are fed into a channel between the tube bundles through the headbox;
FIG. 8a is a top view of an eighth embodiment of a mixer and headbox combination wherein the plurality of parameter controlled partial streams are fed to connections across the top of the headbox past the introduction mixer;
FIG. 8b is a top view of the headbox and mixer combination of FIG. 8a;
FIG. 9a is a side elevational cross-sectional view of a ninth embodiment of a combination of headbox and mixer showing direct feeding of the connections across controlled partial streams into one or more of the tube lines of the turbulence inserts of a section of the headbox;
FIG. 9b is rear view of the headbox of FIG. 9a in the direction of arrow C in FIG. 9a;
FIG. 10a is a side elevational cross-sectional view of an alternate, tenth embodiment of a headbox with direct feed of a controlled mixture partial stream into one or more of the tube lines;
FIG. 10b is a plan longitudinal cross section of the headbox and mixer of FIG. 10a;
FIG. 11a is a side elevational cross-sectional, fragmentary, view of an eleventh embodiment of a headbox showing feeding of the parameter controlled mixture into the nozzle space downstream of the individual sections;
FIG. 11b is a top view of the headbox of FIG. 11a.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the pulp suspension control apparatus shown in FIG. 1a, the mixer 20 delivers to the headbox, not shown in FIG. 1a, a mixed stream 22 having the volume Q M and having the concentration C M of fiber material in the pulp suspension.
The mixer 20 is supplied by two separate pulp suspension streams which are brought together in the mixer. The first stream 24 has the volume Q H and the fiber concentration C H . The second stream 26 has the volume Q L and the fiber concentration C L . The first pulp stream 24 is supplied from a source, not shown, past the volumetric control, adjustable valve 28 that is controlled by flow rate controller 32. The second pulp stream 26 is supplied from another source not shown, and is controlled by an adjustable valve 34. The valve 34 is controlled by the flow ratio controller 36. That controller 36 is supplied by the two flow rate measurement devices 38 and 42 which measure the flows of streams 24 and 26. Adjustment of the volume ratios Q H /Q L will be determined by the flow ratio controller 36 and the valve 34. The total flow rate of suspension flow 22 is controlled by the flow rate controller 32 and the valve 28 in addition to the flow ratio controller 36 and the valve 34.
An actual situation controlled by the control apparatus of FIG. 1a is now described. The arrangement shown in FIG. 1a delivers a pulp suspension flow to a conduit 22 which is connected to one of the individual sections of a headbox. As will be apparent below, there may be an individual one of the control apparatus shown in FIG. 1a for each of the individual sections of the headbox across the machine width, and each of those individual control apparatus shown in FIG. 1a can be operated independently.
During a periodic quality control check of the paper web being produced or of the pulp suspension being dispensed by the headbox, it may be found that the weight per unit area profile basis weight, at the individual section across the width of the web, of the mixed pulp suspension which is supplied through mixer 20 in FIG. 1a and controlled by the control devices shown in FIG. 1a, differs beyond an acceptable level from a desired value, either in flow volume Q M or pulp suspension concentration C M .
Therefore, the pulp density of the suspension in the headbox must be suitably corrected at this section across the width of the headbox.
According to the invention, the adjustment can be made by varying the concentration C M of the individual section stream 22 that is controlled by the control apparatus shown in FIG. 1a. The necessary change in C M , that is dC M , can be determined from a previously prepared weight balance sheet. The resulting corrected concentration C M is dependent exclusively upon the ratio of the control streams Q H /Q L . The total flow through 22 of these two streams 24 and 26 may be halted while the ratio adjustment is made. The corrected value of the basis weight is used as a basis for ratio control to establish the desired value setting. The ratio control sets the new flow ratio Q H /Q L . In FIG. 1a this is accomplished by changing Q L' e.g. through valve 34. However, it is important that the combined volumetric flow Q M remain constant, so that the individual headbox section may be fed with a correct constant volume. Therefore, to correct the volume and concentration, the control volume stream Q H is corrected in accordance with a production continuity equation which had previously been prepared. This control is carried out using the apparatus shown in FIG. 1a. For this purpose, the change in the desired value of the control volume streams must be calculated from new basis weight C M and must then be fed to the controllers effective for bringing this about at 28, 34, and 36. Various types of flow controllers for delivery of pulp suspension at the correct concentration may be used, as is known to one skilled in the art.
Transverse flows of the suspension can take place within the headbox and in the headbox spray nozzle. These could result, for example, due to edge influences in the headbox. This can lead to an undesired effect on the orientation of the fibers in the suspension. In known headboxes, this occurs because of the presence of different volumetric streams over the cross machine width of the headbox.
Due to the flow control apparatus of FIG. 1a, the concentration of fibers in the suspension C M remains constant. The calculated required volumetric stream of Q H is fed as a desired value to the controllers. This adjusts the two streams until the desired volume Q M and concentration C M are present in the stream 22.
In accordance with the alternate control apparatus shown in FIG. 1b, the same types of operations take place and similar elements are present, except that both of the streams Q H and Q L are controlled by the adjustable valves 32 and 35 which correspond in function to the valves 28 and 34. The other elements in FIG. 1b which correspond to those in FIG. 1a are similarly numbered. In the apparatus of FIG. 1b, two calculated volumetric streams Q H and Q L must be fed as new desired values to the controllers.
The present invention may be applied to various types of headboxes, including single layer headboxes, multiple layer headboxes, headboxes for slit formers, paper wires, with and without vibration dampers, having one or two tube bundles, etc.
Various headbox embodiments are shown in FIGS. 2-11 and are now briefly described.
FIGS. 2a and 2b illustrate a headbox having individual mixed suspension streams 22 at Q M , C M delivered to the headbox. In FIG. 2a, the headbox has an entrance section 52 from the mixer (not shown here), individual section channels 54 in a vertical stack, which are defined by partitions between them, and a tapering outlet nozzle 56 leading to the outlet slot 58 from which the stream 62, still at total volume Q M and concentration C M , is sprayed into an inlet nip, onto a wire former, etc., in the usual manner for headboxes.
FIG. 2b shows that there are individual streams Q M' C M across the width of the machine. Each stream may be supplied by a separate control arrangement as in FIG. 1a or FIG. 1b. The headbox entrance section is divided into individual sections 52a, 52b, etc., across the width of the machine. Each of the entrance sections is an inlet which feeds a respective plurality of individual channels 54, which, as can be seen from both of FIGS. 2a and 2b, are arrayed in rows and columns within the headbox. There is a single combined outlet nozzle 56 through which the various flows from the channels 54 combine and then exit the headbox. It is apparent that control over the individual volumes Q M and concentrations of pulp or fiber C M will control the respective flows through the individual partitioned entrance sections 52a, 52b, 52c, for providing a desired profile of flow volume and concentration across the width.
As will be apparent to those of skill in the art, the connections between the mixers supplying the pulp stream Q M C M and the entrance sections 52 can also be in the form of separate pipes, tubes or hoses, either rigid or flexible, and disposed at any angle or in any configuration. In such an embodiment, the sections 52 could be used or they could be dispensed with. In addition, valves can be disposed at the output of certain ones or all of the mixers in the lines between the mixers and the entrance sections 52. This is the case for each of the embodiments described herein.
FIGS. 3a, 3b and 3c show a headbox 70 with a plurality partitioned sections 74 which are separated by individual partitions and supplied by an entrance section 72.
As can be seen in FIG. 3b, the entrance section 72 itself might not have individual sections, but its partitioned design would permit some mixing of the suspension passing through the entrance section before it reaches the partitioned sections 54 of the headbox. In FIG. 3c, in contrast, the entrance section 72 also has individual sections 76a, 76b, etc., each corresponding to and for delivering suspension to respective partitioned sections 74 of the headbox.
FIGS. 4a and 4b show an alternate headbox design 80 from that shown in FIGS. 2 and 3, wherein there is a unitary and not individually sectioned entrance section 81 to the headbox, followed by individual separated channels or tubes 82 through the headbox which are arrayed in vertically spaced apart stacks and horizontally spaced apart columns. This provides partitioned sections across both the height and the width of the headbox. Each section across the width of the headbox is supplied generally from its own respective adjusted suspension stream Q M , C M . There is an outlet nozzle 83 from the headbox where the various flows through the channels 87 are recombined.
FIG. 4c differs from FIG. 4b only in that the entrance section 84 of the headbox 86 itself has individual vertical partitions dividing the entrance section 84 into individual sections 88a, 88b, etc., corresponding to one or more of the individual channels 82. Some of the individual sections 88 may supply more than one of the individual channels 82, as suggested in FIG. 4c.
FIGS. 5a and 5b show an alternate headbox 90 which has an entrance section 92 with panels 94 that separate the entrance section into separate sections 92a, 92b, etc. Downstream of the sections 92a are narrowed channels 96, which in turn lead into a common transmitting chamber 98 and that leads to the individual section channels 102 which correspond in function and placement to the channels shown in FIG. 4a. Following the channels 102 downstream is the outlet nozzle 104. The individual channels 96 are more frequent than the downstream channels 102.
FIGS. 6a, 6b and 6c illustrate a headbox 110 and a common section 112 which cooperate. The headbox includes a plurality of individual cross machine sections 113, as in previous embodiments. Each section has at least one column and more likely a plurality of vertically arrayed columns of tubes or channels 114. An outlet nozzle 116 follows all of the channels 114 downstream. The common section 112 is at and delivers suspension streams Q A +Q M to the inlet ends of the passages 114 in the headbox.
FIGS. 6a and 6b show inlet through the first inlet passage 118 of only part of the total flow to the common section from a control apparatus as in FIG. 1a or 1b. A separate stream is delivered to the mixer through the passageway 120 from a conventional source 122. Therefore the common section 112 combines the streams Q M and Q A . FIG. 6c shows the common section 112 as not having partitions dividing it in the cross machine direction. But the common section 112 could additionally be supplied with partitions like the common section 72 in FIG. 3c.
FIG. 7 shows the feeding of the adjusted quantity and concentration mixture Q M , C M into the common section 130 through the inlet port 131. Just as in the embodiment of FIGS. 6a, 6b and 6c, the partial stream Q M , C M is only part of the liquid supplied to the headbox. A conventional stream of pulp suspension or liquid is delivered to the mixer 130 from the conventional suspension source 132 through the passages 133.
Then the common section delivers the combined suspension to the headbox 134 which has separated upper and lower tube bundles or channels 135, 136 which in turn deliver suspension streams to be mixed in the nozzle 138. The feeding of the partial stream Q M , C M is into a channel between the tube bundles 135, 136, and the tube bundles may, for example, be defined by appropriate perforated plates.
FIGS. 8a and 8b show another common section and headbox arrangement. The headbox 140 has the separate section inlet part 142 which receives only a first liquid stream, e.g., a first controlled adjusted stream or a conventional pulp suspension stream. This is supplied across the width and height of the headbox by the distributor 143. Downstream of the inlet part 142 is a common entrance section 144 into and across the top of which all of the individually adjusted volume and concentration flows Q M , C M from apparatus as in FIGS. 1a or 1b are introduced through respective ports 146 arrayed across the machine width. The section 144 is followed by the individual channels or tubes, which define the headbox sections 152. That is followed by the nozzle 154, as in the other embodiments.
FIGS. 9a and 9b show an alternate arrangement with a headbox 160 having individual channels or tube bundles 162, 164 above one another. A common section 166 delivers pulp suspension from a conventional source 168 through passages 169. The controlled volume and concentration flow Q M , C M is directly fed into the section channels or tubes 164 without also being fed into the channels or tubes 162, while the conventional flow is fed into the tubes 162, but not into the tubes 164. The two flows are therefore separated in their passage through the individual sections of the headbox, but the flows are joined in the nozzle 167 and they exit combined together through the nozzle outlet 170. From FIG. 9b, it can be seen that the common conventional source 168 feeds liquid not in a common flow but rather in long individual separated tubes 169 across the width of and through the intermediate section 174 and into the top part of the common section 166 before that liquid is delivered distributed across the headbox to the tubes 162.
FIGS. 10a and 10b show an alternate headbox design 180 with a supply of suspension by a conventional supply 182 at its entrance through the tube section 184 and into the common section 186. The liquid suspension at controlled volume and concentration Q M , C M is fed through the tubes or channels 188 into the nozzle 192. The conventional liquid leaves the common section 186 and passes through the tubes 194. The separated flow through the tubes 188 and 194 is combined together in the nozzle 192, like in the embodiment of FIGS. 9a and 9b.
Finally, FIGS. 11a and 11b show a headbox 200 having a separated flow, in individual sections in the form of 202 of conventional pulp suspension. The controlled flow Q M , C M for the individual sections is delivered through the entrance conduits 206 arrayed across the machine width in the outlet and combining nozzle 208, which is downstream from the individual sections 202 through which the conventional suspension travels. The distribution of the individual entrance ports 206 across the width provides the individual sections of the headbox with needed flow and concentration adjustment.
In all cases, the flow which has been adjusted across the width of the headbox is reconstituted as a single flow with corrected concentration and flow rate in the downstream nozzle before it exits through the discharge outlet.
FIGS. 12a-12d show other arrangements of the headbox or mixer according to the invention in a schematic fashion. In FIG. 12a, the mixers 300 are each supplied with partial streams 302. The output of each mixer 300 is supplied to a respective section 304 of the pulp suspension guide. The pulp suspension guide sections 304 are separated by a plurality of partitions into the separate sections 304. The pulp suspension guide output feeds into a common nozzle 306.
The pulp suspension guide can be divided into the plurality of sections 304 in various ways. For example, perforated plates can be used to achieve the plurality of sections, bunches of tubes or hoses can be used, horizontal or vertical plates or partitions, or flexible blades can be provided.
In FIG. 12b, a plurality of mixers 300' are provided, each of which is fed by two partial streams 302'. The output of each mixer 300' feeds into a line 303, which may, for example, comprise a tube, hose or pipe, or any other suitable channel. Each pipe 303 feeds into a common section 305, the output of which is fed to a plurality of sections 304' of the pulp suspension guide. The output of each section 304' is then fed to a common nozzle 306'.
In FIG. 12c, similarly, partial streams 302' feed mixers 300'. The outputs of the mixers then feed into a chamber 303', which is separated into a plurality of sections by partitions. The output of each section 303' feeds into a chamber 305, the output of which is provided to each of the sections 304' of the pulp suspension guide. The output of each section 304' is then fed to the common nozzle 306'. As shown in FIGS. 12b and 12c, the chambers 303' can have different widths across the machine, and similarly, the mixers 300' can have different widths across the machine, in accordance with the parameters of the pulp suspensions carried by the particular sections.
FIG. 12c illustrates that in addition to each mixer 300' feeding mixed pulp suspension to one chamber 303', a mixer 300'a may feed mixed pulp suspension to a group of two or three chambers 303', preferably, but not necessarily, arranged side by side, depending on requirements. As also shown in FIG. 12c, a plurality of mixers 300' may also feed mixed pulp suspension to only one chamber 303'a.
FIG. 12d shows an arrangement in which the mixers 300' are disposed so that they only feed certain of the chambers 303'. In addition, the mixers feed the chambers 303' through lines 303", which may comprise tubes, hoses or pipes, flexible or rigid, disposed at any angle or bent or shaped into any configuration. Partial streams 302' are fed to each mixer 300'. Certain of the chambers 303' are also fed by conventional unmixed streams 307. As shown in FIG. 12d, the chamber widths 303' may vary across the machine width. The outputs of the chambers 303' feed into a common chamber 305, which feeds into a plurality of sections 304' of the pulp suspension guide. As shown in FIG. 12d, the widths of the sections 304' of the pulp suspension guide also may vary across the machine width, depending on the parameters of the pulp suspensions carried by the particular sections.
As discussed, each of the partial streams feeding into the mixers may have different properties, e.g., concentration, type of fiber, etc., and these different properties are adjusted by suitable adjusting devices, as disclosed in FIGS. 1a and 1b. As shown in FIGS. 12b, c and d, the distances between neighboring partitions may be different within one chamber as well as in more than one chamber of the overall device. Furthermore, the distances may even change along the flow paths, so that although not shown in FIGS. 12b, c and d, the lengths of the chambers in the direction of pulp flow may change or may be different from other sections of the same chamber.
Additionally, the distances between the partitions may be changeable during operation in order to influence the pulp suspension qualities. Valves or other adjusting members may be disposed at any of the inlets and outlets of any of the mixers or chambers of the device.
Although the present invention has been described in relation to particular embodiments thereof, many other variations and modifications and other uses will become apparent to those skilled in the art. It is preferred, therefore, that the present invention be limited not by the specific disclosure herein, but only by the appended claims. | A headbox for a papermaking machine with an outlet slot that distributes pulp suspension over the, working width of the papermaking machine. For controlling operating parameters of throughput, pulp density and fiber quality of the suspension over the width of the machine, the headbox has a plurality of individual sections across the width of the machine. Each section has respective channels therethrough for passing pulp suspension. At least one connection at each section is to a controllable supply of pulp suspension where the operating parameters of that supply are controllable. Only separate operating parameter controlled streams pass through the sections of the headbox. Operating parameter control devices may deliver adjusted streams to a mixer upstream of the headbox channels. The mixer may also have individual sections across the width of the machine. The headbox has a common outlet nozzle downstream of the individual channels and the individual sections, where the pulp suspension stream from channels with controlled suspension parameters and from any channels without controlled suspension parameters are reconstituted to have the desired suspension operating parameters. | 3 |
BACKGROUND OF THE INVENTION
This invention relates to hand prosthesis. Most of the hands produced for amputees are the old three jaw clinch construction. These hands provide tip prehension. The construction was intended to provide pinch and a crude grasp while the good hand would provide most necessary movement and more delicate handling. However, this device did not provide a secure grip or manipulative function for the amputee. These prior devices do not utilize movement that can easily be translated into a positional sense which is important to the amputee, as he redevelops his skills.
Essentially all of the activity in hand prosthesis has been directed to the tip pinch system which, as explained hereinabove, has been completely inadequate to satisfy the needs of the amputee. For example, in U.S. Pat. No. 1,173,219 to J. F. Rowley, an artificial hand is powered by connection to the same shoulder of the amputated hand and there is no purchase or connection to the upper arm and the strap to the other shoulder provides mere support.
U.S. Pat. No. 1,507,683 to A. Pecorella, et al., discloses an artificial hand with a fixed hinge connection at the elbow. There is and can be no connection between the lower arm amputation stump and the upper arm but only from the hand to the artificial forearm and then to the opposite shoulder.
A similar device is disclosed in U.S. Pat. No. 2,409,884, to B. C. Mollenhour which discloses an artificial arm and hand with cable connection from the hand to the forearm and then to the opposite shoulder with no connection or purchase from the posterior elbow. Additional patents which disclose various types of hand and arm prosthesis include U.S. Pat. No. 645,740 to H. Schenk, U.S. Pat. No. 1,206,753 to P. Desmore, U.S. Pat. No. 1,989,960 to F. E. Wheeler, et al., U.S. Pat. No. 2,542,316 to W. G. Farrar, Jr., U.S. Pat. No. 2,668,959 to J. Sargeson, U.S. Pat. No. 1,263,675 to B. Jeffrey, U.S. Pat. No. 1,285,326 to S. A. Nelson, U.S. Pat. No. 1,277,747 to E. L. O'Connor, and U.S. Pat. No. 861,982 to J. Hinz, Jr. None of these patents disclose or suggest the present invention and in particular do not utilize pronation or supination to power the grip. These hand prosthesis all fail to satisfy the following objects of this invention.
It is an object of this invention to provide amputees with below elbow disarticulation amputations, particularly those with wrist disarticulation amputations, with a functional cosmetic hand which allows the owner to control the position, motion, speed and pressure applied to operate a prosthetic thumb.
It is a further object of this invention to provide a key grip prosthetic hand with a lateral thumb pinch for which motive force and control is provided entirely by the amputee unless operational assistance is needed from external power.
It is an additional object of this invention to provide for opening of the prosthetic thumb in the usually more difficult planes of movement such as over the head, behind the back and close to the body.
It is an additional object of this invention to use purchase sensibility which may be translated through the prosthetic wearer to a positional sense of the prosthetic thumb.
It is a further object of this invention to provide a pinch prosthesis which is in an optimum line of vision of the person utilizing the prosthesis, making the prosthetic hand functional even in the absence of sensibility or in the presence of limited sensibility.
It is an object of this invention to provide a prosthesis with a simplified mechanism but yet facilitates translation of a position sense of a prosthetic thumb.
It is an object of this invention to provide a more effective grip which affords a firmer, more stable and easier grip of tools and objects thus freeing the uninjured hand as a manipulator during activities requiring bilateral function.
It is an object of this invention to provide an easy opening lateral thumb by the use of combined natural movements of the body.
It is an object of this invention to provide a functional use prosthesis in combination with a cosmetic hand that, by its movements and use, becomes even more cosmetic in providing the functions of a normal assistive hand.
It is finally an object of this invention to provide a prosthesis hand that allows the activities of daily living problems of the amputee, such as tying a shoe lace, a great deal easier.
SUMMARY OF THE INVENTION
A hand and lower arm prosthesis is provided for an amputee wherein the amputee's lower arm amputation stump remains muscularly connected to the upper arm. The prosthesis includes an amputation stump socket fitted over the stump, a hand prosthesis movably attached to the lower arm socket, a lateral thumb pinch mechanism in the hand prosthesis utilizing a key grip with spring means to provide closure force on the thumb pinch. A connection means is provided from the thumb pinch means to the posterior elbow to translate force of forearm pronation and supination as well as purchase sensibility to the lateral thumb pinch means. A continuing connection means from the posterior elbow to the opposite shoulder together with strap means to transfer force of humeral flexion of that shoulder to the thumb pinch means is preferred.
It is preferred that the movable attachment of the hand to the lower arm socket be by a flexion means to adjust the wrist angle together with a locking means to fix the wrist angle at the wearer's chosen position. It is also preferred that the wrist connection swivel to provide disarticulation of the hand.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a partial perspective view of the torso and arms of a person wearing the prosthesis device of this invention.
FIG. 2 is an expanded perspective view of the entire prosthesis device of this invention.
FIG. 3 is a perspective view of the attachment to the posterior elbow along with part of the cable system of the prosthesis device.
FIG. 4 is a perspective view of the lateral thumb pinch hand of the prosthesis of this invention showing the thumb in a closed position.
FIG. 5 shows the same hand illustrated in FIG. 4 with the thumb in the open position.
FIG. 6 is a perspective view with a partial cutaway cross-sectional view of the attachment system between the hand and the lower arm socket system.
DESCRIPTION OF PREFERRED EMBODIMENTS
In FIG. 1 hand prosthesis 10 is shown worn by amputee 11. Hand 12 with key grip thumb 13 is attached to stump socket 14 held in position by strap 15 and connected to cuff 16 around the posterior elbow. Cable 22 connects to thumb 13 on one end and includes casing 17 which is anchored to rigid connection 18 located on socket 14. Casing 17 slides through sliding connection 19 on cuff 16 and cable 22 is connected to opposite shoulder harness 20.
An expanded view of hand prosthesis 10, off of the wearer, is illustrated in FIG. 2. Hand 12 is fabricated of two thermoplastic molding materials offered commmercially under trademarks KAY SPLINT from Fred Sammons, Inc., of Pennsylvania, and AQUAPLAST with finger patterns and hand shape individually molded in the shape of a cast of the amputee's normal hand. Thumb 13 is held against flat side 21 of stationary fingers by a spring mechanism illustrated in later figures. Cable 22 includes casing 17 which surrounds the internal cable. Cable 22 is 1/16 inch, Catalog No. C-100 from Hosmer Dorrance Corporation, 561 Division Street, Campbell, Calif. Cable 22 is rigidly attached to the base of thumb 13. Only a slight slack is provided in cable 22 and casing 17 is rigidly attached by rigid connector 18 to socket 14. The slight slack in cable 22 allows that when amputee's 11 stump is pronated, thumb 13 is pulled open. Cable 22 continues from connector 18 and is slidably attached through connector 19 to cuff 16, allowing casing 17 to slide through connector 19 but apply cutaneous pressure to the upper arm. Rotational pressure from excursion of cable 22 and casing 17 on the posterior humerous provides light touch to deep pressure sensibility on the posterior elbow. This pressure sense is utilized in a training program to teach positional sense to the thumb. Cable 22 is rigidly attached at 24 to hook 25 through which ring 26 is held to provide for a loop of strap 27 to be adjustably attached to ring 28 on which conventional shoulder harness 20 is attached. Thus by humeral flexion harness 20 transmits a pulling force through strap 27 on cable 22 thus providing sole force or a combination and additional force to open thumb 13.
An expanded view of FIG. 3 shows a closer view of rigid connector 18 firmly gripping casing 17 at head 29. Cable 22 slides freely inside casing 17 at head 29. Cuff 16 is held in position by VELCRO straps 30 and 31 along with buckle 32 into which strap 15 is connected.
Slidable connector 19 is constructed by attaching U-shaped metal connector through rivets 33 and providing holes 34 and 35 through which cable casing 17 passes and may slide back and forth.
It should be understood that rigid connector 18 is shown here attached to the posterior lateral aspect of the forearm such that it will provide a guide for cable 22. By the tightness of the cable as it passes around the posterior elbow through connection 19 pronation or supination of the forearm results in motive force and control of the thumb. An equally useful alternative is to attach cable casing 17 through an identical attachment 18 at the anterior lateral aspect of the forearm. In that position, voluntary opening will be achieved upon forearm supination by amputee 11.
In FIG. 4 a close-up of hand 12 is shown as connected to stump socket 14 through flexible wrist unit 36, which allows hand 12 to be located in the straight position as shown or by depressing control button 37 to allow flexion to a 30 degree or 50 degree angle. Thumb 13 pivots on hinge 39 and is held in position against finger side 21 by a spring 38 connected between palm 40 and inside thumb connector 41. Cable 22 is connected to outside connnector 42 such that when cable 22 is pulled, thumb 13 will pivot on hinge 39 against resistance spring 38, Catalog No. 3-1976, from Hosmer-Dorrance above, to an open position as illustrated in FIG. 5. A removable KAY SPLINT plastic palm shield (not shown) covers the internal mechanism.
A partial cutaway cross-section of wrist unit 36 is shown in FIG. 6 imbedded in stump socket 14 cast of the KAY SPLINT. The entire flexion wrist unit 36 is available commercially from the Hosmer above as Catalog No. FL749. Hand 12 is attached to wrist unit 36 by imbedding wrist extender 43 also available commercially from Hosmer, Catalog Number FF-749. Wrist extender 43 was secured with AQUAPLAST molding compound available from W.F.R. Corporation 68 Birch Street, Ramsey, N.J. Threaded portion 44, engages threads 45 of wrist unit 36 to hold hand 12 securely into stump socket 14.
The preferred mechanism by which the prosthetic thumb is made to open voluntarily by the combination of motive forces by the wearer is to provide a combination cable connection from the thumb to the posterior elbow and to the opposite shoulder. An alternate means of accomplishing this result is to provide a rigid cable connection of the outside cover of the cable between the thumb and socket 14, but at the same time allowing the cable inside the casing to slide free inside rigid connection 18. Cable casing 17 and, of course, internal cable 22 is allowed to slide freely through sliding connection 19. It is at this point that pressure sense is developed by pressure of the cable to teach a positional sense of the thumb. Internal cable 23 is ultimately connected through the various straps to the shoulder harness on the wearer's opposite shoulder to provide additional motive force to the thumb, directly along the cable.
The combination or alternation of control and force through supination and pronation, plus or through humeral flexion provides a unique and quite controllable movement by the wearer. This dual action or election of operation provides coordinated movement by the prosthetic wearer and facilitates easier opening of the prosthetic thumb. The one thumb lever is operated against the fixed portion of the prosthetic finger base by both forces in combination. Translation of the position sense from the elbow cutaneous receptor is to the single lever. While not necessary, it is sometimes useful to provide a plate or air bladder under cuff 16 directly under connection 19 to provide cutaneous reception distributed over a larger area of the elbow.
Hand prosthesis 10 harnesses the motive force of humeral flexion which, coordinated with pronation and supination opening, provides for more coordinated movements of the prosthetic wearer. The humeral flexion force applied at 19 on cable 22 may override the pronator or supinator force in situations where the selective positioning of the hand is necessary and rotation is not desired, i.e. holding a cup of coffee.
The prosthesis 10 may be easily modified to provide either a voluntary opening on forearm supination or in the alternative, provide voluntary opening on forearm pronation. Similarly, prosthesis 10 may be adjusted to voluntarily open on humeral flexion or in the alternative, voluntarily close on humeral flexion. Thus, humeral flexion force may be used selectively, alternately or in combination with pronation and supination muscles and function force, all directed to the thumb pinch. A positional sense of the prosthetic thumb is translated from a cutaneous receptor at connector 19.
While prosthesis 10 utilizes one cable 22 which, together with casing 17 held secure at 29 and the tightness of cable 22 from ring 28 to connector 42, provides the multiplicity and combination of control of the force, multiple cables may be used. For example, a cable can run from connector 42 to head 29 or, in the alternative, the posterior elbow, and terminate at that point. An alternative provides a cable running from connector 42 to head 29, sliding freely or firmly attached at that point, and then continuing to a connection on cuff 16 at the posterior elbow, terminating at that point. A second cable, in combination with any of the above shorter cable systems, can run from connector 42, slide freely through head 29, slide through sliding connector 19 and firmly attach to end attachment 24. A cutaneous receptor would be placed under cuff 16 or could be provided inside socket 14.
While I have described my invention in connection with specific embodiments, it is to be clearly understood that this description is made only by way of example and not of limitation to the scope of my invention as set forth in the following claims. | A hand and lower arm prosthesis is provided for amputees who have the amputation stump of the lower arm muscularly connected to the upper arm, the prosthesis including a lateral thumb pinch utilizing a key grip with spring closure force connected to the upper arm elbow and in combination connected to the opposite shoulder to translate force of humeral flexion electively, alternately or in combination, with pronation and supination to the thumb pinch. | 0 |
This is a continuation-in-part of U.S. application Ser. No. 883,023 filed May 19, 1992, now U.S. Pat. No. 5,210,211, which is a continuation-in-part of U.S. application Ser. No. 719,271 field Jun. 21, 1991, now abandoned.
BACKGROUND OF THE INVENTION
The present invention relates to novel substituted derivatives of 4-(1H-pyrrol-1-yl)imidazoles which are useful as pharmaceutical agents, to methods for their preparation, to pharmaceutical compositions which include the compounds and a pharmaceutically acceptable carrier, and to pharmaceutical methods of treatment as well as the use of these agents as diagnostic tools. The novel compounds of the present invention are antagonists of angiotensin II (AII) useful in controlling hypertension, hyperaldosteronism, congestive heart failure, atherosclerosis, postsurgical vascular restenosis, renal failure, and glaucoma in mammals.
The enzyme renin acts on a blood plasma α 2 -globulin, angiotensinogen, to produce angiotensin I, which is then converted by angiotensin-converting enzyme to AII. The latter substance is a powerful vasopressor agent which has been implicated as a causative agent for producing high blood pressure in various mammals, such as rats, dogs, and humans. Angiotensin II has also been found to stimulate vascular hyperplasia as reported by W. Osterrieder, et al (Hypertension 18[suppl II]:II60-II64, 1991); H. Azuma, et al (Jpn. J. Pharmacol. 52(4):541-552, 1990); and S. Laporte, et al (FASEB 5(4), Part I: A869, 1991). The compounds of this invention inhibit the action of AII at its receptors on target cells and thus prevent the increase in blood pressure produced by this hormone-receptor interaction. By administering a compound of the instant invention to a species of mammal with hypertension due to AII, the blood pressure is reduced. The compounds of the invention are also useful for the treatment of congestive heart failure, hyperaldosteronism, atherosclerosis, postsurgical restenosis, and glaucoma. European Patent Application 0253310 discloses angiotensin II receptor blocking imidazoles of the formula ##STR1##
European Patent Application 0291969 disclose tetrazole intermediates to antihypertensive compounds ##STR2##
European Patent Application 401030 discloses substituted imidazo-fused seven-member ring heterocycles of Formula I and Ia ##STR3## which are useful as angiotension II antagonists.
WO 91,00277 discloses substituted imidazoles useful as angiotensin II blockers ##STR4##
However, the compounds disclosed in the above references do not disclose or suggest the novel combination of structural variations found in the compounds of the present invention described hereinafter.
SUMMARY OF THE INVENTION
The present invention is a compound of Formula I ##STR5## or a pharmaceutically acceptable salt thereof wherein R 1 , R 2 , R 3 , and R 4 are as described below.
Preferred compounds of the instant invention are those of Formula I wherein
R 1 is --COOH or ##STR6## R 2 is -- n C 3 H 7 or
-- n C 4 H 9 ;
R 3 is
--H,
--COOR 5
--CN,
--CHO,
--CH 2 OH,
--(CH 2 ) n CO 2 R 5 ,
--CH═CHCO 2 R 5 ,
--CH═C(CH 3 )CO 2 R 5 , or
--CONH(CH 2 ) n CO 2 R 5
wherein R 5 is hydrogen or a straight or branched alkyl of from one to four carbon atoms and n is 1 to 10; R 4 is absent or is one or two substituents attached to the pyrrole ring selected from:
2-CH 3 ,
2-CO 2 R 5 ,
3-CO 2 R 5 ,
2-CH 2 OH,
3-CH 2 OH,
2-Cl,
2-Br,
2-CONHOH,
3-CONHOH,
2-COCF 3 ,
2-COCCl 3 ,
2-CH(OH)CF 3 ,
2-CH(OH)CCl 3 ,
2,5-(Cl) 2 ,
2,5-(Br) 2 , and
2,5-(CH 3 ) 2 .
More preferred compounds of the instant invention are those of Formula I wherein
R 1 is ##STR7## R 2 is -- n C 4 H 9 or
-- n C 3 H 7 ;
R 3 is
--H,
--CN,
--CO 2 H,
--CO 2 CH 3 ,
--CO 2 C 2 H 5 , or
--CH 2 OH; and
R 4 is absent or is one or two substituents attached to the pyrrole ring selected from:
2-CO 2 CH 3 ,
2-COCF 3 ,
2-CO 2 H,
2-CH(OH)CF 3 ,
2,5-(Cl) 2 , and
2,5-(CH 3 ) 2 .
Yet still more preferred compounds of the instant invention are selected from the following list of compounds:
1) 2-butyl-5-cyano-4-(1H-pyrrol-1-yl)-1-[(2'-(1H-tetrazol-5-yl)biphen-4-yl)methyl]-1H-imidazole,
2) 5-cyano-2-propyl -4-(1H-pyrrol-1-yl)-1-[(2'-(1H-tetrazol-5-yl)biphen-4-yl)methyl]-1H-imidazole,
3) 2-butyl-4-(1H-pyrrol-1-yl)-1-[(2'-(1H-tetrazol-5-yl)biphen-4-yl)methyl]-1H-imidazole-5-carboxylic acid,
4) 2-propyl-4-(1H-pyrrol-1-yl)-1[(2'-(1H-tetrazol-5-yl)biphen-4-yl)methyl]-1H-imidazole-5-carboxylic acid,
5) 2-butyl-4-(1H-pyrrol-1-yl)-1-[(2,-(1H-tetrazol-5-yl)biphen-4-yl)methyl]-1H-imidazole,
6) ethyl -2-butyl-4-(1H-pyrrol-1-yl)-1-[(2,-(1H-tetrazol-5-yl)biphen-4-yl)methyl]-1H-imidazole-5-carboxylate,
7) methyl -2-butyl-4-(1H-pyrrol-1-yl)-1-[(2'-(1H-tetrazol-5-yl)biphen-4-yl)methyl]-1H-imidazole-5-carboxylate,
8) 2-butyl-5-(hydroxymethyl)-4-(1H-pyrrol-1-yl) 1-[(2'-(1H-tetrazol-5-yl)biphen-4-yl)methyl]-1H-imidazole,
9) 5-cyano-4-[2 (1-oxo-2,2,2-trifluoroethyl) 1H-pyrrol-1-yl]-2-propyl -1-[(2'-(1H-tetrazol-5-yl)biphen-4-yl)methyl]-1H-imidazole,
10) 5-cyano-4-[2-(1-hydroxy-2,2,2-trifluoroethyl)-1H-pyrrol-1-yl]-2-propyl-1-[(2'-(1H-tetrazol-5-yl)biphen-4-yl)methyl]-1H-imidazole,
11) methyl 1-[5-cyano-2-propyl-1-[(2'-(1H-tetrazol-5-yl)-biphen-4-yl)methyl]-1H-imidazol-4-yl]-1H-pyrrole-2-carboxylate,
12) 1-[5-cyano-2-propyl-1-[(2'-(1H-tetrazol-5-yl)biphen-4-yl)methyl]-1H-imidazol-4-yl]-1H-pyrrole-2-carboxylic acid,
13) 5-cyano-4-(2,5-dichloro-1H-pyrrol-1-yl)-2-propyl-1-[(2'-(1H-tetrazol-5-yl)biphen-4-yl)methyl]-1H-imidazole,
14) methyl 4-(2,5-dichloro-1H-pyrrol-1-yl)-2-propyl-1-[(2'-(1Htetrazol-5-yl)biphen-4-yl)methyl]-1H-imidazole-5-carboxylate,
15) 2-cyclopropyl-4-(2,5-dimethyl-1H-pyrrol-I yl) 1-[(2'-(1H-tetrazol-5-yl)biphen-4-yl)methyl]-1H-imidazole-5-carboxylic acid,
16) methyl 2-cyclopropyl-4-(2,5-dimethyl-1H-pyrrol-1-yl)-1-[(2'-(1H-tetrazol-5-yl)biphen-4-yl)methyl]-1H-imidazole-5-carboxylate,
17) methyl 4-(2-propyl-5-methyl-1H-pyrrol-1-yl)-2-propyl-1-[(2'-(1H-tetrazol-5-yl)biphen-4-yl)methyl]-1H-imidazole-5-carboxylate,
18) 4-(2-propyl-5-methyl-1H-pyrrol-1-yl)-2-propyl-1-[(2'-(1H-tetrazol-5-yl)biphen-4-yl)methyl]-1H-imidazole-5-carboxylic acid,
19) 4-(2,5-dimethyl-1H-pyrrol-1-yl) 2-propyl-1-[(2'-(1H-tetrazol-5-yl)biphen-4-yl)methyl]-1H-imidazole-5-carboxaldehyde,
20) methyl (E)-3-[4-(2,5-dimethyl-1H-pyrrol-1-yl)-2-propyl-1-[[2'-(1H-tetrazol-5-yl)biphen-4-yl]methyl]-1H-imidazol-5-yl]-2-propenoate,
21) (E)-3-[4-[2,5-dimethyl-1H-pyrrol-1-yl)-2-propyl-1-[[2'-(1H-tetrazol-5-yl)biphen-4-yl]methyl]-1H-imidazol-5-yl]-2-propenoic acid,
22) 4-(3-carboxyethyl-1H-pyrrol-1-yl)-2-propyl I [(2'-(1H-tetrazol-5-yl)biphen-4-yl)methyl]-1H-imidazole-5-carboxylic acid,
23) methyl -4-(3-carboxyethyl-1H-pyrrol-1-yl)-2-propyl-1-[(2'-(1H-tetrazol-5-yl)biphen-4-yl)methyl]-1H-imidazole-5-carboxylate,
24) 4-(3-carboxy-1H-pyrrol-1-yl)-2-propyl-1-[(2'-(1H-tetrazol-5-yl)biphen-4-yl)methyl]-1H-imidazole-5-carboxylic acid,
25) ethyl (E)-3-[4-(1H-pyrrol-l-yl)-2-propyl-1-[[2'-(1H-tetrazol-5-yl)biphen-4-yl]methyl]-1H-imidazol-5-yl]-2-propenoate,
26) (E)-3-[4-(1H-pyrrol-1-yl)-2-propyl-I-[[2'-(1H-tetrazol-5-yl)biphen-4-yl]methyl]-1H-imidazol-5-yl]-2-propenoic acid,
27) methyl -4-(2,5-dimethyl -1H-pyrrol-1-yl)-2-propyl-1-[(2'-(1H-tetrazol-5-yl)biphen-4-yl)methyl]-1H-imidazole-5-carboxylate,
28) 4-(2,5-dimethyl-1H-pyrrol-l-yl)-2-propyl -1-[(2'-(1H-tetrazol-5-yl)biphen-4-yl)methyl]-1H-imidazole-5-carboxylic acid,
29) 2-propyl-4-(-1H-pyrrol-1-yl)-1-[(2'-(1H-tetrazol-5-yl)biphen-4-yl)methyl]-1H-imidazole-5-carboxaldehyde,
30) 4-(2,5-dimethyl-1H-pyrrol-1-yl)-5-(hydroxymethyl)-2-propyl-1-[(2'-(1H-tetrazol-5-yl)biphen-4-yl)methyl]-1H-imidazole,
31) 5-cyano-4-(2,5-dimethyl-1H-pyrrol-1-yl) 2-propyl-1-[(2'-(1H-tetrazol-5-yl)biphen-4-yl)methyl]-1H-imidazole,
32) methyl -4-(3-carboxymethyl-2-methyl-1H-pyrrol-1-yl)-2-propyl-1-[(2'-(1H-tetrazol-5-yl)biphen-4-yl)methyl]-1H-imidazole-5-carboxylate,
33) 4-(3-carboxymethyl-2-methyl -1H-pyrrol-1-yl)-2-propyl-1-[(2'-(1H-tetrazol-5-yl)biphen-4-yl)methyl]-1H-imidazole-5-carboxylic acid,
34) 4-(3-carboxy-2-methyl-1H-pyrrol-1-yl)-2-propyl-1-[(2'-(1H-tetrazol-5-yl)biphen-4-yl)methyl]-1H-imidazole-5-carboxylic acid,
35) 4-[2-(1-oxo-2,2,2-trifluoroethyl) 1H-pyrrol-1-yl]-2-propyl-1-[(2'-(1H-tetrazol-5-yl)biphen-4-yl)methyl]-1H-imidazole-5-carboxylic acid,
36) 2-butyl-4-[2-(1-oxo 2,2,2-trifluoroethyl) 1H-pyrrol-1-yl]-1-[(2'-(1H-tetrazol-5-yl)biphen-4-yl)methyl]-1H-imidazole-5-carboxylic acid,
37) methyl 4-[2-(1-oxo-2,2,2-trifluoroethyl)-1H-pyrrol-1-yl]-2-propyl -1-[(2'-(1H-tetrazol-5-yl)biphen-4-yl)methyl]-1H-imidazole-5-carboxylate,
38) methyl -2-butyl-4-[2-(1-oxo-2,2,2-trifluoroethyl)-1H-pyrrol-1-yl]-1-[(2'-(1H-tetrazol-5-yl)biphen-4-yl)methyl]-1H-imidazole-5-carboxylate,
39) 1-[5-carboxy-2-propyl-1-[(2'-(1H-tetrazol-5-yl)biphen-4-yl)methyl]-1H-imidazol-4-yl]-1H-pyrrole-2-carboxylic acid
40) ethyl (E)-2-methyl-3-[4-(1H-pyrrol 1-yl)-2-propyl-1-[[2'-(1H-tetrazol-5-yl)biphen-4-yl]methyl]-1H-imidazol-5-yl]-2-propenoate,
41) (E)-2-methyl-3-[4-(1H-pyrrol-1-yl)-2-propyl-1-[[2'-(1H-tetrazol-5-yl)biphen-4-yl]methyl]-1H-imidazol-5-yl]-2-propenoic acid,
42) 4-(2,5-dichloro-1H-pyrrol-1-yl)-2-propyl-1-[(2'-(1H-tetrazol-5-yl)biphen-4-yl)methyl]-1H-imidazole-5-carboxylic acid,
43) 6-[[[2-Propyl-1-[[2'-(1H-tetrazol-5-yl)-[1,1'-biphenyl]-4-yl]methyl]-4-[(2-trifluoroacetyl)-1H-pyrrol-1-yl]-1H-imidazol-5-yl]carbonyl]amino]hexanoic acid,
44) 1,1-Dimethylethyl-6-[[[2-propyl-1-[[2'-(1H-tetrazol-5-yl)-[1,1'-biphenyl]-4-yl]methyl]-4-[(2-trifluoroacetyl) 1H-pyrrol-1-yl]-1H-imidazol-5-yl]carbonyl]amino]hexanoate,
45) 11-Dimethylethyl -4-[[[2-propyl-1-[[2'-(1H-tetrazol-5-yl) [1,1-biphenyl]-4-yl]methyl]-4-[(2-trifluoroacetyl)-1H-pyrrol-1yl]-1H-imidazol-5-yl]carbonyl]amino]butanoate, and
46) N [6-[[2-(4-hydroxyphenyl)ethyl]amino]-6-oxohexyl]-2-propyl-1-[[2'-(2H-tetrazol-5-yl)[1,1'-biphenyl]-4-yl]methyl]-4-[2-(trifluoroacetyl)-1H-pyrrol-1-yl]-1H-imidazole-5 carboxyamide.
Novel intermediates useful in the preparation of compounds of the instant invention are:
1) 4-amino-2-butyl-5-cyanoimidazole,
2) 4-amino-5 cyano-2-propylimidazole,
3) 2-butyl-5-cyano-4-(1H-pyrrol 1-yl)imidazole,
4) 5 cyano-2 propyl-4-(1H-pyrrol-1-yl)imidazole,
5) ethyl 2-butyl-4-(1H-pyrrol-1-yl)imidazole-5-carboxylate,
6) methyl -2-butyl-4-(1H-pyrrol-1-yl)imidazole,
7) 2-butyl-5-(hydroxymethyl)-4-(1H-pyrrol-1-yl)imidazole-5-carboxylate,
8) 5-cyano-4-[2-(1-oxo-2,2,2-trifluoroethyl)-1H-pyrrol-1-yl]-2-propylimidazole,
9) methyl 1-(5-cyano-2-propylimidazol-4-yl)-1H-pyrrole-2-carboxylate,
10) 5-cyano-4-(2,5-dichloro-1H-pyrrol-1-yl)-2-propylimidazole,
11) methyl 4-[2-(1-oxo-2,2,2-trifluoroethyl)-1H-pyrrol-1-yl]-2-propylimidazole-5-carboxylate,
12) methyl -2-butyl-4-[2-(1 oxo-2,2,2-trifluoroethyl)-1H-pyrrol-1-yl]imidazole-5-carboxylate,
13) 5-cyano-4-(2,5-dichloro-1H-pyrrol-1-yl)-2-propylimidazole,
14) methyl 2-cyclopropyl -4-(2,5-dimethyl-1H-pyrrol-1-yl)imidazole-5-carboxylate,
15) methyl 4-(2-propyl-5-methyl-1H-pyrrol-1-yl)-2-propylimidazole 5-carboxylate,
16) 4-(2,5-dimethyl-1H-pyrrol-1-yl)-2-propylimidazole-5-carboxaldehyde,
17) methyl 4-(3-carboxyethyl-1H-pyrrol-I-yl)-2-propyl-imidazole-5-carboxylate,
18) methyl 4-(2,5-dimethyl-1H-pyrrol-1-yl)-2-propylimidazole-5-carboxylate,
19) 2-propyl-4-(1H-pyrrol-1-yl)-imidazole-5-carboxaldehyde,
20) 5-(hydroxymethyl)-2-propyl-4-(1H-pyrrol-1-yl)imidazole,
21) 2-butyl-5-(hydroxymethyl)-4-(1H-pyrrol-1-yl)imidazole,
22) 5-cyano-4-(2,5-dimethyl-1H-pyrrol-1-yl)-2-propylimidazole,
23) methyl 4-(2-methyl-3-carboxymethyl-1H-pyrrol-1-yl)-2-propylimidazole-5-carboxylate,
24) methyl -2-butyl-4-[2-(1-oxo-2,2,2-trifluoroethyl)-1H-pyrrol-1-yl]imidazole-5-carboxylate,
25) methyl 2-propyl-4-(2,5-dichloro-1H-pyrrol-1-yl)-imidazole-5-carboxylate,
26) 5-(hydroxymethyl)-2-propyl-4-(1H-pyrrol-1-yl)-imidazole,
27) methyl -4-amino-2-cyclopropylimidazole-5-carboxylate,
28) 5-(hydroxymethyl)-2-propyl-4-(2,5-dimethyl-1H-pyrrol-1-yl)imidazole, and
29) methyl (E) 3-[4-(2,5-dimethyl-1H-pyrrol-1-yl)-2-propylimidazol-5-yl]-2-propenoic acid.
Angiotensin II mediates a variety of responses in various tissues, including contraction of vascular smooth muscle, excretions of salt and water from kidney, release of prolactin from pituitary, stimulation of aldosterone secretion from adrenal gland, and possible regulation of cell growth in both cardiac and vascular tissue. As antagonists of angiotensin II, the compounds of the instant invention are useful in controlling hypertension, hyperaldosteronism, congestive heart failure, and vascular smooth muscle proliferation associated with atherosclerosis and post-surgical vascular restenosis in mammals. Additionally, antihypertensive agents as a class have been shown to be useful in lowering intraocular pressure. Thus, the other inventions are also useful in treating and/or preventing glaucoma.
One method of particular interest is a method of treating hypertension comprising administering to a host suffering therefrom a therapeutically effective amount of 4-[2-(1-oxo-2,2,2-trifluoroethyl)-1H-pyrrol-1-yl]-2-propyl-1-[(2'-(1H-tetrazol-5-yl)biphen-4-yl)methyl]-1H-imidazole-5-carboxylic acid, or the methyl ester thereof in unit dosage form.
The present invention is also a pharmaceutical composition for administering an effective amount of a compound of Formula I in unit dosage form in the treatment methods mentioned above.
Finally, the present invention is directed to methods for the preparation of a compound of Formula I and synthetic intermediates.
DETAILED DESCRIPTION OF THE INVENTION
The invention is of a compound of Formula I ##STR8## or a pharmaceutically acceptable salt thereof wherein R 1 is
--COOH, or ##STR9## R 2 is --C 2 H 5 ,
-- n C 3 H 7 ,
-- n C 4 H 9 .
--CH 2 CH═CH 2 ,
--CH 2 CH═CHCH 3 , or
--CH 2 CH 2 CH═CH 2 ;
R 3 is
--H,
--CN,
--CHO,
--CH 2 OH,
--COOR 5 ##STR10## --(CH 2 ) n CN, --(Ch 2 ) n CO 2 R 5 ,
--(CH 2 ) n CONH 2 ,
--(CH 2 ) n CONHOH,
--CH═CHCO 2 R 5 ,
C═C(CH 3 )CO 2 R 5 ,
--CONH(CH 2 ) n CO 2 R 5 , ##STR11## wherein R 5 is hydrogen or a straight or branched alkyl of from one to four carbon atoms, n is 1 to 10, and m is 1 to 5; and
R 4 is absent or is one or two substituents attached to the pyrrole ring selected from:
2-CH 3 ,
2-CH 2 CH 3 ,
2-CH 2 CH 2 CH 3
2-CF 3 ,
2-CO 2 R 5 ,
2-CHO,
2-CH 2 OH, ##STR12## 2-NO 2 , 2-Cl,
2-Br,
2I,
2-COCF 3 ,
-COCCl 3 ,
2-CH(OH)CF 3 ,
2-CH(OH)CCl 3 ,
2-CONH 2 ,
2-CONHOH,
3-CH 3 ,
3-CH 2 CH 3 ,
3-CF 3 ,
3-CO 2 R 5 ,
3-CHO,
3-CH 2 OH, ##STR13## 3-NO 2 , 3-CONH 2 ,
3-CONHOH,
2-CO 2 R 5 -4-NO 2 ,
2-COCCl 3 -4-NO 2 ,
2-COCF 3 -4-NO 2 ,
2-CO 2 R 5 -4-Cl,
2-COCCl 3 -4-Cl,
2-COCF 3 -4-Cl,
2-COCF 3 -4-Cl,
2-CO 2 R 5 -4-Br,
2-COCCl 3 -4-Br,
2-COCF 3 -4-Br,
2-CO 2 R 5 -4-I,
2-COCCl 3 -4-I,
2-COCCF 3 -4-I,
2-NO 2 -4-CO 2 R 5 ,
2-Cl-4-CO 2 R 5 ,
2-Br-4-CO 2 R 5 ,
2-I-4-CO 2 R 5 ,
2-CH 3 -3-CO 2 R 5 ,
2,5-(CH 3 ) 2 ,
2,5-COCF 3 ,
2,5-(CH 2 CH 3 ) 2 ,
2-CH 2 CH 2 CH 3 -5-CH 3 ,
2,5-(Cl) 2 ,
2,5-(Br) 2 , and
2,5-(I) 2
wherein R 5 is hydrogen or a straight or branched alkyl of from one to four carbon atoms.
Certain compounds of the present invention can exist in unsolvated forms as well as solvated forms, including hydrated forms. In general, the solvated forms, including hydrated forms, are equivalent to unsolvated forms and are intended to be encompassed within the cope of the present invention.
Certain compounds of the present invention possess one or more chiral centers and each center may exist in the R(D) or S(L) configuration. The present invention includes all enantiomeric and epimeric forms as well as the appropriate mixtures thereof.
In the compounds of Formula I, the term "lower alkyl" means a straight or branched hydrocarbon radical having from one to six carbon atoms and includes, for example, methyl, ethyl, n-propyl, isopropyl, n-butyl, sec-butyl, isobutyl, tert-butyl, n-pentyl, n-hexyl, and the like.
Halogen is fluorine, chlorine, bromine, or iodine.
The compounds of Formula I are capable of further forming both pharmaceutically acceptable acid addition and/or base salts. All of these forms are within the scope of the present invention.
Pharmaceutically acceptable acid addition salts of the compound of Formula I include salts derived from nontoxic inorganic acids such as hydrochloric, nitric, phosphoric, sulfuric, hydrobromic, hydriodic, phosphorous, and the like, as well as the salts derived from nontoxic organic acids, such as aliphatic mono- and dicarboxylic acids, phenyl-substituted alkanoic acids, hydroxy alkanoic acids, alkanedioic acids, aromatic acids, aliphatic and aromatic sulfonic acids, etc. Such salts thus include sulfate, pyrosulfate, bisulfate, sulfite, bisulfite, nitrate, phosphate, monohydrogenphosphate, dihydrogenphosphate, metaphosphate, pyrophosphate, chloride, bromide, iodide, acetate, propionate, caprylate, isobutyrate, oxalate, malonate, succinate, suberate, sebacate, fumarate, maleate, mandelate, benzoate, chlorobenzoate, methylbenzoate, dinitrobenzoate, phthalate, benzenesulfonate, toluenesulfonate, phenylacetate, citrate, lactate, maleate, tartrate, methanesulfonate, and the like. Also contemplated are salts of amino acids such as arginate and the like and gluconate, galacturonate (see, for example, Berge, S. M., et al, "Pharmaceutical Salts," Journal of Pharmaceutical Science 66:1-19 (1977)).
The acid addition salts of said basic compounds are prepared by contacting the free base form with a sufficient amount of the desired acid to produce the salt in the conventional manner. The free base form may be regenerated by contacting the salt form with a base and isolating the free base in the conventional manner. The free base forms differ from their respective salt forms somewhat in certain physical properties such as solubility in polar solvents, but otherwise the salts are equivalent to their respective free base for purposes of the present invention.
Pharmaceutically acceptable base addition salts are formed with metals or amines, such as alkali and alkaline earth metals or organic amines. Examples of metals used as cations are sodium, potassium, magnesium, calcium, and the like. Examples of suitable amines are N,N'-dibenzylethylenediamine, chloroprocaine, choline, diethanolamine, ethylenediamine, N-methylglucamine, and procaine (see, for example, Berge, S. M., et al, "Pharmaceutical Salts," Ibid.
The base addition salts of said acidic compounds are prepared by contacting the free acid form with a sufficient amount of the desired base to produce the salt in the conventional manner. The free acid form may be regenerated by contacting the salt form with an acid and isolating the free acid in the conventional manner. The free acid forms differ from their respective salt forms somewhat in certain physical properties such as solubility in polar solvents, but otherwise the salts are equivalent to their respective free acid for purposes of the present invention.
Compounds of Formula I may be prepared according to the syntheses outlined in Schemes I-VI. Although these schemes often indicate exact structures, the methods apply widely to analogous compounds of Formula I, given appropriate consideration to protection and deprotection of reactive functional groups by methods standard to the art of organic chemistry. The strategy for preparation of compounds of Formula I involves N(1) alkylation of a 4-(1H-pyrrol-1-yl)imidazole fragment with a biphenyl fragment. Schemes I, II, III, IV, and IVa deal with preparation of various 4-(1H-pyrrol-1-yl)imidazole fragments. Scheme V shows the synthesis of several biphenylmethyl halides and Scheme VI depicts the combination of the two fragments and subsequent manipulation to give compounds of Formula I. Additionally, many of the chemical modifications which are described for the N-unsubstituted 4-(1H-pyrrol-1-yl)imidazole fragments are also possible, and often preferable, once the biphenyl fragment is attached at N(1).
Scheme I and II detail methods for the preparation of 2-alkyl-4-(1H-pyrrol-1-yl)imidazoles. The key intermediate in both schemes is 5 which can be prepared by three routes. In the first method (Scheme I), reaction of an alkyl orthoester (1) with an aminonitrile (2) in a polar solvent such as methanol or ethanol affords the imino ether (3) which is treated in situ with methanolic ammonia. A cyclization reaction occurs to give 5. The second method (Scheme I) reacts an alkylimino ether (4) with an aminonitrile (2) in a polar solvent such as methanol or ethanol to give 5 in a single step. In those cases where the aminonitrile (2) and/or the alkylimino ether (4) are available as acid addition salts, it is necessary that at least one equivalent of a mild base such as potassium acetate, sodium acetate or the like be added for each equivalent of acid addition salt used in the reaction. The third method is detailed in Scheme II. In this route, an alkylimino ether (4) is reacted with an excess of aqueous cyanamide buffered (optimum pH 2.5-6.5) with dibasic sodium phosphate to afford the N-cyanoalkylimino ether (7). The N-cyano-alkylimino ether (7) is further reacted in a polar solvent such as methanol or ethanol with an acid addition salt of a glycine ester in the presence of a base such as triethylamine to produce the N-(N'-cyanoalkyl-imidoyl)-glycinate ester (8). Cyclization of (8) to the key intermediate (5) is effected by treatment with an alkoxide base such as sodium methoxide or sodium ethoxide and the like in a polar solvent. Finally, treatment of 5 prepared via Scheme I or Scheme II with 2,5-dimethoxytetrahydrofuran derivatives in buffered acetic acid at reflux converts the free amino group to a substituted or unsubstituted pyrrole, affording 6. Buffering of the acetic acid is best achieved by addition of 2 to 10 equivalents of either potassium or sodium acetate. This conversion of 5 to 6 is an example of the Paal-Knorr pyrrole synthesis which is well known to those skilled in the art of heterocyclic chemistry and has been reviewed in The Chemistry of Heterocyclic Compounds, E. C. Taylor, Editor, Pyrroles (Part 1), R. Alan Jones, Editor; John Wiley and Sons (1990), pp 206-294.
Selected examples of Compound 6 wherein an ester group is located at the 5-position may be further modified to give additional 4-(1H-pyrrol-1-yl)imidazoles according to Scheme 3. Reduction of 6 with a hydride reducing agent such as lithium aluminum hydride, lithium borohydride, and the like affords the alcohol, 9. Manganese dioxide oxidation of 7 gives the aldehyde 10. Knoevenagel condensation of malonic acid with 10 in refluxing piperidine affords the free acid 11a. Alteratively, 10 is converted to ester derivatives (11b) via the Wadsworth-Emmons reaction employing such reagents as, but not limited to, trimethylphosphonoacetate, triethylphosphoacetate, and tert-butyl diethylphosphonoacetate in polar solvents such as, tetrahydrofuran, acetonitrile, dimethylformamide, methanol and ethanol employing such bases as sodium hydride, sodium methoxide, potassium t-butoxide, lithium diethylamide, and 1,8-diazabicyclo[5.4.0]non-5-ene to afford the appropriate ester of 11b.
Electrophilic reactions of pyrrole derivatives are described in great detail in The Chemistry of Heterocyclic Compounds, E. C. Taylor, Editor, Pyrroles (Part 1), R. Alan Jones, Editor; John Wiley and Sons (1990), pp 329-497. Schemes IV and IVa show examples of such electrophilic substitutions pertinent to this invention. Treatment of a compound such as 6 (Scheme IV) with common electrophilic reagents including HNO 3 /acetic anhydride, N-chlorosuccinimide, trichloroacetyl chloride, N-bromosuccinimide or trifluoroacetic anhydride gives compounds of formula 12 with predominantly 2-substitution of nitro, chloro, trichloroacetyl, bromo and trifluoroacetyl groups on the pyrrole ring. Nitration also gives some of the 3-nitro isomer. Use of two equivalents of N-chloro or N-bromosuccinimide gives the 2,5-dichloro and 2,5-dibromopyrrole groups at the 4-position of 12.
Similarly, treatment of compounds of formula 6a (Scheme IVa), wherein the pyrrole ring already has an electron withdrawing group at the 2-position, with common electrophilic reagents affords compounds of formula 12a with a 2,4-substitution pattern on the pyrrole ring. Finally, treatment of compounds of formula 6b (Scheme IV), wherein the pyrrole ring already has an electron withdrawing group at the 3-position, with common electrophilic reactions affords compounds of formula 12b with a 2,4-substitution pattern complementary to the pattern seen on 12a.
The synthesis of the biphenyl fragments (Scheme V) is based on methods of A. Suzuki, et al, Syn. Commun. 11(7):513-519 (1981). The cross coupling of o-bromobenzonitrile 13 or methyl o-bromobenzoate 13a with p-tolylboronic acid 14 (F. R. Bean and J. R. Johnson, J. Amer. Chem. Soc. 54:4415-4424 (1934), European Patent 0470795) is effected by heating in dimethoxyethane or toluene in the presence of a palladium catalysts such as tetrakis(triphenylphosphine)-palladium(0) and two equivalents of an aqueous 2 M solution of sodium carbonate to afford the unsymmetrical biphenyls, 15 and 15a. The biphenylnitrile 15 is then converted to 16 by a two-step process. Thus, 15 is treated with trimethyltin azide in refluxing toluene solution to construct the tetrazole ring by a 1,3-dipolar cycloaddition. Subsequent replacement of the trimethyltin group on the newly constructed tetrazole ring is accomplished by treatment with triphenylmethyl chloride in pyridine solution, affording 16. Both the trityl protected biphenyltetrazole 16 and the biphenylester 15a are brominated at their respective benzylic positions by treatment with N-bromosuccinimide and a catalytic quantity of a radical initiator such as 2,2-azobis(2-methylpropionitrile) or benzoyl peroxide in refluxing carbon tetrachloride to afford the key intermediates 17 and 17a, respectively.
Scheme VI depicts the final assembly of biphenyl and 4-(1H-pyrrol-1-yl)imidazole fragments. Treatment of any of the 4-(1H-pyrrol-1-yl)imidazoles of structure type 6 with 17 in the presence of a suitable base such as Na 2 CO 3 , K 2 CO 3 , Cs 2 CO 3 , potassium t-butoxide, sodium methoxide, sodium hydride and the like in an inert solvent such as tetrahydrofuran or N,N-dimethylformamide gives rise to protected products such as 18. The regiochemistry of this alkylation process is highly selective for N(1) alkylation due to the steric hinderance to N(3) provided by the adjacent pyrrole ring. The preferred base for the transformation of 6 to 18 is Cs 2 CO 3 in a solvent of N,N-dimethylformamide effected at ambient temperature. The trityl protecting group of Compound 18 is removed by either refluxing with methanol overnight, by heating with methanol and a mild acid catalyst such as aqueous citric acid, or by brief treatment with warm acetic acid to afford 19 which is a compound of Formula I. Compounds of structure 19 where R 3 or R 4 or both R 3 and R 4 are esters further deprotection by saponification affords 20 which is also a compound of Formula I. These compounds may be further modified by coupling of the 5-carboxylic acid group with amino acid derivatives to give 21 which is also a compound of Formula I. In certain instances it is necessary to account for the reactivity of groups in R 3 and R 4 as depicted on compounds 18 and 19, adjusting the synthetic strategy slightly in order to obtain additional desired compounds of Formula I. Such adjustments of Scheme VI are within the usual realm of expertise of a practitioner of the art of organic chemistry and include the use of additional protection and deprotection steps and the reordering of synthetic steps. The strategy for assembly of complex organic molecules is described in The Logic of Chemical Synthesis by E. J. Corey and Xue-Min Cheng, John Wiley and Sons (1989). ##STR14##
The compounds of Formula I are valuable antagonists of angiotensin II. Dudley, D. T., et al, Molecular Pharmacology 38:370-377 (1990) reported the existence of two subclasses of angiotensin II binding sites in rabbit adrenal gland and uterus and in the rat liver which differ in their tissue distribution and affinity for various peptide and nonpeptide ligands. Thus, the compounds of Formula I were tested for their ability to inhibit [ 3 H] angiotensin II binding to rat liver membranes (AT 1 test) according to the methods described by Dudley, D. T., et al, Molecular Pharmacology 38:370-377 (1990). Compounds of Formula I are active in the AT 1 test with IC 50 values ranging from 0.1 nM to 1.0 μM.
Also, the compounds of Formula I were tested for functional activity in vitro. Thus, the compounds of the present invention were tested for their ability to antagonize angiotensin II induced contractions in rabbit aortic rings according to the method described by Dudley D. T., et al, Molecular Pharmacology 38:370-377 (1990). The aforementioned test methods are incorporated herein by reference. Compounds of Formula I are active in this in vitro functional assay with IC 50 values ranging from 0.1 nM to 1.0 μM.
Finally, the compounds of Formula I were tested in vivo for blood pressure lowering effects in renal hypertensive rats (2-kidney, 1-clip Goldblatt model) according to the method described by S. Sen, et al, in Hypertension 1:427-434 (1979) and in Clin. Soc. 57:53-6, 1979.
Illustrative of the in vivo antihypertensive activity for compounds of Formula I is the data for 4-[2-(1-oxo-2,2,2-trifluoroethyl)-1H-pyrrol-1-yl]-2-propyl-1-[(2'-(1H-tetrazol-5-yl)biphen-4-yl)methyl]-1H-imidazole-5-carboxylic acid (Example 14). This compound lowers blood pressure by ≧50 mm Hg and is efficacious for more than 24 hours with a single oral dose of 30 mg/kg in the above rodent model.
The compounds of the present invention can be prepared and administered in a wide variety of oral and parenteral dosage forms. It will be obvious to those skilled in the art that the following dosage forms may comprise as the active component, either a compound of Formula I or a corresponding pharmaceutically acceptable salt of a compound of Formula I.
For preparing pharmaceutical compositions from the compounds of the present invention, pharmaceutically acceptable carriers can be either solid or liquid. Solid form preparations include powders, tablets, pills, capsules, cachets, suppositories, and dispersible granules. A solid carrier can be one or more substances which may also act as diluents, flavoring agents, binders, preservatives, tablet disintegrating agents, or an encapsulating material.
In powders, the carrier is a finely divided solid which is in a mixture with the finely divided active component.
In tablets, the active component is mixed with the carrier having the necessary binding properties in suitable proportions and compacted in the shape and size desired.
The powders and tablets preferably contain from five or ten to about seventy percent of the active compound. Suitable carriers are magnesium carbonate, magnesium stearate, talc, sugar, lactose, pectin, dextrin, starch, gelatin, tragacanth, methylcellulose, sodium carboxymethylcellulose, a low melting wax, cocoa butter, and the like. The term "preparation" is intended to include the formulation of the active compound with encapsulating material as a carrier providing a capsule in which the active component with or without other carriers, is surrounded by a carrier, which is thus in association with it. Similarly, cachets and lozenges are included. Tablets, powders, capsules, pills, cachets, and lozenges can be used as solid dosage forms suitable for oral administration.
For preparing suppositories, a low melting wax, such as a mixture of fatty acid glycerides or cocoa butter, is first melted and the active component is dispersed homogeneously therein, as by stirring. The molten homogenous mixture is then poured into convenient sized molds, allowed to cool, and thereby to solidify.
Liquid form preparations include solutions, suspensions, and emulsions, for example, water or water propylene glycol solutions. For parenteral injection liquid preparations can be formulated in solution in aqueous polyethylene glycol solution.
Aqueous solutions suitable for oral use can be prepared by dissolving the active component in water and adding suitable colorants, flavors, stabilizing and thickening agents as desired.
Aqueous suspensions suitable for oral use can be made by dispersing the finely divided active component in water with viscous material, such as natural or synthetic gums, resins, methylcellulose, sodium carboxymethylcellulose, and other well-known suspending agents.
Also included are solid form preparations which are intended to be converted, shortly before use, to liquid form preparations for oral administration. Such liquid forms include solutions, suspensions, and emulsions. These preparations may contain, in addition to the active component, colorants, flavors, stabilizers, buffers, artificial and natural sweeteners, dispersants, thickeners, solubilizing agents, and the like.
The pharmaceutical preparation is preferably in unit dosage form. In such form the preparation is subdivided into unit doses containing appropriate quantities of the active component. The unit dosage form can be a packaged preparation, the package containing discrete quantities of preparation, such as packeted tablets, capsules, and powders in vials or ampoules. Also, the unit dosage form can be a capsules, tablet, cachet, or lozenge itself, or it can be the appropriate number of any of these in packaged form.
The quantity of active component in a unit dose preparation may be varied or adjusted from 0.1 mg to 100 mg preferably 0.5 mg to 100 mg according to the particular application and the potency of the active component. The composition can, if desired, also contain other compatible therapeutic agents.
In therapeutic use, the compounds utilized in the pharmaceutical method of this invention are administered at the initial dosage of about 0.1 mg to about 50 mg per kilogram daily. A daily dose range of about 0.5 mg to about 30 mg per kilogram is preferred. The dosages, however, may be varied depending upon the requirements of the patient, the severity of the condition being treated, and the compound being employed. Determination of the proper dosage for a particular situation is within the skill of the art. Generally, treatment is initiated with smaller dosages which are less than the optimum dose of the compound. Thereafter, the dosage is increased by small increments until the optimum effect under the circumstances is reached. For convenience, the total daily dosage may be divided and administered in portions during the day, if desired.
The following examples illustrate methods for preparing intermediate and final products of the invention. They are not intended to limit the scope of the invention.
EXAMPLE 1
Methyl propionimidate hydrochloride
Hydrogen chloride gas was bubbled through an ether (500 mL) solution of butyronitrile (275.4 g) and methanol (160 g) for a period of 3 hours. The temperature during the addition rose from -4° to 4° C. and the reaction mixture stirred at -1° C. for 1 hour, then stored at -25° C. for 16 hours. The resulting suspension was stirred at -10° C. and ether (1.8 L) added over a period of 40 minutes. The mixture was stirred for 1 hour at -6° C., then filtered under an atmosphere of N 2 . The insoluble product was filtered, washed with ether, and dried to afford 280 g of methyl butyrimidate hydrochloride. The filtrate was cooled to -5° C. for 30 minutes, filtered, and the insoluble product washed with ether to afford an additional 42 g of title product, mp 80°-81° C. MS (DEI) 102 (M+1).
EXAMPLE 2
Methyl N-cyanobutyrimidate
The methyl butyrimidate salt from Example 1 (322 g, 2.34 mol) was dissolved in a 50% aqueous solution of cyanamide (236 g, 2.81 mol) and cooled in an ice-bath. Dibasic sodium phosphate (164 g, 1.15 mol) was added to the reaction mixture in portions over a period of 1 hour. The resulting suspension was stirred at room temperature for 2 hours and the liquid decanted from the reaction mixture. The remaining solid was diluted with water (2 L) and extracted with ether (3×600 mL). The combined organic layers were washed with water and dried over anhydrous magnesium sulfate. The solvent was removed under reduced pressure and the residue distilled under high vacuum to afford 258 g of methyl N-cyanobutyrimidate. MS (DEI) 127 (M+1).
EXAMPLE 3
Methyl N-(N'-cyanobutyrimidoyl)glycinate
Methyl N-cyanobutyrimidate (240 g, 1.90 mol) from Example 2 was dissolved in absolute methanol (1.5 L) and glycine methyl ester HCl (250 g, 1.99 mol) added to the reaction mixture. The suspension was cooled to -5° C. and triethylamine (211 g, 2.09 mol) added over a period of 15 minutes. The resulting solution was stirred at 20° C. for 17 hours, then concentrated under reduced pressure to an oily-solid residue (690 g). The residue was taken up in ethyl acetate and the insoluble salts removed by filtration. The filtrate was washed with water followed by 10% aqueous sodium chloride solution. The organic layer was dried over anhydrous magnesium sulfate and evaporated to dryness under reduced pressure. This product (370 g) was used in the next step without further purification.
EXAMPLE 4
Methyl 4-amino-2-propylimidazole-5-carboxylate
To stirred methanol at -2° C. was added sodium methoxide (108 g, 2.0 mol) in portions over a period of 40 minutes To this clear solution at -3° C. was added a solution of methyl N (N'-cyanobutyrimidoyl)glycinate (Example 3, 344 g, 1.9 mol) in methanol (600 mL) over a period of 30 minutes. The resulting orange solution was allowed to warm to 13° C. over a period of 1 hour, then refluxed for 1 hour. The dark solution was cooled to room temperature and evaporated to dryness under reduced pressure. The residue was partitioned between water and ethyl acetate. The aqueous layer was extracted with ethyl acetate (4×1 L) and the combined organic layers washed with a saturated aqueous solution of sodium chloride. The combined organic layers were dried over anhydrous magnesium sulfate, filtered, and the filtrate evaporated to dryness under reduced pressure. The residue was recrystallized from ethyl acetate at -10° C. to afford 131 g (38% yield) of methyl 4-amino-2-propylimidazol-5-carboxylate, mp 133°-136° C. MS (DEI) 184 (M+1).
EXAMPLE 5
Methyl 2-propyl-4-(1H-pyrrol-1-yl)imidazole-5-carboxylate
To stirred acetic acid (1.5 L) at 80° C. was added over a 5-minute period a mixture of methyl -4-amino-2-propylimidazol-5-carboxylate (Example 4, 145 g, 0.798 mol) and sodium acetate (388 g, 4.73 mol). The mixture was heated at reflux for 5 minutes and then 2,5-dimethoxy-tetrahydrofuran (117 g, 0.885 mol) added all at once. The resulting dark solution was refluxed for 20 minutes, then poured onto ice. The gummy mixture was extracted with dichloromethane, the combined organic layers washed with water and dried over anhydrous magnesium sulfate. The filtrate was concentrated under reduced pressure and the residue dissolved in dichloromethane (2 L). The dichloromethane solution was treated with silica gel (500 g) and the suspension filtered through a bed of silica gel (300 g) eluting with dichloromethane. The filtrate was evaporated to dryness under reduced pressure and the crude product recrystallized from ether/hexane (2:1) to provide 86 g (46% yield) methyl 2-propyl-4-(1 H-pyrrol-1-yl)imidazol-5-carboxylate, mp 135°-138° C. MS (DEI) 234 (M+1).
EXAMPLE 6
Methyl 2-propyl-4-[2-(1-oxo-2,2,2-trifluoroethyl)-1H-pyrrol-1-yl]imidazol-5-carboxylate
To a stirred solution of the methyl -2-propyl-4-(1H-pyrrol-1-yl]imidazol-5-carboxylate (Example 5, 26 g, 0.11 mol) in dichloromethane (500 mL) at room temperature was added trifluoroacetic anhydride (46.61 mL, 0.33 mol) in one portion. The resulting solution was stirred at room temperature for 18 hours, then cooled to 5° C. in an ice-bath. A saturated aqueous solution of sodium bicarbonate (100 mL) was added slowly and the mixture stirred for 10 minutes. The organic layer was separated, washed with a saturated aqueous solution of sodium bicarbonate, then dried over anhydrous magnesium sulfate. The solvent was evaporated to dryness under reduced pressure and the residue taken-up in ether. The crystallizing mixture was cooled to -10° C. and the product collected by filtration to provide 23 g (62% yield) of the title compound, mp 158°-159° C.; MS (DEI) 329 (M + ).
EXAMPLE 7
4-Amino-2-butyl-5-cyanoimidazole
A solution of potassium acetate (2.94 g), anhydrous methanol (30 mL) and trimethyl orthovalerate (9.73 g) was treated with solid aminomalononitrile p-toluenesulfonate and the resulting suspension was stirred at room temperature for 18 hours under nitrogen atmosphere. Solids were removed by filtration and rinsed with anhydrous methanol (30 mL). The combined filtrate and washings were evaporated and the residue was treated with saturated, anhydrous methanolic ammonia (100 mL) at room temperature. The resulting solution was stirred for 18 hours then it was concentrated to about 50 mL. The concentrate was treated with activated charcoal and filtered. The filtrate was evaporated and the residue was purified by flash chromatography on silica gel, eluting with ethyl acetate-hexane (70:30) to give pure product as a gum upon evaporation. This gum was redissolved in chloroform-ether (1:2) and concentrated at reduced pressure to afford a solid which was collected by filtration and rinsed with ether affording the desired product, mp 115°-116° C. 1 H-NMR (CDCl 3 ) δ9.0 (br, 1H),
4.2 (br, 2H), 2.6 (t, 2H), 1.6 (m, 2H), 1.3 (m, 2H), 0.9 (t, 3H).
EXAMPLE 8
2-Butyl-5-cyano-4-(1H-pyrrol-1-yl)imidazole
A solution of potassium acetate (5.0 g), acetic acid (22 mL) and 4-amino-2-butyl-5-cyanoimidazole (Example 7, 1.45 g) was heated to reflux and treated with 2,5-dimethoxy-tetrahydrofuran (1.25 mL). The reaction was held at reflux for 1 minute then cooled back to room temperature with an ice bath. The majority of the acetic acid was evaporated at reduced pressure then the residue was partitioned between ethyl acetate and 10% aqueous K 2 CO 3 (120 mL) each. The organic layer was dried over MgSO 4 and evaporated. The residue was purified by flash chromatography on silica gel, eluting with hexane-ethyl acetate (90:10 to 80:20). Evaporation of solvents gave a gum that was redissolved in dichloromethane and evaporated once again. The residual oil was held under a vacuum overnight to afford a waxy solid. 1 H-NMR (CDCl 3 ) δ9.9 (br, 1H), 7.4 (s, 2H), 6.3 (s, 2H), 2.7 (t, 2H), 1.7 (m, 2H), 1.4 (m, 2H), 1.0 (t, 3H).
EXAMPLE 9
2-Cyano-4'-methylbiphenyl
Nitrogen was bubbled through a solution of 2-bromobenzonitrile (309.4 g, 1.70 mol) in dimethoxyethane (4.2 L) for 30 minutes then the following reagents added in succession: tetrakis(triphenylphosphine)palladium(0), (95 g, 0.082 mol); 2M aqueous sodium carbonate solution (1785 mL, 3.57 mol); and p-tolylboronic acid (239.1 g, 1.76 mol). The reaction mixture was heated under an atmosphere of nitrogen at 70° to 78° C. for 19 hours. The two-phase mixture was cooled to room temperature and the layers separated. The organic layer was evaporated to dryness under reduced pressure. The aqueous layer was extracted with ether (3×1.2 L) and the extracts added to the organic residue. The insoluble material was filtered off and washed with ether. The filtrate was dried over anhydrous magnesium sulfate and evaporated to dryness under reduced pressure. The oily residue was filtered to remove the solids and the filtrate distilled under high vacuum (0.1-0.2 torr) collecting the fraction boiling between 135° to 140° C. to afford 325 g of 2-cyano-4'-methylbiphenyl. MS (DEI) 193 (M+).
EXAMPLE 10
N-Trimethylstannyl-5-(4'-methylbiphenyl-2-yl)tetrazole
A solution of 2-cyano-4'-methylbiphenyl (1.93 g) in toluene (25 mL) was treated with trimethyltin azide (2.65 g) and heated at reflux for 24 hours. The resulting suspension was cooled to 70° C. and filtered. The collected solid was dried at reduced pressure to give the title compound. 1 H-NMR (CDCl 3 ) δ7.5 (m, 4H), 7.0 (q, 4H), 2.3 (s, 3H), 0.4 (s, 9H).
EXAMPLE 11
N-Triphenylmethyl-5-(4'-methylbiphenyl-2-yl)tetrazole
A mixture of N-trimethylstannyl-5-(4'-methylbiphenyl-2-yl)tetrazole (Example 10, 0.4 g) and anhydrous pyridine (10 mL) was treated with triphenylmethyl chloride (0.3 g) and stirred at room temperature under a nitrogen atmosphere for 48 hours. The resulting solution was evaporated and the residue was partitioned between dichloromethane and saturated aqueous CuSO 4 . The organic layer was dried over MgSO 4 and evaporated. The residual solid was triturated with diisopropyl ether and collected by filtration to give the title compound, mp 163°-165° C. (decomp., gas evol.).
EXAMPLE 12
N-Triphenylmethyl-5-[4'-(bromomethyl)biphenyl-2-yl]tetrazole
A mixture of N-triphenylmethyl-5 (4'-methylbiphenyl-2-yl)tetrazole (Example 11, 12.7 g), N-bromosuccinimide (4.6 g), carbon tetrachloride (300 mL), and benzoyl peroxide (75 mg) was heated at reflux for 2.5 hours. The cooled suspension was filtered and the filtrate was evaporated to give the title compound as a crystalline solid. 1 H-NMR (CDCl 3 ) δ8.2-6.7 (complex, 23H), 4.3 (s, 2H).
EXAMPLE 13
Methyl 4-[2 (1-oxo-2,2,2-trifluoroethyl)-1H-pyrrol-1-yl]-2-propyl-1-[(2'-(1H-tetrazol-5-yl)biphen-4-yl)methyl]1H-imidazole-5-carboxylate
Methyl 2-propyl-4-[2-(1-oxo-2,2,2-trifluoroethyl)-1H-pyrrol-1-yl]imidazole-5-carboxylate (15 g, 0.046 mol) from Example 6 was dissolved in DMF (500 mL) and Cs 2 CO 3 (32.9 g, 0.1 mol) added. After 5 minutes, N-triphenylmethyl-5-[4'-(bromomethyl)biphenyl-2-yl]tetrazole (Example 12, 26.9 g, 0.048 mol) was added and the reaction mixture stirred at room temperature for 6 hours. The reaction was filtered to remove insoluble salts and the DMF removed high vacuum. The residue was partitioned between ethyl acetate (150 mL) and water (50 mL). The organic layer was extracted with brine, dried over anhydrous magnesium sulfate, and the solvent evaporated under reduced pressure. Chromatography of the residue on silica gel, eluting with a gradient of ethyl acetate/hexane (1:4) to ethyl acetate/hexane (1:1) afforded 25 g of the title compound in its triphenylmethyl-protected form. The triphenylmethyl protecting group was removed by refluxing in methanol (280 mL) containing 10% aqueous citric acid (28 mL) for 4 hours. The reaction mixture was diluted with water (100 mL) and the milky solution extracted with several times with hexane. The aqueous layer was extracted with ethyl acetate and the combined organic layers extracted with brine. The organic layer was dried over anhydrous magnesium sulfate and the solvent removed under reduced pressure. The residue was recrystallized using Hexane/ethyl acetate (1:1) to afford 13.4 g of the title compound. MS (FAB, thioglycerol) 564(M+1), mp 135°-137° C.
EXAMPLE 14
4-[2-(1-Oxo-2,2,2-trifluoroethyl)-1H-pyrrol-1-yl]-2-propyl-1-[(2'-(1H-tetrazol-5-yl)biphen-4-yl)methyl]-1H-imidazole-5-carboxylic acid
4-[2-(1-Oxo-2,2,2-trifluoroethyl)-1H-pyrrol-1-yl]-2-propyl-1-[(2'-(1H-tetrazol-5-yl)biphen-4-yl)methyl]-1H-imidazole-5-carboxylate (2.5 g) from Example 13 was dissolved in DMF (45 mL). Water (0.4 mL) followed by potassium carbonate (3.1 g) were added and the reaction mixture stirred at room temperature for 48 hours. Tlc of the reaction mixture showed the reaction to be incomplete. Additional potassium carbonate (0.6 g) and water (0.2 mL) were added and the reaction mixture stirred at room temperature for an another 18 hours. The insoluble materials were removed from the reaction mixture by filtration and washed with DMF. A 10% citric acid solution (100 mL) was added slowly to the filtrate and the resulting mixture extracted with ethyl acetate. The organic layer was washed with brine, dried over anhydrous magnesium sulfate, and the solvent removed under reduced pressure. The residue was recrystallized from hexane/ethyl acetate to afford 2.06 g (85% yield) of the title compound, mp 185°-188° C., MS (FAB, thioglycerol) 550.3 (M+1).
EXAMPLE 15
2-Butyl-5-cyano-4-(1H-pyrrol-1-yl)-1-[(2'-(1H-tetrazol-5-yl)biphen-4-yl)methyl]-1H-imidazole
A solution of 2-butyl-5-cyano-4-(1H-pyrrol-1-yl)imidazole (Example 8, 1.7 g) in anhydrous tetrahydrofuran (20 mL) was treated with a solution of potassium tert-butoxide (0.97 g) in anhydrous tetrahydrofuran (20 mL) at room temperature. The mixture was stirred for 5 minutes then a solution of N-triphenylmethyl-5-[4'-(bromomethyl)biphenyl-2-yl]tetrazole (Example 12, 6.0 g) in anhydrous tetrahydrofuran (20 mL) was added. The reaction was stirred at room temperature under nitrogen atmosphere for 18 hours. The resulting suspension was filtered and the filtrate was evaporated. The residue was purified by flash chromatography on silica gel, eluting with chloroform hexane (90:10) to give the title compound in its triphenylmethyl-protected form. The triphenylmethyl protecting group was removed by refluxing in methanol for 24 hours. Evaporation gave a residue that was purified by chromatography on silica gel, eluting with a gradient of ethyl acetate-hexane (50:50) to ethyl acetate. Evaporation of solvents gave a gum that was redissolved in dichloromethane and evaporated to give the title compound as a solid foam. MS (FAB, thioglycerol) 470 (m+Na-1), 448 (m).
EXAMPLE 16
2-Butyl-4-(1H-pyrrol-1-yl)-1-[(2'-(1H-tetrazol-5-yl)biphen-4-yl)methyl]-1H-imidazole-5-carboxylic acid
A mixture of 2-butyl-5-cyano-4-(1H-pyrrol-1-yl)-1-[(2'-(1H-tetrazol-5-yl)biphen-4-yl)methyl]-1H-imidazole (Example 15, 1.4 g) and 2 N NaOH (75 mL) was heated at reflux for 24 hours. The cooled solution was acidified to pH 3.5 by portionwise addition of citric acid. The resulting precipitate was collected by filtration and rinsed well with water. The solid was then purified by C 18 -reversed phase chromatography eluting with acetonitrile-water (40:60). The majority of the acetonitrile was evaporated from the pure fractions at reduced pressure, keeping the temperature below 30° C. The remaining aqueous portion was washed with ethyl acetate and the organic layer was dried over anhydrous magnesium sulfate and evaporated. The residue was dissolved in ether and evaporated once again to give the title compound as a colorless powder. MS (FAB, thioglycerol) 468 (m+1), 424 (m-CO 2 +1).
EXAMPLE 17
2-Butyl-4-(1H-pyrrol-1-yl)-1-[(2'-(1H-tetrazol-5-yl)biphen-4-yl)methyl]-1H-imidazole
A suspension of 2-butyl-4-(1H-pyrrol-1yl)-1-[(2'-(1H-tetrazol-5-yl)biphen-4-yl)methyl]-1H-imidazole-5-carboxylic acid (Example 16, 50 mg) in toluene (10 mL) was heated at reflux for 1 hour. Evaporation gave a gummy solid that was redissolved in ether and evaporated again to give the title compound as a colorless powder. 1 H-NMR (CDCl 3 ) δ7.9 (d, 1H), 7.6 (m, 2H), 7.4 (d, 2H), 7.1 (d, 2H), 6.9 (d, 2H), 6.8 (s, 2H), 6.5 (s, 1H), 6.1 (s, 2H), 5.0 (s, 2H), 2.4 (t, 2H), 1.6 (m, 2H), 1.3 (m, 2H), 0.9 (t, 3H).
EXAMPLE 18
4-Amino-5-cyano-2-propylimidazole
Using the method of Example 7, trimethyl orthobutyrate was substituted for trimethyl orthovalerate to afford the title compound. Recrystallization from tert-butyl methyl ether gave analytically pure material, mp 117°-119° C. 1 H-NMR (DMSO-d 6 ) δ5.9 (br, 2H), 5.7 (br, 1H), 2.4 (m, 2H), 1.6 (m, 2H), 0.9 (t, 3H).
EXAMPLE 19
5-Cyano-2-propyl-4-(1H-pyrrol-1-yl)imidazole
4-Amino-5-cyano-2-propylimidazole (Example 18) was treated as in Example 8 to afford the title compound as a crystalline solid upon evaporation of chromatography solvents, mp 75°-78° C. 1 H-NMR (CDCl 3 ) δ10.1 (br, 1H), 7.4 (s, 2H), 6.4 (s, 2H), 2.7 (t, 2H), 1.8 (m, 2H), 1.0 (t, 3H).
EXAMPLE 20
Ethyl 4-amino-2 butylimidazole-5-carboxylate
A mixture of methyl iminovalerate hydrochloride (4.8 g), ethyl 2-amino-2-cyanoacetate oxalate (4.0 g), anhydrous sodium acetate (9.1 g) and absolute ethanol (75 mL) was stirred at room temperature for 18 hours. Solids were removed by filtration and the filtrate was evaporated. The residue was partitioned between ethyl acetate and water. The ethyl acetate layer was washed with saturated NaCl, dried over MgSO 4 , and evaporated. Flash chromatography on silica gel, eluting with a gradient of dichloromethane-ethyl acetate (75:25) to ethyl acetate gives the title compound (2.7 g) as a pale yellow solid, mp 103°-106° C. MS (DEI) 211 (m).
EXAMPLE 21
Ethyl 2-butyl-4-(1H-pyrrol-1-yl)imidazole-5-carboxylate
Ethyl 4-amino-2-butylimidazole-5-carboxylate (Example 20) was treated as in Example 8 to provide the title compound. Purification was achieved by flash chromatography on silica gel, eluting with dichloromethane-ethyl acetate (90:10), mp 74°-77° C. MS (CI, CH 4 ) 262 (m+1).
EXAMPLE 22
5-Cyano-2-propyl-4-(1H-pyrrol-1-yl)-1-(2'-(1H-tetrazol-5-yl)biphen-4-yl)methyl]-1H-imidazole
Using the method described in Example 15, 5-cyano-2-propyl-4 (1H-pyrrol-1-yl)imidazole (Example 19, 2.0 g), potassium tert-butoxide (1.2 g) and N-triphenylmethyl-5-[4'-(bromomethyl)biphenyl-2-yl]tetrazole (Example 12, 7.0 g) were reacted to give the title product in its triphenylmethyl-protected form after purification by chromatography. This material was dissolved in methanol (200 mL), treated with aqueous 10% citric acid (10 mL) and heated at reflux for 2.5 hours. The resulting solution was diluted with water (40 mL) and washed twice with hexanes. The methanol-water layer was evaporated and the residue was partitioned between ethyl acetate and water. The organic layer was dried over anhydrous magnesium sulfate and evaporated to a gum. This gum was dissolved in tert-butyl methyl ether and evaporated to a gum which was allowed to stand until seed crystals formed. Trituration with tert-butyl methyl ether gives the title compound as a crystalline solid, mp 179°-181° C. MS (CI, CH 4 +NH 3 ) 435 (m+1).
EXAMPLE 23
Ethyl 2-butyl-4-(1H-pyrrol-1-yl)-1-[(2'-(1H tetrazol-5-yl)biphen-4-yl)methyl]-1H-imidazole-5-carboxylate
Using the method described in Example 15, ethyl 2-butyl-4-(1H-pyrrol-1-yl)imidazole-5-carboxylate (Example 21) and N-triphenylmethyl-5-[4'-(bromomethyl)biphenyl-2-yl]tetrazole (Example 12) are reacted and deprotected to give the title compound.
EXAMPLE 24
2-Propyl-4-(1H-pyrrol-1-yl)-1-[(2'-(1H-tetrazol-5-yl)biphen-4-yl)methyl]-1H-imidazole-5-carboxylic acid
5-Cyano-2-propyl-4-(1H-pyrrol-1-yl)-1-[(2'-(1H-tetrazol-5-yl)biphen-4-yl)methyl]-1H-imidazole (Example 22, 2.2 g) was treated with 2N KOH (75 mL) and heated at reflux for 12 hours. The resulting solution was cooled on an ice bath and treated dropwise with concentrated aqueous HCl (8 mL) followed by dropwise addition of aqueous 10% citric acid (50 mL). The resulting precipitate was collected by filtration and then it was partitioned between ethyl acetate and 10% citric acid. The organic layer was washed with brine, dried over anhydrous magnesium sulfate and concentrated on a rotary evaporator, keeping the temperature below 25° C. to give a foam. This foam was dissolved in ether-CH 2 Cl 2 (1:1) and diluted to turbidity with hexanes. Evaporation of solvents as above gives the title compound as a colorless powder. MS (FAB, thioglycerol) 454 (m+1), 410 (m-CO 2 +1).
EXAMPLE 25
2-Propyl-4-(1H-pyrrol-1-yl)-1-[(2'-(1H-tetrazol-5-yl)biphen-4-yl)methyl]-1H-imidazole
Using the method described in Example 17, 2-propyl-4-(1H-pyrrol-1-yl)-1-[(2'-(1H-tetrazol-5-yl)biphenyl)methyl]imidazole-5-carboxylic acid (Example 24) is decarboxylated to give the title compound.
EXAMPLE 26
5-Cyano-4-[2-(1-oxo-2,2,2-trifluoroethyl)-1H-pyrrol-1-yl]-2-propylimidazole
A solution of the 5-cyano-2-propyl-4-(1H-pyrrol-1-yl)imidazole (Example 19, 2.2 g) in toluene (65 mL) was treated with trifluoroacetic anhydride (4.8 mL) and heated at reflux for 2 hours. After cooling to room temperature, the resulting solution was diluted with ethyl acetate (100 mL) and stirred vigorously with 10% K 2 CO 3 (100 mL) for 15 minutes. The organic layer was separated, dried over anhydrous magnesium sulfate and evaporated. The residual gum was purified by flash chromatography on silica gel, eluting with hexane-ethyl acetate (70:30) to afford an oil upon evaporation of solvents. This oil was dissolved in ether, and diluted gradually with hexanes to induce crystallization, affording the title compound as a colorless solid, mp 104°-105° C. 1 H-NMR (CDCl 3 ) δ7.3 (m, 2H), 6.5 (t, 1H), 2.6 (t, 2H), 1.7 (m, 2H), 0.9 (t, 3H). IR (CDCl 3 ) cm.sup. -1 2240 (CN), 1685 (CO).
EXAMPLE 27
5-Cyano-4-[2-(1-oxo-2,2,2-trifluoroethyl)-1H-pyrrol-1-yl]-2-propyl-1-[(2'-(1H-tetrazol-5-yl)biphen-4-yl)methyl]-1H-imidazole
N-triphenylmethyl-5-[4'-(bromomethyl)biphenyl-2-yl]tetrazole (Example 26, 2.1 g), 5-cyano-4-[2-(1-oxo-2,2,2-trifluoroethyl)-1H-pyrrol-1-yl]-2-propylimidazole (Example 18, 0.89 g), N,N-dimethylformamide (10 mL), and anhydrous K 2 CO 3 (0.5 g) were stirred at room temperature under nitrogen atmosphere for 24 hours. Ethyl acetate (50 mL) was added and inorganic solids were removed by filtration. The filtrate was evaporated at reduced pressure and the major product was isolated by flash chromatography on silica gel (toluene acetonitrile 96:4) to afford the title compound in its triphenylmethyl-protected form (1.3 g). This material was dissolved in methanol (50 mL), treated with aqueous 10% citric acid (1.5 mL) and heated at reflux for 90 minutes. After cooling to room temperature, water (10 mL) and hexanes (100 mL) were added and the mixture was shaken vigorously. The methanol layer was separated, washed again with hexanes and evaporated. The residue was partitioned between ethyl acetate and water. The ethyl acetate layer was dried over anhydrous magnesium sulfate and evaporated. The resulting gum was dissolved in ether, concentrated and allowed to stand overnight to give some seed crystals. The remaining gum was dissolved in tertbutyl methyl ether, seeded and diluted with diisopropyl ether. Crystallization gave the title product after filtration. MS (CI, CH 4 +NH 3 ) 531 (m+1).
EXAMPLE 28
5-Cyano-4-[2-(1-hydroxy-2,2,2-trifluoroethyl)-1H-pyrrol-1-yl]-2-propyl-1-[(2'-(1H-tetrazol-5-yl)biphen-4-yl)methyl]-1H-imidazole
A solution of 5-cyano-4-[2-(1-oxo-2,2,2-trifluoroethyl)-1H-pyrrol-1-yl]-2-propyl-1-[(2'-(1H-tetrazol-5-yl)biphen-4-yl)methyl]-1H-imidazole (Example 27, 300 mg) in ethanol (5 mL) was chilled to 10° C. and treated with NaBH 4 (30 mg). There was a period of rapid gas evolution then the reaction was stirred for 1 hour. Acetone (0.1 mL) was added and the reaction was stirred 10 minutes longer before partitioning between ethyl acetate and 10% citric acid (aq). The organic layer was washed with saturated aqueous NaCl, dried over MgSO 4 and evaporated. Flash chromatography on silica gel, eluting with CHCl 3 --CH 3 OHCH 3 CN (90:5:5) gives the title compound as a foam upon evaporation of solvents. The foam was triturated with hexane-diisopropyl ether (3:1) to give a colorless powder. MS (FAB, thioglycerol) 533 (m+1).
EXAMPLE 29
2-Butyl-5-(hydroxymethyl)-4 -(1H-pyrrol-1-yl)imidazole
A solution of ethyl 2-butyl-4-(1H-pyrrol-1-yl)imidazole-5-carboxylate (Example 21, 0.5 g) in tetrahydrofuran (15 mL) was treated with a 1 M solution of LiAlH 4 in ether (2.1 mL). The reaction was stirred overnight at room temperature then quenched by addition of saturated aqueous (NH 4 ) 2 SO 4 . The resulting suspension was extracted three times with ethyl acetate and the combined organic layers were dried over anhydrous magnesium sulfate and evaporated to afford the title compound as an off-white solid. MS (DEI) 205 (m).
EXAMPLE 30
5-Cyano-4-(2,5-dichloro-1H-pyrrol-1-yl)-2-propylimidazole
A mixture of 5-cyano-2-propyl-4-(1H-pyrrol-1-yl)imidazole (Example 19, 200 mg), N-chlorosuccinimide (270 mg) and tetrahydrofuran (4 mL) was stirred at room temperature for 24 hours. Evaporation of solvents, followed by flash chromatography on silica gel (hexane-ethyl acetate, 70:30) gives the title product. 1 H-NMR (CDCl 3 ) δ6.1 (s, 2H), 2.7 (t, 2H), 1.8 (m, 2H), 0.9 (t, 3H).
EXAMPLE 31
1-5-Carboxy-2-propyl-1-[(2'-(1H-tetrazol-5-yl)biphen-4-yl)methyl]-1H-imidazol-4-yl]-1H-pyrrole-2-carboxylic acid
Methyl 4-[2-(1-oxo-2,2,2-trifluoroethyl)-1H-pyrrol-1-yl]-2-propyl-1-[(2'-(1H-tetrazol-5-yl)biphen-4-yl)methyl]-1H-imidazole-5-carboxylate (Example 13, 0.8 g) was dissolved in a solution sodium hydroxide (1.68 g) in water (14 mL) and the resulting solution refluxed overnight. After cooling in an ice-bath, conc HCl was added dropwise until the pH of the mixture was between 3-4. The insoluble product was collected by filtration, washed several times with water, and dried under reduced pressure overnight at room temperature to afford 0.85 g of the title compound. 1 H-NMR (DMSO-d 6 ) δ7.8-7.5 (m, 4H), 7.3-7.0 (m, 5H), 6.9 (m, H), 6.3 (m, 1H), 5.7 (s, 2H), 2.6 (t, 2H), 1.7-1.4 (m, 2H), 0.9 (t, 3H).
EXAMPLE 32
2-Butyl-5-(hydroxymethyl)-4-(1H-pyrrol-1-yl)-1-[ (2'-(1H-tetrazol-5-yl)biphen-4-yl)methyl]-1H-imidazole
Using the method described in Example 13, 2-butyl-5-(hydroxymethyl)-4-(1H-pyrrol-1-yl)imidazole-5-carboxylate (Example 29) and N-triphenylmethyl-5-[4'-(bromomethyl)biphenyl-2-yl]tetrazole (Example 12) are reacted and deprotected to give the title compound.
EXAMPLE 33
5-Cyano-4-(2,5-dichloro-1H-pyrrol-1-yl)-2-propyl-1-[(2'-(1H-tetrazol-5-yl)biphen-4-yl)methyl]-1H-imidazole
Using the procedure from Example 13, 5-cyano-4-(2,5-dichloro-1H-pyrrol-1-yl)-2-propylimidazole (Example 30) and N-triphenylmethyl-5-[4'-(bromomethyl)biphenyl-2-yl]tetrazole (Example 12) are reacted and deprotected to give the title compound.
EXAMPLE 34
Methyl 1-(5-cyano-2-propylimidazol-4-yl)-1H-pyrrole-2-carboxylate
Using the method of Example 5, 4-amino-5-cyano-2-propylimidazole (Example 7) was reacted with methyl 2,5-dimethoxy-tetrahydrofuran-2-carboxylate to afford the title compound. 1 H-NMR 9.4 (br, 2H), 7.3 (m, 1H), 7.2 (m, 1 H), 6.4 (t, 1H), 3.8 (s, 3H), 2.7 (t, 2H), 1.8 (m, 2H), 1.0 (t, 3H).
EXAMPLE 35
Methyl 1-[5-cyano-2-propyl-1-[(2'-(1H-tetrazol-5-yl)biphen-4-yl)methyl]-1H-imidazol-4-yl]-1H-pyrrole-2-carboxylate
Using the procedure from Example 13, methyl 1-(5-cyano-2-propylimidazol-4-yl)-1H-pyrrole-2-carboxylate (Example 34) and N-triphenylmethyl-5-[4'-(bromomethyl)biphenyl-2-yl]tetrazole (Example 12) were reacted and deprotected to give the title compound. MS (CI, CH 4 +NH 3 ) 507(M+CH 3 ).
EXAMPLE 36
1-[5-Cyano-2-propyl-1-[(2'-(1H-tetrazol-5-yl)biphen-4-yl)methyl]-1H-imidazol-4-yl]-1H-pyrrole-2-carboxylic acid
A solution of methyl 1-[5-cyano-2-propyl-1-[(2'-(1e,uns/H/ -tetrazol-5-yl)biphen-4-yl)methyl]-1H-imidazol-4-yl]-1H-pyrrole-2-carboxylate (Example 35) in tetrahydrofuran-methanol (2:1) was treated with two equivalents of 1N NaOH at 0° C. The reaction mixture was stirred at reflux for 20 hours then treated with two equivalents of 1N HCl. The reaction mixture was then partitioned between ethyl acetate and brine and the organic layer is dried over MgSO 4 and evaporated to afford the title compound. MS (FAB, thioglycerol) 479 (M+1).
EXAMPLE 37
Methyl cylcopropylformimidate hydrochloride
Using an analogous procedure to that described in Example 1, but starting from cyclopropyl cyanide was obtained the title compound methyl cyclopropylimidate hydrochloride. 1 H-NMR (CDCl 3 ) 12.42 (br s, 1H), 11.28 (br. S, 1H), 4.21 (s, 3H), 2.42 (m, 1H), 1.23 (m, 4H).
EXAMPLE 38
Methyl N-cyanocyclopropylformimidate
Using an analogous procedure to that described in Example 2, but starting from methyl cyclopropylformimidate hydrochloride (Example 37) afforded the title compound methyl N-cyanocyclopropylformimidate. 1 H-NMR (CDCl 3 ) 3.80 (s, 3H), 2.27 (m, 1H), 1.19 (m, 4H).
EXAMPLE 39
Methyl N-(N'-cyano-cylcopropylformimidoyl)glycinate
Using an analogous procedure to that described in Example 3, but starting from methyl N-cyanocyclopropylformimidate (Example 38) was obtained the title compound methyl N-(N'-cyanocyclopropylformimidoyl)glycinate. 1 H-NMR (CDCl 3 ) 6.10 (br s, 1H), 4.04 (d, 2H), 3.79 (s, 3H), 2.18 (m, 1H), 1.12 (m, 4H).
EXAMPLE 40
Methyl 4-amino-2-cyclopropylimidazole-5-carboxylate
Using an analogous procedure to that described in Example 4, but starting from methyl N-(N'-cyanocylcopropylformimidoyl)glycinate (Example 39) was obtained the title compound methyl 4-amino-2-cyclopropylimidazole-5-carboxylate in 78% yield. MS (DEI) 181 (M + ) and 182(M+1).
EXAMPLE 41
Methyl 2-cyclopropyl-4-(2,5-dimethyl-1H-pyrrol-1-yl)imidazole-5-carboxylate
A suspension of methyl 4-amino-2-cyclopropylimidazole-5-carboxylate (Example 40, 5.72 g, 0.032 mol) in ethanol (40 mL) was treated with acetic acid (25 mL) and the mixture refluxed to effect solution. To the hot solution was added acetonylacetone (5.41 g, 0.047 mol) and the whole stirred and refluxed for 18 hours. The solvent was removed under reduced pressure and the residue purified by flash chromatography eluting with a gradient of CH 2 Cl 2 to 20% EtOAc in CH 2 Cl 2 to afford 7.93 g of the title compound methyl 2-cyclopropyl-4-(2,5-dimethyl-1H-pyrrol-1-yl)imidazole-5-carboxylate. 1 H-NMR (CDCl 3 ) 5.85 (s, 2H), 3.68 (s, 3H), 2.0 (s, 6H), 1.80-2.0 (m, 1H), 1.0-1.18 (m, 4H).
EXAMPLE 42
Methyl 2-cyclopropyl-4-(2-5-dimethyl-1H-pyrrol-1-yl)-1-[(2'-(1H-tetrazol-5 -yl)biphen-4-yl)methyl]-1H-imidazole-5-carboxylate
Using an analogous procedure to that described in Example 13, but starting from methyl 2-cyclopropyl-4-(2,5-dimethyl-1H-pyrrol-1-yl)imidazole-5-carboxylate (Example 41) was obtained the title compound methyl 2-cyclopropyl-4-(2,5-dimethyl-1H-pyrrol-1-yl)-1-[(2'-(1H-tetrazol- 5-yl)biphen-4-yl)methyl]-1H-imidazole-5-carboxylate. MS (CI, CH 4 +NH 3 ) 494(M + ).
EXAMPLE 43
2-Cyclopropyl-4-(2,5-dimethyl-1H-pyrrol-1-yl)-1-[(2'-(1H-tetrazol-5-yl)biphen-4-yl)methyl]-1H-imidazole-5-carboxylic acid
To a solution of methyl 2-cyclopropyl-4-(2,5-dimethyl-1H-pyrrol-1-yl)-1-[(2'-(1H-tetrazol-5-yl)biphen-4-yl)methyl]-1H-imidazole-5-carboxylate (Example 42, 1.91 g) in anhydrous THF was added potassium trimethylsilanolate (1.57 g) and the mixture stirred at ambient temperature for 20 hours. The solvent was removed under reduced pressure and the residue taken-up in water (25 mL). The aqueous solution was filtered and extracted with ethyl acetate. The aqueous layer was acidified to pH 4.5 with 1N HCl and extracted with ethyl acetate. The combined organic extracts were dried over anhydrous magnesium sulfate and evaporated to give the title compound 2-cyclopropyl-4-(2,5-dimethyl-1H-pyrrol-1-yl)-1-[(2'-(1H-tetrazol-5-yl)biphen-4-yl)methyl]-1H-imidazole-5-carboxylic acid. MS (CI, CH 4 +NH 3 ) 480 (M + ).
EXAMPLE 44
Methyl 4-(2-methyl-5-propyl-1H-pyrrol-1-yl)-2-propylimidazole-5-carboxylate
Using an analogous procedure to that described in Example 41, but starting from 2,5-octanedione was obtained the title compound methyl 4-(2-methyl-5-propyl-1H-pyrrol-1-yl)-2-propyl-imidazole-5-carboxylate. 1 H-NMR (CDCl 3 ) 5.90 (s, 2H), 3.70 (s, 3H), 2.75 (t, 2H), 2.30 (t, 2H), 2.0 (s, 3H), 1.90-1.70 (m, 2H), 1.58-1.35 (m, 2H), 0.98(t, 3H), 0.8 (t, 3H).
EXAMPLE 45
Methyl 4-(2-methyl-5-propyl-1H-pyrrol-1-yl)-2-propyl-1[(2'-(1H-tetrazol-5-yl)biphen-4-yl)methy]-1H-imidazole-5-carboxylate
Using an analogous procedure to that described in Example 13, but starting from methyl 4-(2-methyl-5-propyl-1H-pyrrol-1-yl)-2-propyl-imidazole-5-carboxylate (Example 44) was obtained the title compound methyl 4-(2-methyl-5-propyl-1H-pyrrol-1-yl)-2-propyl-1-[(2'-(1H-tetrazol-5-yl)biphen-4-yl)methyl]-1H-imidazole-5-carboxylate, mp 95°-101° C. MS (DEI) 523(M + ) 524(M+1).
EXAMPLE 46
4-(2-Methyl-5-propyl-1H-pyrrol-1-yl)-2propyl-1-[(2'-(1H-tetrazol-5-yl)biphen-4-yl)methyl]-1H-imidazole-5-carboxylic acid
Using an analogous procedure to that described in Example 43, but starting from methyl 4-(2-methyl-5-propyl-1H-pyrrol-1-yl)-2-propyl-1-[(2'-(1H-tetrazol-5-yl)biphen-4-yl)methyl]-1H-imidazole-5-carboxylate (Example 45) was obtained the title compound 4-(2-methyl-5-propyl-1H-pyrrol-1-yl)-2-propyl-1-[(2'-(1H-tetrazol-5-yl)biphen-4-yl) methyl]-1H-imidazole-5-carboxylic acid. MS (DEI) 523(M + ) 524(M+1).
EXAMPLE 47
Methyl 4-(2,5-dimethyl-1H-pyrrol-1-yl)-2-propylimidazole-5-carboxylate
Using an analogous procedure to that described in Example 41, but starting from methyl 4-amino-2-propylimidazol-5-carboxylate (Example 4) provided the title compound methyl 4-(2,5-dimethyl-1H-pyrrol-1-yl)-2-propyl-imidazole-5-carboxylate, mp 175°-176° C.
EXAMPLE 48
5-(Hydroxymethyl)-2-propyl-4-(2,5-dimethyl-1H-pyrrol-1-yl)imidazole
Using an analogous procedure to that described in Example 29, but starting from methyl 4-(2,5-dimethyl-1H-pyrrol-1-yl)-2-propyl-imidazole-5-carboxylate (Example 47) was obtained the title compound 5-(hydroxy-methyl)-2-propyl-4-(2,5-dimethyl-1H-pyrrol-1-yl)imidazole. MS (DEI) 233(M + ) 234(M+1).
EXAMPLE 49
4-(2,5-Dimethyl-1H-pyrrol-1-yl)-2-propylimidazole-5-carboxaldehyde
To a solution of 5-(hydroxy-methyl)-2-propyl-4-(2,5-dimethyl-1H-pyrrol-1-yl)imidazole (Example 48, 6.0 g, 0.026 mol) in dry THF (125 mL) was added MnO 2 (11.2 g, 0.13 mol) and the reaction mixture refluxed for 4 hours under an atmosphere of nitrogen. The reaction mixture was cooled, filtered through celite, and the resulting filtrate evaporated under reduced pressure. Purification by flash chromatography (silica; 2:1 hexane ethyl acetate) gave the title compound 4-(2,5-dimethyl-1H-pyrrol-1-yl)-2-propylimidazole-5-carboxaldehyde (4.5 g, 75%), mp 119°-121° C.
EXAMPLE 50
4-(2,5-Dimethyl-1H-pyrrol-1-yl)-2-propyl-1-[2'-(N-triphenylmethyl-tetrazol-5-yl)-1,1'-biphenyl-4-yl]methyl]-1H-imidazole-5-carboxaldehyde
A mixture of N-(triphenylmethyl)-5-[4'-(bromomethyl)-biphenyl-2-yl]tetrazole (Example 12, 9.66 g, 17.34 mmol), 4-(2,5-dimethyl-1H-pyrrol-1-yl)-2-propyl-1H-imidazole-5-carboxaldehyde (Example 49, 4.0 g, 17.4 mmol), and cesium carbonate (13 g, 40 mmol) in DMF (30 mL) was stirred under an atmosphere of dry nitrogen at room temperature overnight. The reaction mixture was poured over water (750 mL) and the resulting precipitate was collected by filtration. The solid was taken up in ethyl acetate and extracted with water, adjusting the pH of the aqueous layer to pH 8.9 by the addition of sodium bicarbonate. The organic layer was dried over MgSO 4 and evaporated to give the crude product as a mixture of regioisomers which were separated by flash chromatography (silica; 3:1 hexane/EtOAc). High Rf regioisomer: 4-(2,5-dimethyl-1H-pyrrol-1-yl)-2-propyl-1-[[2'-(N-triphenylmethyl-tetrazol-5-yl)-1,1'-biphenyl-4-yl]methyl]-1H-imidazole-5-carboxaldehyde. 1 H-NMR (DMSO-d 6 ) 5.62 (s, 2H, benzylic CH 2 ).
Analysis for C 46 H 41 N 7 O: Calc.: C, 78.05; H, 5.84; N, 13.85. Found: C, 77.64; H, 5.65; N, 13.65.
EXAMPLE 51
Methyl (E)-3-[4-(2,5-dimethyl-1H-pyrrol-1-yl)-2-propyl-1-[[2'-2-(triphenylmethyl)-2H-tetrazol-5-yl]-1,1'-biphenyl-4-yl]methyl-1H-imidazol-5-yl]-2-propenoate
A solution of 4-(2,5-dimethyl-1H-pyrrol-1-yl)-2-propyl-1-[[2'-(N-tri-phenylmethyl-tetrazol-5-yl)-1,1'-biphenyl-4-yl]methyl]-1H-imidazole-5-carboxaldehyde (Example 50, 5 g) and (carbomethoxymethylene)triphenylphosphorane (13 g) in toluene (50 mL) was heated at reflux for 30 minutes. The reaction mixture was cooled and filtered and the filtrate was concentrated on the rotovap. Purification of the residue by flash chromatography (silica; 2:1 hexane/EtOAc) gave the pure (E)-isomer (2.7 g) as an oil.
Analysis for C 49 H 45 N 7 O 2 : Calc.: C, 77.04; H, 5.94; N, 12.83. Found: C, 77.02; H, 5.76; N, 12.70.
EXAMPLE 52
Methyl (E)-3-[4-(2,5-dimethyl-1H-pyrrol-1-yl)-2-propyl-1-[[2'-(1H-tetrazol-5-yl)-1,1'-biphenyl-4-yl]methyl]-1H-imidazol-5-yl]-2-propenoate
A solution of methyl (E)-3-[4-(2,5-dimethyl 1H-pyrrol-1-yl)-2-propyl-1-[[2'-2-(tri-phenylmethyl)-2H-tetrazol-5-yl]-1,1'-biphenyl-4-yl]methyl]-1H-imidazol-5-yl]-2-propenoate (Example 51, 1.0 g) in 100 mL methanol was treated with 10% aqueous citric acid (20 mL) and the resulting mixture was heated at reflux for 30 minutes. The reaction mixture was cooled, diluted with 20 mL water and extracted with hexane. The methanol layer was collected and concentrated to 50 mL on the rotovap. It was diluted with water and the resulting precipitate was collected by filtration. Recrystallization from isopropyl ether gave pure deprotected tetrazole (490 mg), mp 212°-213° C.
Analysis for C 30 H 31 N 7 O 2 : Calc.: C, 69.08; H, 5.99; N, 18.80. Found: C, 69.24; H, 6.15; N, 18.59.
EXAMPLE 53
(E)-3-4-(2,5-Dimethyl-1H-pyrrol-1-yl)-2-propyl-1-[[2'-(1H-tetrazol-5-yl)-1,1'-biphenyl-4-yl]methyl]-1H-imidazol-5-yl]-2-propenoic acid
A solution of methyl (E)-3-[4-(2,5-dimethyl-1H-pyrrol-1-yl)-2-propyl-1-[[2'-(1H-tetrazol-5-yl)-1,1'-biphenyl-4-yl]methyl]-1H-imidazol-5-yl]-2-propenoate (Example 52, 1.55 g, 3 mmol), and potassium trimethylsilanolate (0.96 g, 7.5 mmol) in dry THF (80 mL) was stirred at room temperature for 3 hours under an atmosphere of dry nitrogen. The resulting precipitate was collected by filtration, air dried, and then dissolved in water (50 mL). The free acid was precipitated out by the addition of 1N HCl and collected by filtration giving (E)-3-[4-(2,5-dimethyl-1H-pyrrol-1-yl)-2-propyl-1-[[2'-(1H-tetrazol-5-yl)-1,1'-biphenyl-4-yl]methyl]-1H-imidazol-5-yl]-2-propenoic acid (1.3 g, 83%) as a partial hydrate, mp 144°-150° C.
Analysis for C 29 H 29 N 7 O 2 .0.7H 2 O: Calc.: C, 66.84; H, 5.90; N, 18.81. Found: C, 66.94; H, 5.82; N, 18.72.
EXAMPLE 54
5-(Hydroxymethyl)-2-propyl-4-(1H-pyrrol-1-yl)imidazole
Using an analogous procedure to that described in Example 29, but starting from methyl 2-propyl-4-(1H-pyrrol-1-yl)imidazol-5-carboxylate (Example 5) the title compound 5-(hydroxymethyl)-2-propyl-4-(1H-pyrrol-1-yl)imidazole was obtained, mp 155°-158° C.
EXAMPLE 55
2-Propyl-4-(1H-pyrrol-1-yl)-imidazole-5-carboxaldehyde
Using an analogous procedure to that described in Example 49, but starting from 5-(hydroxymethyl)-2-propyl-4-(1H-pyrrol-1-yl)imidazole (Example 54) was obtained the title compound 2-propyl-4-(1H-pyrrol-1-yl)-imidazole-5-carboxaldehyde, mp 118.5°-120° C.
EXAMPLE 56
4-(1H-Pyrrol-1-yl)-2-propyl-1-[[2'-(N-triphenylmethyltetrazol-5-yl)-1,1'-biphenyl-4-yl]methyl]-1H-imidazole-5-carboxaldehyde
Using an analogous procedure to that described in Example 50, but starting from 2-propyl-4-(1H-pyrrol-1-yl)-imidazole-5-carboxaldehyde (Example 55) was obtained the title compound 4-(1H-pyrrol-1-yl)-2-propyl-1-[[2'-(N-tri-phenylmethyl-tetrazol-5-yl)-1,1'-biphenyl-4-yl]methyl]1H-imidazole-5-carboxaldehyde which was used in the next step without further purification.
EXAMPLE 57
Ethyl (E)-3-[4-(1H-pyrrol-1-yl)-2-propyl-1-[[2'-2-(triphenylmethyl)-2H-tetrazol-5-yl]-1,1'-biphenyl-4-yl]methyl]-1H-imidazol-5-yl]-2-propenoate
Using an analogous procedure to that described in Example 51, but starting from 4-(1H-pyrrol-1-yl)-2-propyl-1-[[2'-(N-tri-phenylmethyl-tetrazol-5-yl)-1,1'-biphenyl-4-yl]methyl]-1H-imidazole-5-carboxaldehyde (Example 56) and (carbethoxymethylene)triphenylphosphorane was obtained the title compound ethyl (E)-3-[4-(1H-pyrrol-1-yl)-2-propyl-1-[[2'-2-(triphenylmethyl)-2H-tetrazol-5-yl]-1,1'-biphenyl-4-yl]methyl]-1H-imidazol-5-yl]-2-propenoate which was used directly in the next step.
EXAMPLE 58
Ethyl (E)-3-[4-(1H -pyrrol-1-yl)-2-propyl-1-[[2'-(1H-tetrazol-5-yl)-1,1'-biphenyl-4-yl]methyl]-1H-imidazol-5-yl]-2-propenoate
Using an analogous procedure to that described in Example 52, but starting from ethyl (E)-3-[4-(1H-pyrrol-1-yl)-2-propyl-1-[[2'-2-(triphenylmethyl)-2H-tetrazol-5-yl]-1,1'-biphenyl-4-yl]methyl]-1H-imidazol-5-yl]-2-propenoate (Example 57) afforded the title compound ethyl (E)-3-[4-(1H-pyrrol-1-yl)-2-propyl-1-[[2'-(1H-tetrazol-5-yl)-1,1'-biphenyl-4-yl]methyl]-1H-imidazol-5-yl]-2-propenoate which was hydrolyzed to the directly to the acid in the next step.
EXAMPLE 59
(E)-3-[4-(1H-Pyrrol-1-yl)-2-propyl-1-[[2'-(1H-tetrazol-5-yl)-1,1'-biphenyl-4-yl]methyl]-1H-imidazol-5-yl]-2-propenoic acid
Using an analogous procedure to that described in Example 53, but starting from ethyl (E)-3-[4-(1H-pyrrol-1-yl)-2-propyl-1-[[2'-(1H-tetrazol-5-yl)-1,1'-biphenyl-4-yl]methyl]-1H-imidazol-5-yl]-2-propenoate (Example 53) was obtained the title compound (E) 3-[4-(1H-pyrrol-1-yl)-2-propyl-1-[[2'-(1H-tetrazol-5-yl)-1,1'-biphenyl-4-yl]methyl]-1H-imidazol-5-yl]-2-propenoic acid. MS (FAB, thioglycerol) 480 (M+1) 588 (M+thioglycerol).
EXAMPLE 60
Ethyl (E)-2-methyl-3-[4-(1H-pyrrol-1-yl)-2-propyl-1-[[2'-2-(triphenylmethyl)-2H-tetrazol-5-yl]-1,1'-biphenyl-4-yl]methyl]-1H-imidazol-5-yl]-2-propenoate
Using an analogous procedure to that described in Example 51, but starting from 4-(1H-pyrro-1-yl)-2-propyl-1-[[2'-(N-tri-phenylmethyl-tetrazol 5-yl)-1,1'-biphenyl-4-yl]methyl]-1H-imidazole-5-carboxaldehyde (Example 56) and (carbethoxyethylidene)triphenylphosphorane was obtained the title compound ethyl (E)-2-methyl-3-[4-(1H-pyrrol-1-yl)-2-propyl-1-[[2'-2-(triphenylmethyl)-2H-tetrazol-5-yl]-1,1'-biphenyl-4-yl]methyl]-1H-imidazol-5-yl]-2-propenoate. MS (FAB, thioglycerol) 764(M+1).
EXAMPLE 61
Ethyl (E)-2-methyl-3-[4-(1H-pyrrol-1-yl)-2-propyl-1-[[2'-(1H-tetrazol-5-yl)-1,1'-biphenyl-4-yl]methyl]-1H-imidazol-5-yl]-2-propenoate
Using an analogous procedure to that described in Example 52, but starting from ethyl (E)-2-methyl-3-[4-(1H-pyrrol-1-yl)-2-propyl-1-[[2'-2-(triphenylmethyl)-2H-tetrazol-5-yl]-1,1'-biphenyl-4-yl]methyl]-1H-imidazol-5-yl]-2-propenoate (Example 60) afforded the title compound ethyl (E) 2-methyl-3-[4-(1H-pyrrol-1-yl)-2-propyl-1-[[2'-(1H-tetrazol 5-yl)-1,1'-biphenyl-4-yl]methyl]-1H-imidazol-5-yl]-2-propenoate. MS (CI, CH 4 +NH 3 ) 522(M+1).
EXAMPLE 62
(E)-2-Methyl-3-[4-(1H-pyrrol-1-yl)-2-propyl-1-[[2'-(1H-tetrazol-5 yl)-1,1'-biphenyl-4-yl]methyl]-1H-imidazol-5-yl]-2-propenoic acid
Using an analogous procedure to that described in Example 53, but starting from ethyl (E) 2-methyl-3-[4-(1H-pyrrol-1-yl)-2-propyl-1-[[2'-(1H-tetrazol-5-yl)-1,1'-biphenyl-4-yl]methyl]-1H-imidazol-5-yl]-2-propenoate (Example 61) was obtained the title compound (E)-2-methyl-3-[4-(1H-pyrrol-1-yl)-2-propyl-1-[[2'-(1H-tetrazol-5-yl)-1,1'-biphenyl-4-yl]methyl]-1H-imidazol-5-yl]-2-propenoic acid. MS (CI, CH 4 +NH 3 ) 494 (M+1).
EXAMPLE 63
4-(2,5-Dimethyl-1H-pyrrol-1-yl)-2-propyl-1-[[2'-(1H-tetrazol-5-yl)-1,1'-biphenyl-4-yl]methyl-1H-imidazole-5-carboxaldehyde
Prepared from 4-(2,5-dimethyl-1H-pyrrol-1-yl)-2-propyl-1-[[2'-(N-triphenylmethyl-tetrazol-5-yl)-1,1'-biphenyl-4-yl]methyl]-1H-imidazole-5-carboxaldehyde according to the procedure of Example 52. MS (EI, CH 4 +NH 3 ) 465 (M + ).
EXAMPLE 64
Methyl 4-(2-methyl-3-carboxymethyl-1H-pyrrol-1-yl)-2-propylimidazole-5-carboxylate
Using an analogous procedure to that described in Example 5, but starting from methyl 4-amino-2-propylimidazol-5-carboxylate (Example 4) and methyl 5-acetoxy-2-methyl-4,5-dihydrofuran-3-carboxylate (Synthetic Communications 20(13):1923-1929 (1990)) afforded the title compound methyl 4-(2-methyl-3-carboxymethyl-1H-pyrrol-1-yl)-2-propylimidazole-5-carboxylate, mp 161°-162° C.
Anal for C 15 H 19 N 3 O 4 : Calc.: C, 59.01; H, 6.27; N, 13.76. Found: C, 58.85; H, 6.44; N, 13.59. MS (CI, CH 4 +NH 3 ) 305 (M + ).
EXAMPLE 65
Methyl 4-(3-carboxymethyl-2-methyl-1H-pyrrol-1-yl)-2-propyl-1-[(2'-(2-triphenylmethyl-2H-tetrazol-5-yl)biphen-4-yl)methyl]-1H-imidazole-5-carboxylate
Using an analogous procedure to that described in Example 50, but starting from methyl 4-(2-methyl-3-carboxymethyl-1H-pyrrol-1-yl)-2-propylimidazole-5-carboxylate (Example 64) afforded the title compound methyl 4-(3-carboxymethyl-2-methyl-1H-pyrrol-1-yl)-2-propyl-1-[(2'-(2-triphenylmethyl-2H-tetrazol-5-yl)biphen-4-yl)methyl]-1H-imidazole-5-carboxylate. MS (FAB, thioglycerol) 782 (M + ).
EXAMPLE 66
Methyl 4-(3-carboxymethyl-2-methyl-1H-pyrrol-1-yl)-2-propyl-1-[(2'-(1H-tetrazol-5-yl)biphen-4-yl)methyl]-1H-imidazole-5-carboxylate
Using an analogous procedure to that described in Example 52, but starting from methyl 4-(3-carboxymethyl-2-methyl-1H-pyrrol-1-yl)-2-propyl-1-[(2'-(2-triphenylmethyl-2H-tetrazol-5-yl)biphen-4-yl)methyl]-1H-imidazole-5-carboxylate (Example 65) afforded the title compound methyl 4-(3-carboxymethyl-2-methyl-1H-pyrrol-1-yl)-2-propyl-1-[(2'-(1H-tetrazol-5-yl)biphen-4-yl)methyl]-1H-imidazole-5-carboxylate. MS (CI, CH 4 +NH 3 ) 540 (M + ).
EXAMPLE 67
4-(3-Carboxymethyl-2-methyl-1H-pyrrol-1-yl)-2-propyl-1-[(2'-(1H-tetrazol-5-yl)biphen-4-yl)methyl]-1H-imidazole-5-carboxylic acid and 4-(3-carboxy-2-methyl-1H-pyrrol-1-yl)-2-propyl-1-[(2'-(1H-tetrazol-5-yl)-biphen-4-yl)methyl]-1H-imidazole-5-carboxylic acid
To a solution of methyl 4-(3-carboxymethyl-2-methyl-1H-pyrrol-1-yl) 2-propyl-1-[(2'-(1H-tetrazol-5-yl)biphen-4-yl)methyl]-1H-imidazole-5-carboxylate (Example 66, 1.98 g) in methanol (10 mL) was added 2N KOH (4.5 mL) and the reaction mixture heated under reflux for 4 hours. The solvent was diluted with water and acidified with 1N HCl and the crude mixture of products collected by filtration. Purification by chromatography over silica gel eluting with CH 2 Cl 2 /MeOH/AcOH (9/1/0.1) afforded two products in order of elution:
A) 4-(3-carboxymethyl-2-methyl-1H-pyrrol-1-yl)-2-propyl-1-[(2'-(1H-tetrazol-5-yl)biphen-4-yl)methyl]-1H-imidazole-5-carboxylic acid (0.5 g). MS (CI, CH 4 +NH 3 ) 482 (m-CO 2 ).
B) 4-(3-carboxy-2-methyl-1H-pyrrol 1-yl)-2-propyl-1-[(2'-(1H-tetrazol-5-yl)biphen-4-yl)methyl]-1H-imidazole-5-carboxylic acid (1.05 g). MS (FAB, thioglycerol) 512 (M + ).
EXAMPLE 68
Methyl 4-(2,5-dimethyl-1H-pyrrol-1-yl)-2-propylimidazole-5-carboxylate
Using an analogous procedure to that described in Example 41, but starting from methyl 4-amino-2-propylimidazol-5-carboxylate (Example 4) was obtained the title compound methyl 4-(2,5-dimethyl-1H-pyrrol-1-yl)-2-propylimidazole-5-carboxylate.
Anal for C 14 H 19 N 3 O 2 : Calc.: C, 64.35; H, 7.33; N, 16.08. Found: C, 64.64; H, 7.52; N, 16.08.
MS (CI, CH 4 +NH 3 ) 261 (M + ).
EXAMPLE 69
Methyl 4-(2,5-dimethyl-1H-pyrrol-1-yl)-2-propyl-1-[2'-(2-triphenylmethyl-2H-tetrazol-5-yl)biphen-4-yl)methyl]-1H-imidazole-5-carboxylate
Using an analogous procedure to that described in Example 50, but starting from methyl 4-(2,5-dimethyl-1H-pyrrol-1-yl)-2-propylimidazole-5-carboxylate (EXAMPLE 68) afforded the title compound methyl 4-(2,5-dimethyl-1H-pyrrol-1-yl)-2-propyl-1-[(2'-(2-triphenylmethyl-2H-tetrazol-5-yl)biphen-4-yl)methyl]-1H-imidazole-5-carboxylate. MS (FAB, thioglycerol) 738 (M + ).
EXAMPLE 70
Methyl 4-(2,5-dimethyl-1H-pyrrol-1-yl)-2-propyl-1-[(2'-(1H-tetrazol-5-yl)biphen-4-yl)methyl]-1H -imidazole-5-carboxylate
Using an analogous procedure to that described in Example 50, but starting from methyl 4 (2,5-dimethyl-1H-pyrrol-1-yl)-2-propyl-1-[(2'-(2-triphenylmethyl-2H-tetrazol-5-yl)biphen-4-yl)methyl]-1H-imidazole-5-carboxylate (Example 69) was obtained the title compound methyl 4-(2,5-dimethyl-1H-pyrrol-1-yl)-2-propyl-1-[(2'-(1H-tetrazol-5-yl)biphen-4-yl)methyl]-1H-imidazole-5-carboxylate.
Anal for C 28 H 29 N 7 O 2 .CH 3 OH: Calc.: C, 66.02; H, 6.30; N, 18.58. Found: C, 65.93; H, 5.92; N, 18.25.
MS (FAB, thioglycerol) 496 (M + ).
EXAMPLE 71
4-(2,5-Dimethyl-1H-pyrrol-1-yl)-2-propyl-1-[(2'-(1H-tetrazol-5-yl)biphen-4-yl)methyl]-1H-imidazole-5-carboxylic acid
A mixture of methyl 4-(2,5-dimethyl-1H-pyrrol-1-yl)-2-propyl-1-[(2'-(1H-tetrazol-5-yl)biphen-4-yl)methyl]1H-imidazole-5-carboxylate 9 (Example 70) in methanol (5 mL) containing 5 mL of 2.5N NaOH was heated under reflux for 3 hours. The reaction mixture was cooled, acidified with 10% citric acid to pH 4, and extracted with ethyl acetate. The combined organic layers were dried over anhydrous MgSO 4 and the solvent removed under reduced pressure. The acid was further purified by flash chromatography on silica gel eluting with 5% methanol in ethyl acetate to furnish 0.2 g for the title compound 4-(2,5-dimethyl-1H-pyrrol-1-yl)-2-propyl-1-[(2'-(1H-tetrazol-5-yl)biphen-4-yl)methyl]-1H-imidazole-5-carboxylic acid. MS (FAB, thioglycerol) 482 (M + ).
EXAMPLE 72
Methyl 4-(3-carboxyethyl-1H-pyrrol-1-yl)-2-propylimidazole-5-carboxylate
Using an analogous procedure to that described in Example 5, but starting from methyl 4-amino-2-propylimidazol-5-carboxylate (Example 4) and 3-carboethoxy-2,5-dimethoxytetrahydrofuran (prepared by the method of Niels Clauson-Kaas, Acta Chem. Scand. 6:556-559 (1952)) afforded the title compound methyl 4-(3-carboxyethyl-1H-pyrrol-1-yl)-2-propylimidazole-5-carboxylate. MS (CI, CH 4 +NH 3 ) 305 (M + ) 306 (M+1).
EXAMPLE 73
Methyl 4-(3-carboxyethyl-1H-pyrrol-1 yl)-2-propyl-1-[(2'-(1H-tetrazol-5-yl)biphen-4-yl)methyl]-1H-imidazole-5-carboxylate
Using an analogous procedure to that described in Example 13, but starting from 4-(3-carboxyethyl-1H-pyrrol-1-yl)-2-propylimidazole-5-carboxylate (Example 72) afforded the title compound methyl 4-(3-carboxyethyl-1H-pyrrol-1-yl)-2-propyl-1-[(2'-(1H-tetrazol-5-yl)biphen-4-yl)methyl]-1H-imidazole-5-carboxylate.
Anal for C 29 H 29 N 7 O 2 : Calc.: C, 64.55; H, 5.42; N, 18.17. Found: C, 64.68; H, 5.35; N, 18.56.
MS (CI, CH 4 +NH 3 ) 539 (M + ).
EXAMPLE 74
4-(3-Carboxyethyl-1H-pyrrol-1-yl)-2-propyl-1-[(2'-(1H-tetrazol-5-yl)biphen-4-yl)methyl]-1H-imidazole-5-carboxylic acid
A solution of methyl 4-(3-carboxyethyl-1H-pyrrol-1-yl)-2-propyl-1-[(2'-(1H-tetrazol 5-yl)biphen-4-yl)methyl]-1H-imidazole-5-carboxylate (Example 73, 0.2 g) in ethanol (2.5 mL) and water (1.25 mL) was treated with lithium hydroxide (0.17 g) ant the reaction mixture stirred a room temperature for 3 days. The reaction mixture was diluted with water, extracted with ether, and the aqueous layer acidified to pH 2 with 1N HCl. The cloudy solution was extracted with ether and the combined organic layers dried over anhydrous magnesium sulfate. The solvent was evaporated under reduced pressure and the residue taken-up in ethyl acetate. Petroleum ether was added dropwise to precipitate the product which was collected by filtration to yield 0.11 g of the title compound 4-(3-carboxyethyl-1H-pyrrol-1-yl)-2-propyl-1-[(2'-(1H-tetrazol-5-yl)biphen-4-yl)methyl]-1H-imidazole-5-carboxylic acid. MS (CI, CH 4 +NH 4 ) 410 (M-CO 2 H, --CO 2 Et).
EXAMPLE 75
4-(3-Carboxy-1H-pyrrol-1-yl)-2-propyl-1-[(2'-(1H-tetrazol-5-yl)biphen-4-yl)methyl]-1H-imidazole-5-carboxylic acid
Using an analogous procedure to that described in Example 71, but starting from methyl 4-(3-carboxyethyl-1H-pyrrol-1-yl)-2-propyl-1-[(2'-(1H-tetrazol-5-yl)biphen-4-yl)methyl]-1H-imidazole-5-carboxylate (Example 73) afforded the title compound 4-(3-carboxy-1H-pyrrol-1-yl)-2-propyl-1-[(2'-(1H-tetrazol-5-yl)biphen-4-yl)methyl]-1H-imidazole-5-carboxylic acid. MS (CI, CH 4 +NH 4 ) 410 (M-2CO 2 H).
EXAMPLE 76
4-(2,5-Dimethyl-1H-pyrrol-1-yl]-5-(hydroxymethyl)-2-propyl-1-[(2'-(2-triphenylmethyl-2H-tetrazol-5-yl)biphen-4-yl)methyl]-1H-imidazole
To a solution of methyl 4-(2,5-dimethyl-1H-pyrrol-1-yl)-2-propyl-1-[(2'-(2-triphenyl-methyl-2H-tetrazol-5-yl)biphen-4-yl)methyl]-1H-imidazole-5-carboxylate (Example 69, 1.0 g) in THF (12 mL) was added dropwise 1.5 mL of a 1M solution of LAH in ether. The reaction mixture was stirred overnight then quenched with aqueous ammonium sulfate. The resulting suspension was filtered and the insoluble material washed with hot ethyl acetate. The filtrate was separated and the organic layer extracted with brine. The organic layer was dried over anhydrous magnesium sulfate and evaporated under reduced pressure. The crude product was purified by flash chromatography eluting with 5% acetone in CH 2 Cl 2 to afford title compound 4-(2,5-dimethyl-1H-pyrrol-1-yl)-5-(hydroxymethyl)-2-propyl-1-[(2'-(2-triphenylmethyl-2H-tetrazol-5-yl)biphen-4-yl)methyl]-1H-imidazole, mp 185°-186° C.
EXAMPLE 77
4-(2,5-Dimethyl-1H-pyrrol-1-yl)-5-(hydroxymethyl)-2-propyl-1 -[(2'-(1H-tetrazol-5-yl)biphen-4-yl)methyl)-1H-imidazole
Using an analogous procedure to that described in Example 52, but starting from 4-(2,5-dimethyl-1H-pyrrol-1-yl)-5-(hydroxymethyl)-2-propyl-1-[(2'-(2-triphenylmethyl-2H-tetrazol-5-yl)biphen-4-yl)methyl]-1H-imidazole (Example 76) was obtained the title compound 4-(2,5-dimethyl-1H-pyrrol-1-yl)-5-(hydroxymethyl)-2-propyl-1-[(2'-(1H-tetrazol-5-yl)biphen-4-yl)methyl]-1H-imidazole.
EXAMPLE 78
Methyl 2-propyl-4-(2,5-dichloro-1H-pyrrol-1-yl)imidazole-5-carboxylate
Using an analogous procedure to that described in Example 30, but starting from methyl 2-propyl-4-(1H-pyrrol-1-yl)imidazole-5-carboxylate (Example 5) was obtained the title compound methyl 2-propyl-4-(2,5-dichloro-1H-pyrrol-1-yl)imidazole-5-carboxylate.
EXAMPLE 79
Methyl 4-(2,5-dichloro-1H-pyrrol-1-yl)-2-propyl-1-[(2'-(1H tetrazol-5-yl)biphen-4-yl)methyl]-1H -imidazole-5-carboxylate
Using an analogous procedure to that described in Example 13, but starting from methyl 2-propyl-4-(2,6-dichloro-1H-pyrrol-1-yl)imidazole-5-carboxylate (Example 77) was obtained the title compound methyl 4-(2,5-dichloro-1H-pyrrol-1-yl)-2-propyl-1-[(2'-(1H-tetrazol-5-yl)biphen-4-yl)methyl]-1H-imidazole-5-carboxylate.
EXAMPLE 80
4-(2,5-Dichloro-1H-pyrrol-1-yl)-2-propyl-1-[(2'-(1H-tetrazol-5-yl)biphen-4-yl)methyl]-1H-imidazole-5-carboxylic acid
Using an analogous procedure to that described in Example 14, but starting from methyl 4-(2,5-dichloro-HH-pyrrol-1-yl)-2-propyl-1-[(2'-(1H-tetrazol-5-yl)biphen-4-yl)methyl]-1H-imidazole-5-carboxylate (Example 79) was obtained the title compound 4-(2,5-dichloro-1H-pyrrol-1-yl)-2-propyl-1-[(2'-(1H-tetrazol-5-yl)biphen-4-yl)methyl]-1H-imidazole-5-carboxylic acid.
EXAMPLE 81
Methyl 2-butyl-4-[2-(1-oxo-2,2,2-trifluoroethyl)-1H-pyrrol-1-yl]-1-[(2'-(1H-tetrazol-5-yl)biphen-4-yl)methyl]-1H-imidazole-5-carboxylate
Using an analogous procedure to that described in Example 13, but starting from methyl 2 butyl-4-[2-(1-oxo-2,2,2-trifluoroethyl)-1H-pyrrol-1-yl]imidazol-5-carboxylate was obtained the title compound methyl 2-butyl-4-[2-(1-oxo-2,2,2-trifluoroethyl)-1H-pyrrol-1-yl]-1-[(2'-(1H-tetrazol-5-yl)biphen-4-yl)methyl]-1H-imidazole-5-carboxylate, mp 91°-96° C. MS (CI, CH 4 +NH 3 ) 592 (M+CH 3 ).
EXAMPLE 82
2-Butyl-4-[2-(1-oxo-2,2,2-trifluoroethyl)-1H-pyrrol-1-yl]-1-[(2'-(1H-tetrazol-5-yl)biphen-4-yl)methyl]-1H-imidazole-5-carboxylic acid
Using an analogous procedure to that described in Example 14, but starting from methyl 2-butyl-4-[2-(1-oxo-2,2,2-trifluoroethyl)-1H-pyrrol-1-yl]-1-[(2'-(1H-tetrazol-5-yl)biphen-4-yl)methyl]-1H-imidazole-5-carboxylate (Example 81) was obtained the title compound 2-butyl-4-[2-(1-oxo-2,2,2-trifluoroethyl)-1H-pyrrol-1-yl]-1-[(2'-(1H-tetrazol-5-yl)biphen-4-yl)methyl]-1H-imidazole-5-carboxylic acid, mp 160°-173° C. MS (FAB, thioglycerol) 564(M+1).
EXAMPLE 83
6-[[[2-Propyl-1-[[2'-(1H-tetrazol 5-yl)-[1,1'-biphenyl]-4-yl]methyl]-4-[(2-triflouroacetyl)-1H-pyrrol-1-yl]-1H-imidazol-5-yl]carbonyl]amino]hexanoic acid
A quantity of 0.72 g (1.0 mmol) of 1,1-Dimethylethyl 6-[[[2-propyl-1-[[2'-(1H-tetrazol-5-yl)[1,1'-biphenyl]-4-yl]methyl]-4-[(2-trifluoracetyl)-1H-pyrrol-1-yl]-1H-imidazol-5-yl]carbonyl]amino]hexanoate is added to a solution of 0.062 g (0.5 mmol) of thioanisole and 4.0 mL of trifluoroacetic acid (TFA). The resulting solution is allowed to stand for 3 hours at room temperature. The TFA is distilled at reduced pressure. Water (10 ml) is added to the residue and the separated gum is extracted into 30 mL of CH 2 Cl 2 . The solution is dried (MgSO 4 ), filtered, and concentrated. The residual gum is trituated with 15 mL of warm ether. The resulting solid is filtered and washed with ether; weight 0.50 g of crude product. Silica gel chromatography, eluting from 2% to 10% methanol in chloroform, gives 0.25 g of pure product; tlc (1:10 MeOH-CHCl 3 ) one spot Rf 0.2 to 0.3. Recrystallizing from ethyl acetate gives crystals; mp 171°-173°; MS (CI) 663 (M+1).
Anal. for C 33 H 33 F 3 N 8 O 4 . 0.5H 2 O. 0.2EtOAc: Calcd.: C, 58.89; H, 5.21; N, 16.25. Found: C, 59.18; H, 5.38; N, 16.06.
EXAMPLE 84
1,1-Dimethylethyl 6-[[[2-propyl-1-[μ2'-(1H-tetrazol-5-yl)-[1,1'-biphenyl]-4-yl]methyl]-4-[(2-trifluoracetyl)-1H-pyrrol-1-yl]-1H-imidazol-5-yl]carbonyl]amino]hexanoate
A solution of 0.378 g (1.8 mmol) of dicyclohexylcarbodiimide in 1.0 mL of DMF is added to a solution of 0.972 g (1.80 mmol) of 4-[2-(1-Oxo-2,2,2-trifluoroethyl)-1H-pyrrol-1-yl]-2-propyl-1-[(2'-(1H-tetrazol-5-yl)biphen-4-yl)methyl]-1H-imidazole-5-carboxylic acid, 0.252 g (1.80 mmol) of 1-hydroxybenzotriazole hydrate and 0.375 g (2.00 mmol) of ε-aminocaproic acid, t-butyl ester in 6.0 mL of DMF. The dicyclohexylurea separates immediately. The mixture is allowed to stand at room temperature overnight. The DCU is filtered and washed with 2 mL of DMF. Ice water (100 mL) is added to the filtrate to precipitate a tacky solid that was filtered. The crude product is dissolved in 100 mL of CH 2 Cl 2 and the solution is washed with water, dried (Na 2 SO 4 ), filtered, and concentrated. The residue is chromatographed (silica gel) eluting with 5% methanolchloroform to obtain 0.90 g of pure crystalline product; mp 171°-174° C.; tlc (1:10 MeOH-CHCl 3 ) one spot Rf 0.4; MS (FAB, thioglycerol) 719.4 (M+1).
Anal. for C 33 H 41 F 3 N 8 O 4 : Calcd.: C, 61.83; H, 5.75; N, 15.59. Found: C, 61.69; H, 5.86; N, 15.25.
EXAMPLE 85
1,1-Dimethylethyl 4-[[[2-propyl-1-[[2'-(1H-tetrazol-5-yl)-[1,1-biphenyl]-4-yl]methyl]-4-[(2-trifluoroacetyl)-1H-pyrrol-1-yl]-1H-imidazol-5-yl]carbonyl]amino]butanoate.
A mixture of 0.108 g (0.2 mmol) of 4-[2-(1-oxo-2,2,2-trifluoroethyl)-1H-pyrrol-1-yl]-2-propyl-1-[(2'-(1H-tetrazol-5-yl)biphen-4-yl)methyl]-1H-imidazole-5-carboxylic acid, 0.042 g (0.20 mmol) of DCC, 0.028 g (0.20 mmol) of 1-hydroxy-benzotriazole hydrate and 0.36 g (0.20 mmol) of β-alanine, t-butyl ester, hydrochloride is added to 1.0 mL of DMF to dissolve. Solid immediately begins to separate. Triethylamine (0.20 g, 0.20 mmol) is added and the mixture is allowed to stand at room temperature for 3 days. The solids are filtered and washed with 0.5 mL of DMF. Water (15 mL) is added to the filtrate to precipitate 0.11 g of solid. Recrystallization from ethyl acetate gives pure product; mp 178°-183° C.; tlc (1:10 MeOH-CHCl 3 ) one spot, Rf 0.4; MS (FAB, thioglycerol) 677.3 (M+1).
Anal. for C 34 H 33 F 3 N 8 O 4 : Calcd.: C, 60.35; H, 5.21; N, 16.56. Found: C, 60.52; H, 5.33; N, 16.08.
EXAMPLE 86
Step 1: 2-Propyl-4-[2-(trifluoroacetyl)-1H-pyrrol-1-[[2'-[2-(triphenylmethyl)-2H-tetrazol-5-yl][1,1'-biphenyl]-4-yl]methyl-1H-imidazole-5-carboxylic acid
A suspension of 1.00 g (1.24 mmol) of methyl 2-propyl-4-[2-(trifluoroacetyl)-1H-pyrrol-1-yl]-1-[[2'-[2-(triphenylmethyl)-2H-tetrazol-5-yl][1,1'-biphenyl]-4-yl]-1H-imidazole-5-carboxylate in 20 mL of MeOH is treated with a solution of 0.23 g NaOH in 2 mL of water. The mixture is heated at reflux for 8 hours. The resulting solution is evaporated. The residue is treated with 5 mL of water and extracted with ether. The aqueous phase is acidified to pH 3 with 1N HCl and the separated gum is extracted with ether. Evaporation affords 0.56 g of crude which is used directly in the next step.
Step 2: N-[6-[[2-(4-hydroxyphenyl)ethyl]amino]-6-oxohexyl]-2-propyl-4-[2-(trifluoroacetyl)-1H-pyrrol-1-yl]-1-[[2'-(triphenylmethyl)-2H-tetrazol-5-yl][1,1'-biphenyl]-4-yl] methyl]-1H-imidazole-5-carboxamide
A solution of 0.56 g (0.76 mmol) of 2-propyl-4-[2-(trifluoroacetyl)-1H-pyrrol-1-[[2'-[2-(triphenylmethyl)-2H-tetrazol-5-yl][1,1'-biphenyl]-4-yl]methyl-1H-imidazole-5-carboxylic acid in 5 mL of DMF is treated with 0.10 g (0.74 mmol) of 1 hydroxy. benzotriazole hydrate and then 0.16 g (0.77 mmol) of DCC. The mixture is stirred at room temperature under nitrogen for 30 minutes. The suspension is treated with 0.20 g (0.80 mmol) of 6-amino-N-[2-(4-hydroxyphenyl)ethyl]hexanamide and stirred at room temperature overnight. The mixture is filtered, washed with EtOAc, and the solvents evaporated. The residue is extracted again with EtOAc, filtered, and evaporated. The remaining oil is purified by silica gel chromatography, eluting the CHCl 3 /MeOH (95:5) to give 0.4 g (52%) of a light yellow solid foam; HPLC (Beckmann 4.6×250 mm C 18 column eluted at 1.5 mL/min with 55:45 0.1%TFA-H 2 O/MeCN, detection at 214 nM) R. T. 9.29 minutes, 99.7%; MS (FAB, thioglycerol) 782 (M--CPh 3 ).
Step 3: N-[6-[[2-(4-hydroxyphenyl)ethyl]amino]-6-oxohexyl]-2-propyl-1-[[2'-(2H-tetrazol-5-yl)[1,1'-biphenyl]-4 yl]methyl]-4-[2-(trifluoroacetyl)-1H-pyrrol-1-yl]-1H-imidazole-5-carboxyamide
A solution of 0.40 g (0.39 mmol) of N-[6-[[2-(4-hydroxyphenyl)ethyl]amino]-6-oxohexyl]-2-propyl-4-[2-(trifluoroacetyl)-1H pyrrol-1-yl]-1-[[2'-(triphenylmethyl)-2H-tetrazol-5-yl][1,1'-biphenyl]-4-yl]methyl]-1H-imidazole-5-carboxamide in 40 mL of MeOH and 2 mL of 10% aqueous citric acid is heated at reflux overnight. The reaction mixture is cooled to room temperature, diluted with 10 mL of water, and extracted with hexane. The aqueous MeOH phase is concentrated to ca. 10 mL volume and partitioned between EtOAc and water. The organic phase is dried (MgSO 4 ) and evaporated. The residue is purified via silica gel chromatography by eluting with 9:1 CHCl 3 -MeOH to give 0.28 g of solid foam: HPLC (55:45 0.1% TFA-H 2 O/MeCN, 1.5 mL/min flow rate, 214 nm) R. T. 9.44 minute, 99.5% purity; MS (FAB, thioglycerol) 782 (M+ 1), 548 [M-(CH 2 ) 5 CONH(CH 2 ) 2 Ph(4-OH)].
EXAMPLE 87
6-(Benzyloxycarbonylamino)-N-[2-(4-hydroxyphenyl)ethyl]hexanamide
A mixture of 0.84 g (3.01 mmol) of N-carbobenzyloxy-ε-aminocaproic acid, 0.39 g (2.89 mmol) of 1-hydroxybenzotriazole hydrate, and 0.59 g (2.86 mmol) of DCC in 3 mL of acetonitrile and 6 mL of DMF is stirred at room temperature under nitrogen for 20 minutes. A quantity of 0.50 g (2.88 mmol) of tyramine hydrochloride followed by 0.40 mL (2.88 mmol) of triethylamine are added and the mixture is stirred for 2 days at room temperature. The mixture is filtered and the filtrate is evaporated. The residue is taken-up into EtOAc, refiltered, and evaporated to give a yellow oil. Purification via silica gel chromatography eluting with 9:1 CHCl 3 -MeOH gives crystalline product; wt 0.98 g (88%); mp 107.8°-108.4° C.; MS (CI) 385 (M+1).
EXAMPLE 88
6-Amino-N-[2-(4-hydroxyphenyl)ethyl]hexanamide
A mixture of 0.50 g (1.30 mmol) of the carbobenzyloxy derivative of 6-amino-N-[2-(4-hydroxyphenyl)ethyl]hexanamide, 75 mL of methanol, and 0.10 g of 20% palladium-on-carbon catalyst is hydrogenated at low pressure for 35 minutes. After filtration the solution is concentrated to give a white glassy solid; weight, 0.35 g; tlc (MeOH) Rf 0.13 (I 2 stain). | Novel substituted 4-(1-H-pyrrol-1-yl)imidazoles are disclosed as well as methods of preparing them, pharmaceutical compositions containing them, and methods of using them. Novel intermediates useful in the preparation of the compounds of the invention are also disclosed and synthetic methods for preparing the novel intermediates. The compounds are useful as antagonists of angiotensin II and thus are useful in the control of hypertension, hyperaldosteronism, congestive heart failure, glaucoma, vascular smooth muscle proliferation associated with atherosclerosis, and with postsurgical vascular restenosis. | 2 |
BACKGROUND OF THE INVENTION
The present invention is directed to a dental patient chair having an adjustable headrest that is pivotably hinged to a bracing member around a first transverse axis and the bracing member is adjustable in a longitudinal direction of the backrest, the headrest is pivotably connected to a link at an offset second axis, so that the first transverse axis forms a lever arm together with the second axis and an application of either tensile or compressive forces by an adjustment arrangement to the link causes a pivoting of the headrest.
Taking ergonomic perceptions into consideration, a design of a dental treatment chair occurs in view of adapting the motion sequence of the headrest of the dental treatment chair to the natural nodding motion that the head of a patient situated in the dental treatment chair executes when the head is brought into various treatment positions. This is particularly difficult to implement for the two extreme positions, namely the extreme "extension position" on the one hand, wherein the head and, thus, the headrest should be highly inclined in a backward direction in comparison to the backrest for an upper jaw treatment to give a direct view into the patient and, on the other hand, for the "prothetic position", wherein the head should be inclined forward to such an extent given an upright backrest position until, for instance, a horizontal occlusion plane is reached.
U.S. Pat. No. 4,515,406 discloses a design wherein a bracing carrying the head support is fashioned as a circularly curved, narrow plate that contains the center of a circle that lies approximately in the cervical vertebra joint of a patient sitting in the chair. The curved plate is guided in a slot held adjustably along the backrest and can be moved into and out of the carriage or, respectively, the backrest on the basis of a hydraulic drive.
Even though this design proves physiologically beneficial and allows a relatively narrow thin headrest shape, this arrangement has some disadvantages. Due to the brace member's guidance, the motion angle of the headrest is highly restricted. In addition, a relatively bulky mechanism is required in the upper backrest part. Given this design, every attempt to design the backrest thinner in this region, which would be inherently desirable in order to position the patient's head as low as possible in the fully reclining position, but to, nonetheless, have adequate freedom for the knees of the attending person, would lead to a further restriction of the kinematics in this design and, thus, the positioning possibilities for the patient's head. An additional disadvantage may be seen wherein the adaptation to relatively tall patients is only conditionally possible and extremely tall patients are lent no support in the neck region in this particular arrangement.
Another headrest which, also, is only adjustable within limits is disclosed in German OS 36 11 282. In this particular design, the two extreme positions recited at the outset can be only inadequately set. By contrast to the above-mentioned design wherein the headrest itself can be executed relatively flat and thin, the headrest in this particular design is constructed relatively thick because of the tilt mechanism provided therein, and this is disturbing in view of the optimally great freedom of legs or, respectively, knees that the attending person desires when the backrest is greatly inclined. An adaptation of the size of the patient is also only conditionally possible in this known design. Extremely tall patients, likewise, have no adequate support for the neck region.
U.S. Pat. No. 4,840,429, whose disclosure is incorporated herein by reference thereto and which claims priority from German Application 37 27 204, discloses another headrest design wherein the parallelogram-like linkage is hinged to the backrest or, respectively, to a carrier part held in the backrest. The pairs of articulations of this linkage form a four-bar mechanism having articulation spacings of different sizes. Whereas the pair of articulations having the smallest articulation space is arranged approximate to the backrest, the pair of articulations provided with the largest articulation spacing is arranged distal of the backrest. The pair of articulations distal from the backrest is formed by an articulated connection of the two articulated arms with the movable part of a straight-line mechanism provided in the longitudinal direction of the headrest. The one linkage arm is provided with a roller lever that is supported against a guideway which is rigidly secured in the housing of the headrest. The movable part is moved relative to the fixed part of the straight-line mechanism with a drive motor. Even though the two extreme positions mentioned in the beginning can be achieved rather well with this adjustment mechanism, the mechanism provided in the head support here has a relatively thick wall structure.
SUMMARY OF THE INVENTION
The object of the present invention is to provide a dental chair comprising a headrest that is pivotably hinged around a transverse axis on a bracing member which is adjustable in a longitudinal direction so that the dental chair does not have the aforementioned disadvantages. Thus, an optimally thin and flat headrest can be achieved and allows an optimum support of the patient's head in all treatment positions, whereby the motion sequence between the two, initially-cited extreme positions should be physiologically beneficial and should occur in accordance with the natural nodding motion of a patient's head during the adjustment thereof. In addition, a better support of not only the head, but also the back in the region of the upper spinal vertebra and cervical vertebra should be enabled, particularly given both taller and relatively short patients.
To accomplish these goals, the dental patient chair of the present invention comprises a headrest that is pivotably hinged around a first transverse axis of a bracing member, which is adjustable in a longitudinal direction of the backrest. The transverse axis forms a lever arm together with an articulated axis or second axis of a link hinged to the headrest and loadable with either a tensile or a compression force on the basis of the adjustment means and, thus, effects the pivotability of the headrest, whereas the link and the adjustment means are allocated to the headrest carrier that contains the bracing member and is adjustable vis-a-vis the backrest.
On the basis of the inventively proposed displacement of the adjustment mechanism for the head support into the head support carrier, particularly into the lower and middle sections of the head support carrier, the head support itself can be constructed extremely flat and, preferably, as a headrest shell. Particularly in the treatment positions having the recumbent patient, the attending person is, thus, given considerably more freedom in the knee region than previously.
A further proposal of subdividing the head support carrier into three sections including a base part, main carrier and bracing, as well as their arrangement yields the great advantage that the optimal support, in particular the upper portion of the back, is guaranteed, even given extremely tall patients. As a result of the gentle lowering and raising of the main carrier that is a quasi-part of the backrest, the movement of the upper spinal vertebra of the patient is co-involved into the overall head motion, and this is extremely advantageous because the movement of the head does not occur only from the region of the cervical vertebra.
The measures of the invention achieve the further advantage that the backrest, in its extreme position, roughly forms a straight line together with the headrest carrier, and this is advantageous for this treatment position. In the other treatment positions, by contrast, particularly in the initially-cited, other extreme position, such as the prothetic position, there is a clear gradient between the backrest and the main carrier that corresponds to the natural anatomical conditions given a relaxed, seated patient's posture better than the aforementioned straight line in the extended position.
The two tilting motions, for example of the headrest and that of the main carrier, proceed simultaneously and in the same direction, but at different speeds, as a result whereof a harmonic adjustment of the patient's head is achieved.
A compact, harmonically closed, external shape that is easy to clean and care for can be achieved by the matching of the headrest carrier with reference to the external contour of the backrest.
Other advantages and features of the invention will be readily apparent from the following description of the preferred embodiments, the drawings and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of a dental chair in accordance with the present invention;
FIG. 2 is a plane view of a headrest and backrest of the patient chair in accordance with the present invention with the backrest cushions being removed;
FIG. 3 is a rear view of the headrest adjustment mechanism with portions removed for purposes of illustration;
FIG. 4 is a perspective view of a portion of the headrest adjustment mechanism in accordance with the present invention;
FIG. 5 is a partial side view of the headrest arrangement in accordance with the present invention in a first extreme position; and
FIG. 6 is a side view similar to FIG. 5 showing the headrest in the other or second extreme position.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The principles of the present invention are particularly useful when incorporated in a dental chair of FIG. 1, which chair contains an upper chair part containing a chair seat 1, which is connected by a connecting element 6 to a backrest 2, which is connected by a headrest carrier 7 to a headrest 3, which are all arranged adjustable relative to one another with respect to a base chair part 5 in a known way on the basis of an adjustment mechanism (not shown) which is covered by an accordion bellows 4. An example of the adjustment mechanism for the seat 1 within the bellows 4 can be the mechanism described in U.S. Pat. No. 5,015,035, whose disclosure is incorporated herein by reference thereto. The adjustment possibilities recited herein are indicated by the arrows and are to be considered only by way of example. Thus, it is definitely possible to also arrange the backrest adjustable relative to the seat by the connecting element 6, which is correspondingly guided in the chair seat 1.
As best illustrated in FIG. 2, the headrest 3 and the headrest carrier 7 have the same width and are arranged for longitudinal displacement in the backrest 2. To this end, the backrest 2 comprises a central cutout portion 8, which is opened toward the top, to which at least the lower part of the headrest carrier 7 is matched. In order to shift the headrest carrier 7 and the headrest 3 in the backrest 2, the backrest is provided with first means which include a pair of guide rods 9 which slidably receive guide bushings 10 that are secured to the headrest carrier 7. To shift the bushings 10 on the rods 9, a gear motor 11 is provided in the backrest 2 and drives a toothed belt 12, which is secured to one of the guide bushings 10. A position sensor 13 with which the exact position of the headrest carrier 7 with reference to the backrest 2 can be acquired, is provided and is also driven by the toothed belt 12. The articulation or pivoting of the headrest carrier 7 to the headrest 3 will be described in greater detail and is covered by an accordion bellows 14 that follows the outer contour of the headrest and headrest carrier and, thus, creates a harmonic transition that is easy to clean.
It should be pointed out that in this context, part of the headrest carrier 7 adjoining the accordion bellows 14 downwardly in the direction toward the backrest 2 has a cushion adapted to the backrest. As a result of this cushion, an optimum support of the upper spine and cervical vertebra of the patient is established, even in the extreme position that corresponds to extremely tall patients.
The headrest 3 and headrest carrier 7, as illustrated in FIG. 3, has the cladding portions removed. As illustrated, the headrest 3 contains an angled frame 3a that advantageously is a contour-emphasized shaped part and contains a shell-shaped depression for the head support of the patient. The headrest carrier 7 can be divided into three sections, including a lower portion or section I, a middle portion or section II, and an upper portion or section III. The lower section I contains a base part 15 that carries the two guide bushings 10. The middle section II contains the main carrier 16 and the upper section III contains a bracing member 17. The bracing member 17 is fashioned plate-shaped, wherein one upper end is fashioned in a fork-like manner and contains two bearing necks or projections that form a pivot bearing or first axis 18, around which the headrest 3 is pivotably mounted for rotation, as indicated by the arrow. An additional pivot or second axis 19 is arranged at approximately half the width of the headrest 3. A rod or link 20 is pivotably connected to the pivot bearing 19 and extends downward in a slot-like recess 21 that is between the member 17. The two axes of the pivot bearings 18 and 19 form a lever arm, as a result whereof the pivoting of the headrest around the first axis of the pivot bearings 18 is achieved, given either a pulling force or a pushing force on the link or rod 20. The end of the rod 20 which lies opposite the pivot bearing 19 is coupled to a transition lever 22, which coupling is set forth in greater detail with regard to FIG. 4. The lever 22 is mounted for rotation on a bearing journal 23 of the main carrier 16. A support arm or element 24, which is supported against a surface 25 of the base part 15, is also arranged on an extension 22a of the lever arm 22 to form a tilt mechanism. As shall be set forth in greater detail later, the main carrier 16 can be tilted vis-a-vis the base part 15 in a defined angular range around the two bearing axes 26 with this adjustment or, respectively, tilt mechanism, as indicated by the arrow.
The bracing member 17 is guided on both sides in a slideway 27 secured to the main carrier 16. To shift the member 17 in the slideway 27 during adjustment of the length of the headrest carrier 7, an electric motor 28 is arranged in the base part 15, and this electric motor 28 drives a toothed belt 29 that is secured with a suitable fastening element 30 to the member 17 and is otherwise guided around a guide roller.
A coupling of the link or rod 20 to the translational lever 22 is illustrated in FIG. 4. It may be seen from this Figure that the lower end of the rod or link 20 is provided with a groove 31 which receives a roller 32 mounted for rotation on one end of the lever 22. A second connecting member is formed on the bracing or member 17. This second connecting member includes a portion 33 of the member 17 being provided with a transverse extending slot 34, which receives a second roller 35, which is mounted for rotation on the lever 22. A male member or pin 36 is eccentrically arranged on the extension 22a of the translational lever 22 relative to the bearing journal 23. A support element 24 is mounted by this male member 36. The bearing journal 23 and the eccentric member 36 form a spacing b that effects the tilt of the main carrier 16 relative to the base part 15 when the bracing member 17 is motor-adjusted along the cutout 8 of the backrest 2. This is accomplished by the member 24 acting against the ledge or bracket 25 of the element 15.
Synchronously with the combined motion of the bracing member 17, given simultaneous tilting of the headrest in a backward direction, the main carrier 16 is, likewise, inclined or pivoted backward by a specific angular dimension proceeding from a position that was previously slightly inclined forward. This is accomplished by the supporting element 24, which is slightly lifted via the lever arm b between the supporting element 24 and the journal bearing 23 given a tilting motion of the translational lever, due to a contraction or retraction of the member 17 toward the base part 15. As a result, the main carrier is moved backward in the above-mentioned way due to the normal load of the backrest by the patient.
The analogous case applies for the opposite motion, i.e., for the extension of the member 17.
The two ultimate positions of the headrest are illustrated in FIGS. 5 and 6. FIG. 5 shows the extended position of the bracing member 17 within the bellows 14, while FIG. 6 shows the withdrawn position of the bracing member 17 within the bellows 14. As may be seen by comparing the two Figures, the main carrier 16 is inclined by an angle α 1 between 20° and 25° with respect to a base part 15 when the bracing member 17 is in the extended position (FIG. 5). This extended position is well-suited for a prothetic treatment at the patient seated relaxed or, respectively, lying slightly inclined. When the bracing member is in a retracted position, such as illustrated in FIG. 6, the main carrier 16 is only slightly inclined to the base part 15 by an angle of α 2 , which is a range of 2° to 6°. As illustrated, when in the extended position, the headrest 3 will assume the position where it is substantially in a horizontal plane, while in the contracted or second position of FIG. 6, the headrest 3 is tilted back.
Although various minor modifications may be suggested by those versed in the art, it should be understood that we wish to embody within the scope of the patent granted hereon all such modifications as reasonably and properly come within the scope of our contribution to the art. | A dental patient chair has an adjustable headrest on a headrest carrier. The headrest is pivotably hinged around a transverse first axis on a bracing member which, in turn, is adjustable in the longitudinal direction in the backrest. In addition, the headrest is connected by a linkage which is pivotably connected on a second axis offset from the first axis so that movement of the linkage causes tilting of the headrest. The linkage is shifted as the headrest carrier is extended and contracted. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a data conversion apparatus for converting index data to real data and to an image generation apparatus for converting, for example, index texture data to real texture data by the data conversion to make it possible to suitably carry out texture mapping.
2. Description of the Related Art
When storing a large amount of data such as, for example, image data in a computer or other processing apparatus, to make effective use of the limited storage region of the apparatus, it is preferable to reduce the amount of data stored. As a general method for reducing the amount of data for this purpose, there is the method of using index data.
In this method, actual data (hereinafter referred to as “actual data” or “real data”) is given a number expressed by a smaller bit width than the data bit width. By storing data by such numbers, it is possible to store the data by a smaller amount of data than that by directly storing the actual data. The numbers given to the actual data are referred to as “indexes”, and the data converted to a format referred to by indexes is referred to as “index data”.
When using index data, it is necessary to store both a list establishing correspondence between the index data and the real data, that is, an index table and the data expressed by the index data in the processing apparatus. However, usually the decrease of the amount of data caused due to the use of the index data is overwhelmingly larger than the increase of the amount of data caused due to the storage of the index table, therefore the amount of data can be greatly reduced as a whole.
When the method of storage using index data is applied to image data, the image data is stored in the form of index-data inside the processing apparatus. When displaying the image data on a display or otherwise outputting the image data to the outside, the index data is converted to real data for output. The conversion of the index data to the real data must be carried out at a high speed in accordance with, for example, the speed of display of the display device. Therefore, usually this data conversion processing is frequently carried out by data conversion apparatus constituted by hardware.
Specifically, the data conversion apparatus is constituted by using, for example, a memory. When the index is input as an address, the converted real data is output as the output data.
An example of such a data conversion apparatus constituted by a memory is shown in FIGS. 1A and 1B.
FIG. 1A is a view of a data conversion apparatus constituted by a memory for converting 3-bit index data to 32-bit real data. The content of the index data stored in this memory is shown in FIG. 1 B.
In a field of computer graphics, color image data consisting of a very large amount of data is processed, therefore processing by “index color” expressing color data using indexes is frequently utilized.
“Processing by index color” means processing which defines index color data of for example 4 bits, 8 bits, and 16 bits for real color data of 24 bits comprised by for example 8 bits each of R, G and B by the number of required specified colors, maintains an index table corresponding to the index color data, and converts index color data to real color data.
For processing using computer graphics, there are many applications where there are no problems in actual use even if used while limiting the number of colors. In such a case, processing by index color is being used even more.
A data conversion apparatus for converting this index color data to real color data at a high speed is referred to as a “color look-up table” since it converts color data.
When using such index data, the types of usable data are limited by the number of entries of the index table. However, in some applications, there are cases where it is desired to use a larger amount of data than the number of entries of the index table. Therefore, in such a case, the methods of rewriting the index table for use or providing a plurality of index tables and using the same by switching in accordance with the situation are usually used. The method of rewriting of the index table, however, causes a reduction in the processing speed by an amount corresponding to the rewriting time. Therefore, in general the method of providing many index tables within a range allowed by the storage region of the memory of the data conversion apparatus is adopted.
Even if a plurality of index tables are provided due to such a method, there is no change in the fact that the types of data which can be used at each point of time are limited by the number of entries of the selected index table, but by providing many index tables and using them by appropriately switching in a series of continuous processing, substantially a large amount of data is used when seen from the standpoint of the application.
In this way, in processing by index data, provision of many index tables is becoming one of the most important factors in actual use.
Further, when using such index data, the bit width of the data output from the index table, that is, the precision of the index table, is also becoming important.
The requests on the data precision of an index table differ according to application. There are a variety of requests. For example, some require data precision, while others do not. When taking as an example the field of computer graphics, in CADs for graphic design, for example, the ability to display fine differences in the tone of colors is very important for designers and a high precision is required for the data of the index table. In the case of CADs for mechanical design, however, it is sufficient so far as parts can be discriminated by color and fine differences of colors of individual parts are not so important.
In this way, in processing using index data, the number of entries and the precision of the index table are very important items.
In the data conversion apparatuses heretofore, however, there has been a one-to-one correspondence between entries and addresses of the memory. The precision of the index table has corresponded to the data bit width of the memory and has been substantially fixed, so could not be adjusted corresponding to the application etc.
For this reason, there are many cases where the precision of the index table is set in advance so as to become a precision that can be also applied to applications for which a relatively high precision is required. Namely, in many cases each data has a certain longer bit width. As a result, even in a case of use with an application where not that high a precision is required, the processing is carried out with an index table having a precision of more than required.
Further, the number of entries is preferably made as large as possible, but an increase of the number of entries leads to an increase of the capacity of the memory which ends up being used. Therefore usually it cannot be sufficiently increased in many cases.
Namely, in the data conversion apparatuses heretofore, there tended to be the disadvantage that the number of entries was not sufficient despite the unnecessarily high precision etc., so there was a disadvantage in that it was difficult to effectively use the memory and carry out the processing using suitable indexes for the application.
As a result, in various processing apparatuses to which such a data conversion apparatus is applied, there has been a disadvantage in that suitable processing could not be carried out.
For example, when this data conversion apparatus is applied to processing for generating an image etc., the disadvantages having arisen that the number of usable colors has not been sufficient and therefore discrimination by color could not be suitably achieved and that the display of fine tones of color was not possible and therefore the desired image could not be displayed.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a data conversion apparatus that can suitably change the precision of the index table with respect to an entry and the number of entries according to need and that can suitably carry out the conversion from index data to real data in a desired format suited to the application.
Further, another object of the present invention is to provide an image generation apparatus which can suitably change the precision of the index table with respect to an entry and the number of entries in accordance with the type of the image data to be processed etc., which can thereby convert from index color to real color in the desired format suited to the application, and which can suitably generate the intended image.
So as to achieve the objects, the present invention provides a data conversion apparatus comprising a first memory and a second memory each for storing data having a n bit width and in which any data is stored, an address detecting means for detecting addresses of the first memory and the second memory based on input data at which data corresponding to the input data are stored, a data reading means for reading data stored at the detected addresses of the first memory and the second memory, a first data selecting means for selecting either of the data read from the first memory or the data read from the second memory based on the input data, a data extending means for extending the selected data to data having a 2×n bits width, and a second data selecting means for selecting either of the first data formed by connecting the data output from the first memory and the data output from the second memory or the second data of the extended data based on an input selection signal and outputting data selected by the second data selecting means with respect to the input of the data.
Preferably, the address detecting means adds the input data and a predetermined base address to detect the address at which the corresponding data is stored.
Specifically, the first memory and the second memory store real color data, the address detecting means is input index color data given corresponding to real color data to be read, and the index color data is converted to real color data.
Further specifically, said real color data is data having red luminance data, green luminance data, blue luminance data, and transparency data.
Further specifically, the first memory and the second memory are memories each storing data having a 16 bits width, the real color data is 32 bits width data having 8 bits each of red luminance data, green luminance data, blue luminance data, and transparency data or 16 bits width data of 5 bits, 5 bits, 5 bits, and 1 bit, the data extending means extends the selected data to 32 bits width real color data when the read data is the 16 bits width real color data, and the second data selecting means selects the 32 bits width real color data formed by connecting the data output from the first memory and the data output from the second memory when the read data is 32 bits width real color data and selects the extended 32 bits width real color data when the read data is 16 bits width real color data.
Preferably, a data width of the input data is smaller than n bits.
Further preferably, the first memory, the second memory, the address detecting means, the data reading means, the first data selecting means, the data extending means, and the second data selecting means are comprised in an integrated circuit.
Further, so as to achieve the objects, the present invention provides an image generation apparatus comprising a coordinate transforming means for carrying out a predetermined coordinate transformation with respect to vertexes of basic polygons of three-dimensional image data by which any three-dimensional cubic model may be shown as a set of basic polygons indicated by vertexes having at least three-dimensional position information, a pixel data generating means for generating pixel data of the basic polygons based on the data of vertexes of the basic polygons, a data conversion apparatus which converts texture index data to real texture data for carrying out texture mapping with respect to the generated each pixel data, a texture mapping means for generating display use three-dimensional image data by carrying out texture mapping with respect to the generated pixel data by using the converted real texture data, an image memory for storing the generated three-dimensional image data as display use image data, and an outputting means for reading data of a desired region from among the stored display use image data and outputting the same as display use screen data, the data conversion apparatus comprising a first memory and a second memory each for storing data having n bits width and in which real texture data is stored, an address detecting means for detecting addresses of the first memory and the second memory based on input index texture data at which real texture data corresponding to the input index texture data are stored, a data reading means for reading real texture data stored at the detected addresses of the first memory and the second memory, a first data selecting means for selecting either of the real texture data read from the first memory or the real texture data read from the second memory based on the input index texture data, a data extending means for extending the selected data to data having a 2×n bits width, and a second data selecting means for selecting either of the first data formed by connecting the real texture data output from the first memory and the real texture data output from the second memory or the second data of the extended data based on an input selection signal and outputting real texture data with respect to the input of index texture data.
Preferably, the address detecting means adds the input index texture data and a predetermined base address of the index table to detect the address at which the real texture data is stored.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other objects and features of the present invention will become clearer from the following description of the preferred embodiments given with reference to the attached drawings, in which:
FIGS. 1A and 1B are views of the data conversion apparatus constituted by a memory as an example of a data conversion apparatus of the related art;
FIG. 2 is a block diagram of the configuration of a three-dimensional computer graphic system of an embodiment of the present invention;
FIGS. 3A and 3B are views of formats of 16-bit and 32-bit real color data;
FIG. 4 is a block diagram for explaining the configuration of a color look-up table provided in a mapping unit of the three-dimensional computer graphic system shown in FIG. 2;
FIG. 5 is a detailed block diagram of the color look-up table shown in FIG. 4; and
FIG. 6 is a view of the number of color look-up tables which can be set in a memory unit of the color data conversion apparatus shown in FIG. 5 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
A preferred embodiment according to the present invention will be explained below with reference to FIG. 2 to FIG. 6 .
In the present embodiment, an explanation will be made of a case where the data conversion apparatus of the present invention is applied to a three-dimensional computer graphic system for displaying a desired three-dimensional image for any three-dimensional object model, such as applied to a computer game machine, on a display device at a high speed.
First, an explanation will be made of a three-dimensional computer graphic system to which the memory apparatus of the present invention is applied by referring to FIG. 2 .
This three-dimensional computer graphic system is a system which carries out polygon rendering processing which expresses a cubic model as a combination of unit graphics, that is, triangles (polygons), draws the polygons, determines the color of each pixel of the displayed screen, and displays the same on a display.
Further, in the three-dimensional computer graphic system 1 , a three-dimensional object is expressed by using a z-coordinate expressing the depth in addition to the (x, y) coordinates expressing the plane. Any point in three-dimensional space is specified by these three x-, y-, and z-coordinates.
FIG. 2 is a block diagram of the configuration of the three-dimensional computer graphic system 1 .
The three-dimensional computer graphic system 1 has an input unit 2 , a three-dimensional image generation apparatus 3 , and a display device 4 .
Further, the three-dimensional image generation apparatus 3 has a geometric processing circuit 32 , a parameter calculating circuit 33 , a pixel generation circuit 34 , a mapping circuit 35 , a texture memory 36 , a memory control circuit 37 , an image memory 38 and a display control circuit 39 .
First, an explanation will be made of the structure and function of each unit.
The input unit 2 inputs the data of the cubic model to be displayed to the three-dimensional image generation apparatus 3 . In the present embodiment, the three-dimensional computer graphic system 1 is applied to a computer game machine, therefore the input unit 2 is connected to a main control device etc. for controlling the game per se of the computer game machine. The main control device determines the screen to be displayed based on the state of progress of the game etc., selects the cubic model necessary for the screen display, and generates the information of the display method. Accordingly, the input unit 2 receives this information from the main control device of the computer game machine, converts the same to a format suitable for input to the three-dimensional image generation apparatus 3 , and inputs this to the three-dimensional image generation apparatus 3 .
Specifically, the input unit 2 inputs the polygon data of the cubic model to be displayed as mentioned above to the geometric processing circuit 32 of the three-dimensional image generation apparatus 3 . Further, the polygon data input consists of x-, y-, and z-coordinate data of the vertexes and the color, transparency, texture, and other additional data.
The geometric processing circuit 32 arranges a polygon input from the input unit 2 at the desired position in the three-dimensional space and generates the polygon data at that position. Specifically, it carries out geometric transformation processing such as a parallel transference transformation, parallel transformation, and rotation conversion for every vertex (x, y, z) of a polygon. The polygon data subjected to the geometric transformation processing is output to the parameter calculating circuit 33 .
The parameter calculating circuit 33 finds the parameters necessary for generating the pixel data inside a polygon in the pixel generation circuit 34 based on the data of the polygon input from the geometric processing circuit 32 , that is, the data of each vertex of the polygon, and outputs the same to the pixel generation circuit 34 . Specifically, it finds for example the information of the color, depth, and inclination of the texture.
The pixel generation circuit 34 carries out linear interpolation between vertexes of the polygon based on the polygon data subjected to the geometric transformation processing at the geometric processing circuit 32 and the parameters found at the parameter calculating circuit 33 and generates the pixel data of the internal portion of the polygon and an edge part. Further, the pixel generation circuit 34 generates an address on a predetermined two-dimensional plane corresponding to the display of the pixel data. The generated pixel data and addresses are sequentially input to the mapping circuit 35 .
The mapping circuit 35 reads the pixel data and address generated at the pixel generation circuit 34 and carries out texture mapping processing with respect to the pixel data by using the texture data stored in the texture memory 36 . The pixel data and addresses subjected to the texture mapping processing are output to the memory control circuit 37 .
The texture memory 36 is a memory for storing a texture pattern used when carrying out the texture mapping at the mapping circuit 35 . In the present embodiment, in this texture memory 36 , the texture data is stored in the form of index data.
The memory control circuit 37 generates new pixel data based on the pixel data and address input from the mapping circuit 35 and the corresponding pixel data already stored in the image memory 38 and stores the same in the image memory 38 . Namely, the memory control circuit 37 reads the pixel data corresponding to the address input from the mapping circuit 35 from the image memory 38 , carries out the desired pixel operation processing by using this pixel data and the pixel data input from the mapping circuit 35 , and writes the obtained pixel data into the image memory 38 .
Further, the memory control circuit 37 reads the pixel data of the display region from the image memory 38 when the display region is designated from the display control circuit 39 and outputs the same to the display control circuit 39 .
The image memory 38 is a memory for recording the image data for display and has two memory buffers which can be simultaneously accessed, i.e., a frame buffer and a Z-buffer. The frame buffer stores the color information of the pixels, that is, the frame data. Further, the Z-buffer stores the depth information (Z values) of the pixels, that is, the Z-data.
The display control circuit 39 converts the pixel data of the display region read from the image memory 38 via the memory control circuit 37 to for example predetermined analog signals which can be displayed by the display device 4 , and outputs the same to the display device 4 . Note that, preceding this, the display control circuit 39 requests the pixel data of the display region to be displayed to the memory control circuit 37 .
The display device 4 is a television receiver having a video input terminal and so forth usually used in homes. From the display control circuit 39 of the three-dimensional image generation apparatus 3 , an analog video signal is input via a video signal input terminal. A three-dimensional picture is displayed on the screen based on the signal.
Next, an explanation will be made of the operation of this three-dimensional computer graphic system 1 .
First, in the main control device and so forth for controlling the game per se of the computer game machine, if the three-dimensional image to be displayed is determined, the information of the cubic model required for the screen display thereof is input to the input unit 2 . The input unit 2 inputs the polygon data of the cubic model for displaying the image to the three-dimensional image generation apparatus 3 based on this information.
Each polygon data input to the three-dimensional image generation apparatus 3 is first subjected to geometric transformation processing such as parallel transference transformation, parallel transformation, and rotation transformation in the geometric processing circuit 32 so as to be arranged at a desired position in the three-dimensional space for the screen display.
Next, the parameters necessary for generating the pixel data inside the polygon are found in the parameter calculating circuit 33 with respect to the polygon data transformed in coordinates The pixel generation circuit 34 carries out linear interpolation between vertexes of the polygon and generates the pixel data of the internal portion of the polygon and the edge part.
The generated pixel data is sequentially input to the mapping circuit 35 . The mapping circuit 35 converts the index data recorded in the texture memory 36 , that is, the texture pattern data, to the real color data, carries out texture mapping processing by using this, and stores the generated pixel data in the image memory 38 via the memory control circuit 37 .
The pixel data stored in the image memory 38 is suitably subjected to the desired processing based on other pixel data input by a similar route or any control data.
Due to this, the newest image data is always stored in the image memory 38 and supplied to the screen display. Namely, the request for output of the data of a predetermined region for display on the display device 4 is made from the display control circuit 39 to the memory control circuit 37 . The pixel data of the region is suitably read from the image memory 38 , converted to the predetermined signal for the screen display in the display control circuit 39 , and output to the display device 4 .
By this, the desired image is displayed on the screen of the display device 4 .
Next, an explanation will be made of the color data conversion apparatus 100 according to the present invention by referring to FIG. 3A to FIG. 5 .
The color data conversion apparatus 100 is accommodated in the mapping circuit 35 for the texture mapping processing of the three-dimensional image generation apparatus 3 of the three-dimensional computer graphic system 1 mentioned above. The mapping circuit 35 reads the texture data from the texture memory 36 and maps this to the pixel data input by the pixel generation circuit 34 . As explained above, the texture data read from the texture memory 36 is stored as index color. Accordingly, the color data conversion apparatus 100 is provided for converting this index color to the real color and applying the same to the processing of the texture mapping.
First, the function of the color data conversion apparatus 100 will be explained in brief.
As explained above, the color data conversion apparatus 100 is an apparatus for converting index color data to real color data by referring to the index table (hereinafter referred to as a color look-up table).
As the index color data, use can be made of 2-bit, 4-bit, and 8-bit data.
A plurality of color look-up tables can be provided, and the table designated by indicating the base address.
As the real color data managed by the color look-up table, two index data having different precisions, that is, 16-bit data and 32-bit data, can be handled. The precision of the index data is selected by the mode signal “mode” of the precision of the index table.
Note that the data output from the color data conversion apparatus 100 is the 32-bit real color data.
The formats of the 16-bit and 32-bit real color data are shown in FIGS. 3A and 3B.
As shown in FIG. 3A, the 16-bit real color data is structured, from the LSB side, of 5 bits of red luminance data R, 5 bits of green luminance data G, 5 bits of blue luminance data B, and one bit of transparency data A.
Further, as shown in FIG. 3B, the 32-bit real color data is structured of 8 bits each of red luminance data R, green luminance data G, blue luminance data B, and transparency data A arranged from the LSB side.
Next, an explanation will be made of the concrete structure of the color data conversion apparatus 100 by referring to FIG. 4 and FIG. 5 .
First, the structure of the color data conversion apparatus 100 will be briefly explained by referring to FIG. 4 .
As shown in FIG. 4, the color data conversion apparatus 100 has an input interface unit 110 , a memory unit 120 , and a data extension unit 130 as fundamental structural units.
The input interface unit 110 picks out the required field from among the data read and input from the texture memory 36 , extracts the index color data, and inputs the same to the memory unit 120 .
The memory unit 120 accommodates the index table and converts the input index color to real color.
The data extension unit 130 extends the real color data read from the memory unit 120 to 32-bit full color data when it is 16-bit data and outputs the same.
Next, the structure of each unit of the color data conversion apparatus 100 will be explained in detail by referring to FIG. 5 .
As shown in FIG. 5, the color data conversion apparatus 100 has a selector (SEL) 111 and an adder (ADD) 112 as the input interface unit 110 , a first memory (MEM 1 ) 121 and a second memory (MEM 2 ) 122 as the memory unit 120 , a first multiplexer (MUX1) 131 , a data extender (EXT) 132 , and a second multiplexer (MUX 2 ) 133 as the data extension unit 130 .
The selector 111 selects a valid part in 32 bits of data “mdata” read from the texture memory 36 based on the mode signal “mode” of the precision of the index table and the lower significant 4 bits “maddr” [ 3 : 0 ] of the data read from the texture memory 36 , extends 0 to the upper significant bits according to need, generates the 8-bit index data “index”, and outputs the same to the adder 112 .
The adder 112 adds the base address “base” of the index table used and the value of the index data index input from the selector 111 to generate the 9-bit memory address “addr” [ 8 : 0 ] for designating the intended entry. The lower 8 bits “addr” [ 7 : 0 ] of the generated memory address are supplied to the first memory 121 and the second memory 122 . The most significant data “addr” [ 8 ] is output to the first multiplexer 131 as the selection signal.
The first memory 121 and the second memory 122 are each 256 address×16-bit data SRAMs in which the color look-up tables are actually stored.
The first memory 121 and the second memory 122 store the color look-up tables via the 32-bit, thereby total 64-bit, input data lines WD.
Further, the data read from the first memory 121 and the second memory 122 are output to the first multiplexer 131 and the second multiplexer 133 .
Note that when the mode of precision of the index table is the 16-bit mode, the storage regions of these first memory 121 and second memory 122 are allocated to different address spaces. The entire memory unit 120 becomes a storage unit having 512 address×16-bit structure. Accordingly, the number of index entries at this time becomes 512 entries.
Further, when the mode of precision of the index table is the 32-bit mode, the storage regions of the first memory 121 and the second memory 122 are allocated to the region of the upper significant 16 bits and the region of the lower significant 16 bits of the same address space, and the entire memory unit 120 becomes a storage unit having a 256 address×32-bit structure. Accordingly, the number of index entries at this time becomes 256 entries.
The first multiplexer 131 selects either of the 16-bit data input from the first memory 121 or the 16-bit data input from the second memory 122 based on the signal “adder” [ 8 ] of bit 8 of the memory address generated at the adder 112 and outputs the same to the data extender 132 .
The data extender 132 extends the 16-bit data input from the first multiplexer 131 to 32-bit data and outputs the same to the second multiplexer 133 .
The 16-bit real color data is comprised, as shown in FIG. 3A, of 5 bits of red luminance data R, 5 bits of green luminance data G, 5 bits of blue luminance data B, and one bit of transparency data A. The data extender 132 prepares 8-bit data for the luminance data R, G, and B by adding the data “d” [ 4 : 2 ] of the upper significant 3 bits to the LSB side of “d” to the 5-bit data “d” [ 4 : 0 ]. Further, for the transparency data A, it prepares 8-bit data with respect to the transparency data A=0 and 8-bit data with respect to the transparency data A=1 in advance and prepares the 8-bit data by replacing this by the 8-bit data based on the value of the transparency data A.
As a result, the 32-bit real color data of the format as shown in FIG. 3 B.
The second multiplexer 133 selects either of the 32-bit data input from the data extender 132 or the 32-bit data consisting of the 16-bit data output from each of the first memory 121 and the second memory 122 based on the mode signal “mode” of precision of the index table and outputs the same as the output data from the color data conversion apparatus 100 , that is, 32-bit real color data.
The second multiplexer 133 selects the output of the data extender 132 when the mode of precision of the index table is the 16-bit mode, while selects the outputs of the first memory 121 and the second memory 122 when it is the 32-bit mode.
The output data is input to the calculating circuit for carrying out the texture mapping of the mapping circuit 35 .
Next, an explanation will be made of the operation of the color data conversion apparatus 100 .
First, in the color data conversion apparatus 100 , as the initial setup, the writing of the color look-up table to the first memory 121 and the second memory 122 is carried out.
The color look-up table is written by inputting the addresses via the selector 111 , supplying the write data to the 64-bit input data line WD, switching the read/write control signal “r/w” to “write”, and enabling the chip enable signal “ce”.
When carrying out the data conversion, the read/write control signal “r/w” is set at “read”, the mode “mode” of precision of the index table and the base address “base” of the index table to be used are designated, and then the lower significant bits of the data and the address read from the texture memory 36 are input to the selector 111 .
Based on these input data and address, the index data “index” is generated at the selector 111 and added to the base address base at the adder 112 , whereby the memory address “addr” is generated.
The lower 8 bits “addr” [ 7 : 0 ] of the generated address “ddr” are applied to the first memory 121 and the second memory 122 , and the real data is read from the first memory 121 and the second memory 122 .
When the mode of precision of the index table is the 32-bit mode, 32-bit real color data is output from the first memory 121 and the second memory 122 , therefore they are output to the texture mapping processing circuit of the mapping circuit 35 as they are via the second multiplexer 133 .
Further, when the mode of precision of the index table is the 16-bit mode, the data read from the first memory 121 and the second memory 122 are 16-bit real color data different from each other. Accordingly, either of the data output from the first memory 121 or the data output from the second memory 122 is selected at the first multiplexer 131 based on the most significant bit “addr” [ 8 ] of the address signal output from the adder 112 and is output to the data extender 132 .
The 16-bit real color data input to the data extender 132 is extended to the 32-bit real color data by the method as mentioned above and output to the texture mapping processing circuit of the mapping circuit 35 via the second multiplexer 133 .
Note that the number of entries of one color look-up table is determined by how many number of bits the index color data has. When 2-bit index colors are used, there are four index color values, i.e., 0, 1, 2, and 3, and there are four entries corresponding to this. Similarly, when 4-bit index colors are used, there are 16 entries in the color look-up table is 16, while when 8-bit index colors are used, there are 256 entries.
As the entire color data conversion apparatus 100 , the memory unit 120 is constituted by two memories each consisting of 16 bits×256 addresses, therefore when the mode of precision of the index table to be used is the 16-bit mode, there are 512 entries, while when it is the 32-bit mode, there are 256 entries.
The number of color look-up tables which can be set in the memory unit 120 in accordance with the number of bits of the index color data and the mode of precision of the index table is shown in FIG. 6 .
In this way, in the color data conversion apparatus 100 of the present embodiment, the number of bits of the index color data, that is, the precision of one color look-up table, and the number of entries can be selected according to necessity. Accordingly, the color look-up input can be constituted with the required precision and required number of entries in accordance with the type etc. of application, and suitable color data in accordance with the application can be generated.
Further, in the three-dimensional computer graphic system 1 of the present embodiment, at the time of texture mapping, the precision of the index table and the number of entries thereof can be suitably adjusted in accordance with the application. Accordingly, the desired color image can be obtained in accordance with the application, and the effective use of the memory and the enhancement of performances of the system by this become possible.
Note that the present invention is not limited to the present embodiment. Various modifications are possible.
For example, the data extension method in the data extender 132 of the data extension unit 130 can be any method. For example, a method of extension by entering a specific pattern such as 000 or 111 on the LSB side of each data can also be adopted.
Further, if the content of the color look-up table is fixed, it is also possible to constitute the first memory 121 and the second memory 122 of the memory unit 120 by ROMs. If they are constituted by ROMs, the color data conversion apparatus 100 can be made smaller in size.
Further, by entering various operation results in the memory unit 120 , it is also possible to constitute a general purpose processor.
As explained above, if the data conversion apparatus of the present invention is used, the precision of the index table with respect to one entry and the number of entries may be appropriately changed according to need and the conversion from index data to real data can be suitably carried out in the desired format adapted to the application.
Further, according to the image generation apparatus of the present invention, in accordance with the type of the image data to be processed, etc., the precision of the index table with respect to one entry and the number of entries can be appropriately changed. Due to this, the conversion from index color to real color can be suitably carried out in the desired format adapted to the application, and the desired image can be suitably generated. | A data conversion apparatus for converting index data to real data and an image generation apparatus for converting index texture data to real texture data by the data conversion to make it possible to suitably carry out texture mapping. A data conversion apparatus comprises a first memory and a second memory each for storing data having a n bit width and in which any data is stored, an address detecting means for detecting addresses of the first memory and the second memory based on input data, a data reading means for reading data stored at the detected addresses of the first memory and the second memory, a first data selecting means for selecting either of the data read from the first memory or the data read from the second memory, a data extending means for extending the selected data to data having a 2×n bits width, and a second data selecting means for selecting either of the first data formed by connecting the data output from the first memory and the data output from the second memory or the second data of the extended data. | 6 |
FIELD OF THE INVENTION
Our invention relates to an improved turret cup supply and delivery mechanism and, more particularly, to a cup supply for use in a merchandiser machine adapted to dispense beverages.
BACKGROUND OF THE INVENTION
There are known in the prior art merchandising machines which are adapted to dispense beverages in response to the deposit of money in the machine and the actuation of a selection button. One of the subassemblies of each of these machines of the prior art is a cup dispensing unit which is adapted to deliver cups one by one from a supply. Most of these cup-delivery mechanisms of the prior art include a plurality of radially moveable elements which support a column of cups above a chute, or the like, leading to the delivery location at which the beverage is received by the customer. These cup-delivery devices include a ring which is adapted to be rotated through a given angular displacement to withdraw the radially moveable members to release one cup at a time from the column.
In addition to the cup-delivery mechanism described above, most of the machines of the prior art include a turret which is adapted to hold a plurality of columns of cups, one column of which is positioned over the delivery mechanism. When the cups in the one column are depleted a fresh column of cups moves into position over the cup delivery ring.
While these cup-delivery mechanisms of the prior art described hereinabove function fairly satisfactorily, they suffer from a number of defects. Most of them are relatively complicated in construction and hence somewhat uncertain in operation. A number of them require individual electromechanical elements for operating the cup-delivery mechanism and for operating the turret rotating mechanism. Many of the mechanisms are not adapted for interchangeable use with the different cup-delivery rings known in the prior art. They do not facilitate interchangeable use with turrets having different numbers of columns.
SUMMARY OF THE INVENTION
One object of our invention is to provide an improved turret cup supply and delivery apparatus which overcomes the defects of cup-delivery and supply assemblies of the prior art.
Another object of our invention is to provide an improved turret cup supply and delivery apparatus which is simpler than are mechanisms of the prior art intended to achieve the same purpose.
A still further object of our invention is to provide an improved turret cup supply and delivery apparatus in which a single electromagnetic device operates both the cup drop and the turret drive.
Yet another object of our invention is to provide an improved turret cup supply and delivery apparatus which can be interchangeably used with various cup-delivery rings available from the prior art.
Still another object of our invention is to provide an improved turret cup supply and delivery apparatus in which the danger of cup jamming is minimized.
Yet another object of our invention is to provide an improved turret cup supply and delivery apparatus in which the indexing position is relatively easily adjusted.
Yet another object of our invention is to provide an improved turret cup supply and delivery apparatus for use with turrets having different numbers of columns.
A still further object of our invention is to provide an improved turret cup supply and delivery apparatus which is lighter in weight than are systems of the prior art.
Other and further objects of our invention will appear from the following description:
In general our invention contemplates the provision of a cup delivery and turret indexing arrangement, in which a motor receives a signal indicating the cup is to be delivered to drive its shaft first to actuate a cup drop ring and to release a cup supply sensing arm which moves to permit a full cycle switch to close. When the last cup has been dropped the arm moves to position a turret drive slide in the path of a crank pin driven by the motor shaft to rotate the turret to position a fresh column of cups over the cup-delivery ring. We provide our system with means for accurately positioning the turret column relative to the cup-delivery ring.
BRIEF DESCRIPTION OF THE DRAWINGS
In the accompanying drawings to which reference is made in the instant specification and which are to be read in conjunction therewith and in which like reference characters are used to indicate like parts in the various views:
FIG. 1 is an elevation of our improved turret cup supply and delivery apparatus with parts broken away and with other parts shown in section.
FIG. 2 is a bottom plan view of the form of our improved turret cup supply and delivery apparatus illustrated in FIG. 1.
FIG. 3 is a sectional view of the form of our improved cup turret supply and delivery apparatus shown in FIG. 1 and taken along the line 3--3 thereof.
FIG. 4 is a fragmentary view illustrating an alternate embodiment of our improved turret cup supply and delivery apparatus.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIGS. 1 to 3 of the drawings, our apparatus includes a turret indicated generally by the reference character 10 made up of a number of tubes 12 adapted to receive respective columns of cups 14. We form an inboard wall portion 15 of each of the tubes 12 in such a manner that a lug 17 extending downwardly from an upper plate 16 engages the outside of wall portion 15 and respective lugs 18 extending downwardly from the plate 16 at each side of a lug 17 engage the inner surface of the wall portion 15. Similarly, a lower plate 19 has a lug 20 associated with each tube 12 which extends upwardly so as to engage the outer surface of wall portion 15, while a pair of lugs 21 extending upwardly from the bottom plate 19 at the sides of the lug 20 engage the inner surface of the wall portion 15 of tube 12. In this manner, the tubes 12 are held in position on the turret. A central tubular member 22 of the turret carries one or more radially extending arms 23, the upper and lower ends of which are provided with flanges 24 to which the plates 16 and 19 can be secured by any suitable means, such for example as by screws 25, or the like. A spindle 26 supported on a stationary housing or frame 28 secured to the machine (not shown) with which the cup dispenser is used receives the tube 22 to position the turret, so that the supplies of cups 14 in the tubes 12 are supported on a plate 30. Preferably, the turret 10 is provided with a cover 31 resting on top of the tubes 12.
As will be explained more fully hereinbelow, in the normal position of the turret 10, one of the tubes 12 registers with an opening 32 in the plate 30, so that the column of cups 14 is permitted to drop downwardly through a guide 34 to a cup-delivery ring assembly indicated generally by the reference character 36. Since this assembly per se forms no part of our invention, it will not be described in detail. As is known in the art, the assembly 36 includes a plurality of cams or fingers 38 which normally support the column of cups but which are withdrawn upon actuation of the assembly 36 to permit one cup to drop from the bottom of the column. An example of one form of actuatable delivery ring which might be incorporated in our assembly is shown and described in Atwood et al. U.S. Pat. No. 3,071,292.
Our apparatus includes a motor indicated generally by the reference character 40 which, in a manner known to the art, receives an electrical signal at a time at which a cup is to be delivered by the assembly 36. Motor 40 drives a reduction gear box 42 having a double ended output shaft 44. The downwardly extending end of shaft 44 carries for rotation therewith a releasing member 46 for the drive for assembly 36. Member 46 has an arcuate slot 48 which receives a pin 50 carried by a link 52. A slot 54 in the link 52 receives a pin 56 carried by a drive link 58 supported for movement on the underside of the frame 28 by one or more pin and slot connections including a slot 60 in the link and a pin 62 on the frame 28. A downwardly extending flange 64 running along one side of the link 58 has an offset 66. A spring 68 connected at one end to the offset 66 and at the other end to the frame 28 normally urges link 58 to move to the left as viewed in FIG. 2. A notch 70 in the flange 64 is adapted to receive the end of an arm 72 forming part of the mechanism 36.
In the rest position of the parts just described the pin 50 is held in the position shown in FIG. 2 by a stationary cam 73, thus to inhibit the action of spring 68. However, as soon as shaft 44 begins to rotate in a counterclockwise direction as viewed in FIG. 2, pin 50 moves radially outwardly past cam 73 and spring 68 is permitted to act rapidly to move link 58 and link 52 to the left as viewed in FIG. 2 until offset 66 strikes a bumper 67. In the course of this movement, arm 72 is moved in a counterclockwise direction to operate the mechanism 36 to withdraw the fingers 38 to permit a cup to drop to the delivery location. In a manner to be described hereinbelow, the circuit of motor 44 is maintained for a single revolution of shaft 44 upon completion of which the parts are restored to the position shown in FIG. 2. It is to be understood that the description of the means for operating the mechanism 36 outlined hereinabove is by way of example only. It may be that where a different ring assembly is used a different direction of drive may be required.
Referring again to FIGS. 1 and 3, a bracket 74 is formed with a lug 78 which is received in an opening 80 in the plate 19. Any suitable means, such for example as a screw 84 secures a turret drive gear 82 to the bracket 74. Loosening of screw 84 permits adjusting the rotary position of turret 10 on gear 82. Gear 82 has a hub 76 surrounding shaft 26. We secure a gear 86 which meshes with gear 82 to a turret drive ring 88 for rotation therewith. A suitable bearing ring 89 supports the assembly of gear 86 and ring 88 in the upper wall of frame 28 in registry with the opening 32, so that cups from a column can pass through the assembly of the gear 86 and the drive ring 88. We form drive ring 88 with a number of circumferentially spaced downwardly extending lugs 90 adapted to be driven in a manner to be described to advance the turret 10 through an angular distance equal to the distance between a pair of tubes 12 when the supply of cups in the tube 12 which is positioned over opening 32 is exhausted.
Our structure for actuating the ring 88 includes an arm 92 supported for pivotal movement on a pin 94 carried by a bracket 95 welded to frame 28. A torsion spring 96 normally urges the arm 92 to rotate in a clockwise direction around pin 94 as viewed in FIG. 3. A slot 98 extending along arm 92 slideably receives an actuator ring-driving slide indicated generally by the reference character 100. A spring 102 extending between a pin 104 on slide 100 and a flange 106 on the end of arm 92 remote from pin 94 normally urges the slide to a right-hand limit position as viewed in FIG. 3. When the supply of cups in a column 12 disposed over opening 32 is depleted a surface 108 on the slide 100 is positioned to engage a lug 90 when the slide is driven to the left as viewed in FIG. 3 in a manner to be described.
The upwardly extending portion of shaft 44 carries a crank arm 110 for rotation therewith. Arm 110 supports a pin 112 which, in the rest position of the parts, is engaged by a flange 114 on arm 92 to hold the arm in position against the action of spring 96 to relieve the pressure of the arm 92 on the cups.
When the motor 40 is energized, shaft 44 rotates in a clockwise direction as viewed in FIG. 3. This action frees arm 92 to permit the arm to swing in a clockwise direction. If the supply of cups in the column 12 positioned over the opening 32 has not reached a predetermined low level, the movement of arm 92 will be arrested by the cups in the column. If, on the other hand, a supply of cups has reached a predetermined low level, so that the movement of arm 92 is not impeded by the cups in the column, the arm will move to the broken line position illustrated in FIG. 3. In this position of the arm, a boss 116 on the underside of slide 100 is in a position to be engaged by crank pin 112. When that occurs, the slide is moved from right to left as viewed in FIG. 3 to cause the surface 108 to engage a pin 90 to produce a predetermined angular movement of the ring 88. This angular movement of the ring causes gear 86 to drive gear 82 through an angular displacement equal to half the angular spacing of a pair of adjacent tubes 12. Thus two cup drops are necessary to achieve column replacement. In the particular arrangement illustrated in FIGS. 1 to 3, nine columns of cups are provided, so that the angular displacement necessary to replace one column with an adjacent column is 40°. It is to be understood that the action of dropping the bottom cup of the column takes place very rapidly after the initial displacement of shaft 44. The dropping action is completed before pin 112 permits any appreciable angular displacement from its home position. Stated otherwise, the configuration of flange 114 and its relationship to pin 112 is such that no appreciable pivotal movement of arm 92 is permitted until the cup dropping operation is complete.
Referring now to FIGS. 3 and 4, in an alternative embodiment of our turret assembly in which we provide six columns of cups, means including an opening 127 in the top of the frame 28 supports spindle 26. In this embodiment, we replace the gear 82 with a gear 124 secured to the bracket 74 in the same manner as that outlined hereinabove in connection with the embodiment illustrated in FIGS. 1 to 3. That is, the alternate six column turret base plate 19' is provided with an opening 80' for receiving the lug 78 to couple the reduced capacity turret to the shaft 26. In the alternative embodiment, the gear 118 drives an intermediate gear 120 supported on a common shaft 121 which carries gear 122 for rotation therewith. Gear 122 drives the gear 124. It will readily be apparent that in this alternative embodiment, the turret is rotated in a direction which is opposite to that in which it is rotated in the embodiment illustrated in FIGS. 1 to 3. Moreover, since there are only six columns of cups in this instance, we rotate the turret through 60° each time the column of cups is to be replenished.
In both forms of our invention, we provide the arm 92 with a flange 126 carrying a tab 128 which prevents overtravel of the ring 88 in the direction in which it is driven to replace the column of cups. Referring again to FIG. 2, a pawl 130 pivotally supported on a pin 132 is urged by a spring 134 to a position at which it engages ring 88 between a pair of adjacent lugs 90 accurately to locate the ring.
As the shaft rotates in a clockwise direction as viewed in FIG. 3, arm 92 is permitted sufficient movement in a clockwise direction even in the presence of cups above a predetermined level to release a full cycle switch 136 which completes the circuit of motor 40 for a full revolution of shaft 44. When the pin 112 moves back to its home position, it gain engages the flange 114 to restore the arm 92 to its initial position and to open the full cycle switch 136.
We provide our cup supply with an empty signal switch 138 having an actuating arm 140. A feeler 142 mounted for pivotal movement on a pin 144 is adapted to move under the influence of gravity into the guide 34 when the last cup from the turret 10 has been delivered. When this occurs, finger 142 moves into the guide and the upper end thereof swings to a position at which it actuates switch arm 140 to disable the merchandising machine and to light a signal or the like (not shown) indicated that the machine is out of cups.
It will be seen that we have accomplished the objects of our invention. We have provided an improved turret cup supply which minimizes the possibility of cup jamming. Our supply is easily adjusted for index position. Our cup supply is relatively simple in construction. It requires only a single motor which operates both the cup drop and the turret indexer. Our apparatus is adapted for use with various cup delivery rings of the prior art. It is readily converted from a turret having a greater number of columns to one having a lesser number of columns or vice versa.
It will be understood that certain features and subcombinations are of utility and may be employed without reference to other features and subcombinations. This is contemplated by and is within the scope of our claims. It is further obvious that various changes may be made in details within the scope of our claims without departing from the spirit of our invention. It is, therefore, to be understood that our invention is not to be limited to the specific details shown and described. | A cup delivery and turret indexing arrangement in which a motor receives a signal indicating that a cup is to be delivered to drive its shaft first to actuate a cup drop ring over which one turret column is positioned and to release a cup supply sensing arm which moves to permit a full cycle switch to close. When the last cup at a predetermined column level has been dropped, the arm moves to position a turret drive slide in the path of a crank pin driver by the shaft to rotate the turret to position a fresh column over the cup drop ring. | 6 |
BACKGROUND OF THE INVENTION
This invention relates in general to flow control valves for drill stem test tools of the type used to test oil producing formations and specifically to flow control valves which are opened and closed in response to external pressure in the well annulus.
Drill stem test (DST) tools are mounted in the drill stem or string and are used to evaluate the producing potential or productivity of an oil or gas bearing zone prior to completing a well. Thus, as drilling proceeds, various indications such as core samples may suggest the desirability of testing a certain formation for producing potential. To conduct the test, a packer and valve assembly is lowered on the drill stem into the uncased well bore to the zone to be tested. The packer is then set and the valve is opened for flow to the well surface.
Various techniques have been utilized to open and close DST valves once the tool has been placed in the well bore. Such techniques commonly comprise rotating the drill stem in a clockwise or counter-clockwise direction, sometimes coupled with lifting up or setting weight down on the tool from the surface. Such techniques are satisfactory in straight well bores such as are commonly encountered on land but are problematical in deviated well bores of the type commonly employed in off-shore drilling operations. A need exists, therefore, for a DST valve which is operable between open and closed positions with a minimum of mechanical manipulation of the drill stem. One solution to this problem is to incorporate an operating means in the DST valve which moves the valve between open and closed positions in response to pressure in the surrounding well annulus. The well bore can then be enclosed and "pressured-up" to operate the valve. Since annulus pressure varies with depth, unexpected variations in pressure can cause the valve to open prematurely. The tool must, therefore, be designed to compensate for variations in the hydrostatic head in the well annulus as the tool is placed and retrieved from the well bore.
SUMMARY OF THE INVENTION
The improved annulus operated valve of this invention has a ball which is movable between an open position to allow flow through the drill string for testing and a closed position to block flow through the drill string during placement and retrieval of the tool in the well bore. Operating means are provided for moving the ball between the open and closed positions in response to pressure in the well annulus. A pressure balancing means is movable between an active position to compensate for variations in annulus pressures and prevent premature opening of the ball and a static position which allows the operating means to open the ball in response to annulus pressure. Actuating means allow the pressure balancing means to be set between the active and static positions by lifting up or setting weight down on the tool at the well surface.
In the preferred embodiment, a pair of shifting linkages extend from opposite sides of the ball. The linkages are adapted to shift in opposite relative directions to open and close the ball valve. A pressure operated inner mandrel slidably engages the first shifting linkage. The inner mandrel is movable between retracted and extended positions in response to pressures in the annulus to shift the first linkage and open the ball.
A sliding spring sleeve surrounds the inner mandrel and engages the second shifting linkage so that movement of the inner mandrel and first linkage causes opposite relative movement of the spring sleeve and second shifting linkage. The spring sleeve is spring-biased thereby urging the ball to the closed position when pressure in the annulus is reduced.
The pressure balancing means includes a fluid-containing pressure chamber having a balancing piston at one end. One side of the balancing piston communicates with the well annulus when the pressure balancing means is active but is isolated from the well annulus when the pressure balancing means is in the static position. Movement of the inner mandrel from the retracted to the extended position compresses fluid in the pressure chamber and exerts pressure on the opposite side of the balancing piston. As long as the pressure balancing means is in the active position, pressure in the well annulus acts on the balancing piston opposing movement of the inner mandrel and holding the ball closed. Actuating means are provided to move the pressure balancing means to the static position, thereby isolating the balancing piston from pressure in the well annulus and allowing the inner mandrel to move and open the ball.
Additional objects, features, and advantages of the invention will be apparent in the following description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1a, 2a, 3a, 4, and 5a, together constitute a longitudinal quarter section of the valve of this invention in the closed position, FIGS. 1a through 5a, respectively, constituting successive downward continuations of FIG. 1a.
FIGS. 1b, 2b, 3b, 4, and 5b, together constitute a longitudinal quarter section of the valve of this invention in the open position, FIGS. 1b through 5b, respectively, constituting successive downward continuations of FIG. 1b.
FIG. 6 is a simplified view of the operation of the ball of the valve showing the movement of the ball from the closed to the open position;
FIG. 7 is similar to FIG. 6 but shows the ball in the fully open position.
FIG. 8 is a cross-sectional view taken along lines VIII--VIII in FIG. 5b.
FIG. 9 is an isolated view of the ball support ring of the valve.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to FIG. 1a, there is shown an annulus operated test valve designated generally as 11 which is designed to be installed in a string of well production tubing by means of a top connection 13. The test valve will normally be run into the well bore with the top connection 13 toward the surface. The tubing string will normally be anchored into position and the test zone sealed off by means of a packer (not shown) located below the test valve in a length of tubing secured to the pin end 45 (FIG. 5) of the test tool. For the purposes of this discussion "top" or "upward" will mean in the direction of the top connection 13 of the tool and toward the surface and "bottom" or "downward" will mean in the direction of the pin end 45.
Top connection 13 is internally threaded on the upper end 15 for connection in the drill string and externally threaded on the lower end 17 for connection to the internally threaded upper portion 19 of a tubular housing 21. The lower portion 23 of tubular housing 21 (FIG. 2a) is threadedly connected to one end of an elongated, downwardly extending body section 25, the opposite end 27 (FIG. 4) of which is threadedly connected to an externally threaded connector sub 29. Sub 29 is threadedly connected to an externally threaded lower connector sub 31.
Sub 31 is threadedly connected to a weight operated sleeve 33 (FIG. 5a) having a splined lower end 35. Lower end 35 of weight operated sleeve 33 slidingly engages the splined surface 37 of an upper extent 39 of a bottom connection 46. Upper extent 39 of bottom connection 46 has an externally threaded surface 41 which engages a complimentary internally threaded surface of a guide sleeve 43.
Guide sleeve 43 has an inner circumferential rib 49 which engages a shoulder 51 of a lower spring-retaining ring 47, thereby securely positioning lower retaining ring 47 between the interior sidewalls 53 of guide sleeve 43, the exterior sidewalls 55 of weight operated sleeve 33 and the upper extent 39 of bottom connection 46. The bottom surface 57 of lower retaining ring 47 thus serves as an upper "stop" limiting the travel of splined lower end 35 of weight operated sleeve 33 along splined surface 37. A shoulder 59 in the interior of bottom connection 46 formed between splined surface 37 and bore 60 of bottom connection 46 serves as a lower "stop" for splined end 35.
The internal diameter of guide sleeve 43 is greater than the external diameter of weight operated sleeve 33, thereby defining an annular clearance 61 above lower retaining ring 47. A coil spring 63 is located in annular clearance 61 and has a lower extent 65 which contacts the upper surface 67 of retaining ring 47, and an upper extent 69. An upper spring retaining ring 71 is threadedly connected to the lower extent 73 of lower sub 31 between the exterior surface 75 of lower extent 73 and the interior sidewall 53 of guide sleeve 43. The bottom surface 81 of upper ring 71 contacts the upper extent 69 of coil spring 63. A pair of O-rings 77, 79 in upper retaining ring 71 sealingly engage sidewall 53 and surface 75 respectively to seal off that portion 83 of annular clearance 61 above ring 71 from inner bore 60.
A seal ring 89 is carried on exterior surface 75 of sub 31 between a stop ring 291 and a shoulder 85 formed in the exterior surface of sub 31 between exterior surface 75 and upper surface 87. Seal ring 89 is comprised of an upper ring 91, a lower ring 93, and a pair of circumferential elastomeric seals 95, 97 located between oppositely facing shoulders 98, 99 in rings 91, 93.
As shown in FIGS. 5a and 5b, the external diameter of seal ring 89 is slidingly received within the interior sidewall of guide sleeve 43 as lower end 35 of weight operated sleeve 33 moves toward shoulder 59. As seal ring 89 is received within guide sleeve 43, the upper surfaces 94, 96 of seals 95, 97 sealingly engages interior sidewall 53. O-rings 80, 82 are provided in the lower surfaces of rings 91, 93 respectively.
Stop ring 291, as shown in FIG. 8, has a series of ports 92 which communicate with a passageway 90 between the interior sidewall of sub 31 and an inner cylinder 174. Passageway 90 communicates with a similar passageway 88 (FIG. 4) between the interior sidewall of sub 29 and inner cylinder 174 which, in turn, communicates with a flow passage 86 (FIG. 4) in sub 29. Stop ring 291 is held in place about the exterior surface 75 of lower extent 73 by a series of shear screws 84 (FIG. 8).
Returning now to FIG. 1a, top connection 13 has an interior bore 103 to allow flow of fluids to the surface. The internal diameter of bore 103 increases toward the lower end 17, forming a shoulder 105 and seat bore 107. A ball seat 109 sealingly engages a ball 111 located within tubular housing 21. Ball 111 is generally spherical in shape with a passageway 113 extending through the ball and a small, generally circular opening 115 in one side.
Ball seat 109 is generally ring-shaped and has ears 117 which are received within the sidewalls of a depending member 119 where it is maintained in sealling engagement by "O" ring 121. The sidewalls 123 of depending member 119 are slidingly engaged by the interior surface of tubular housing 21. Depending member 119 has an external shoulder 125 and a longitudinal extent 127 which is slidingly received within the seat bore 107 of top connection 13. Resilient means, such as springs 129, are positioned between external shoulder 125 of depending member 119 and the lowermost extent 131 of top connection 13. Springs 129 thus serve to urge depending member 119 and ball seat 109 downwardly into engagement with ball 111, upward movement of longitudinal extent 127 within seat bore 107 serving to compress or load the springs 129. Movement of longitudinal extent 127 within bore 107 allows a proper seal to be maintained on ball 111 as the ball is shifted within tubular housing 21 and helps to compensate for dimensional variations in the parts of the device due to machining tolerances and the like.
As shown in FIG. 1a, ball 111 rests on a support ring 133 which in turn rests on a ledge 135 within tubular housing 21. Support ring 133 as shown in FIG. 9, has oppositely positioned slots 137, 139 in which first and second shifting linkages 141, 143 respectively are free to slide. Outwardly extending flanges 145, 147 (FIG. 1a) of linkages 141, 143 are received by a shoulder 149 within the interior of support ring 133, thus limiting downward travel of the linkages 141, 143. Upward travel of linkages 141, 143 is limited by engagement with the lower surface of ball seat 109, and the lower end of depending member 119.
As shown in FIGS. 6 and 7, upward movement of first shifting linkage 141 accompanied by opposite relative movement of second shifting linkage 143 causes ball 111 to shift from the closed position shown in FIG. 1a to the open position shown in FIGS. 1b and 7.
The end of shifting linkage 141 opposite flange 145 is connected to a pressure operated mandrel 151 (FIG. 1a) by means of a coupling 153. Pressure mandrel 151 has an interior bore 155 which communicates with the surface and has an enlarged circumferential protrusion or piston ring 157 (FIG. 3a) which slidingly engages the internal diameter of a collar 159. Collar 159 has a shoulder 161 which limits the downward travel of ring 157 and a cylindrical lower portion 163 which threadedly engages a cylindrical member 165. Cylindrical member 165 has a lower end 167 (FIG. 4) which is supported on an interior ledge 168 in connector sub 29. An oppositely facing ledge 170 in tool connector sub 29 contacts the upper end 172 of inner cylinder 174. The opposite end 176 rests on a shoulder 178 in sub 31.
A port 171 in body section 25 (FIG. 3a) allows fluid communication between the well annulus and the bottom wall 173 of piston ring 157 by means of fluid passages 175, 177, and 179. An "O" ring 181 assures a tight seal between ring 157 and collar 159. Pressure operated mandrel 151 is thus operable between a retracted position as shown in FIGS. 1a, 2a, 3a, 4, and 5a and an extended position as shown in FIGS. 1b, 2b, 3b, 4, and 5b responsive to pressure in the well annulus acting through port 171 and passages 175, 177, and 179 on the bottom wall 173 of piston ring 157. As shown in FIGS. 1a and 1b, movement of mandrel 151 from the retracted position to the extended position causes upward movement of the first shifting linkage 141 to move the ball 111 from the closed position to the open position.
An outer sleeve 183 (FIG. 1a) surrounds the upper extent of pressure operated inner mandrel 151 and has an upper lip 185 adapted to slidingly engage the interior sidewalls 189 of tubular housing 21. Coupling 153 limits the upward travel of outer sleeve 183 but allows the lower end 187 of second shifting linkage 143 to contact upper lip 185. Downward movement of linkage 143 thus causes corresponding downward movement of outer sleeve 183 until lip 185 contacts a shoulder 191 (FIG. 2a) in tubular housing 21.
The end of outer sleeve 183 opposite lip 185 is attached to a spring sleeve 193 by means of a sliding block 195 and screw 197. The upper end 199 of spring sleeve 193 is slidably received within a recess 201 between the lower portion of tubular housing 21 and the interior sidewalls of body section 25. Sliding block 195 is contained within a window 203 in the lowermost extent 205 of tubular housing 21.
The bottom end 194 of spring sleeve 193 rests on a spring retainer ring 207. A coil spring 209 is positioned about the lower extent of pressure mandrel 151 in the space 210 between mandrel 151 and the interior sidewalls of body section 25. Spring 209 is maintained in compression by retainer ring 207 and a lower retaining ring 208 carried on the upper extent of collar 159.
Space 210 between body section 25 (FIG. 3a) and pressure mandrel 151 communicates with a similar space 213 between cylindrical member 165 and body section 25 by means of an opening 215 between collar 159 and body section 25 and by means of conduit 217 through cylindrical lower portion 163 of collar 159. Spaces 210 and 213 together comprise a pressure chamber containing a pressurized fluid, preferably nitrogen gas. A balancing piston 219 (FIG. 4) located in space 213 seals the lower end of the chamber and "T-seals" 221, 223, 225 (FIG. 2a) and "O"-ring 227 in tubular housing 21 seal the upper end of the chamber. "T-seals" 182, 184, 186 (FIG. 3a), and "O"-ring 188 in lower portion 163 of collar 159 seal off the chamber from port 171 and passageways 175, 177 and 179.
As shown in FIG. 5a, when weight operated sleeve 33 is in the position shown, pressure in the well annulus communicates with the lower wall 231 (FIG. 4) of balancing piston 219 by means of flow passage 86, passageways 88 and 90, ports 92 in stop ring 291 and the annular clearance 83 (FIG. 8) between stop ring 291 and guide sleeve 43.
The operation of the annulus operated test valve will now be described in greater detail.
PLACEMENT
FIGS. 1a, 2a, 3a, 4, and 5a show the test valve arranged for "running in" and placement in the well bore. Ball 111 is in the closed position shutting off flow through interior bore 103. The pressure chamber, comprising spaces 210, 213, and connecting conduit 217, is filled with nitrogen gas at, for example, 3000 psi by means of an inlet valve (not shown). Weight operated sleeve 33 (FIG. 5a) is in the "up" position allowing fluid communication between the well annulus and the lower wall 231 of balancing piston 219 by means of ports 92 passageways 88 and 90, and flow passages 83 and 86.
Pressure in the well annulus also acts on the bottom wall 173 of piston ring 157 by means of port 171 and passageways 175, 177 and 179 tending to force piston ring 157 and pressure operated mandrel 151 upward from the retracted to the extended position shown in FIGS. 1b, 2b, 3b, 4 and 5b. Were it not for the pressure balancing feature of the invention, upward movement of mandrel 151 would engage first shifting linkage 141 by means of coupling 153. Upward movement of first shifting linkage 141 would then cause the ball 111 to rotate to the open position as shown in FIGS. 6 and 7 and be accompanied by downward movement of second shifting linkage 143.
Lower end 187 of second shifting linkage 143 would then contact upper lip 185 of outer sleeve 183 which is connected to spring sleeve 193 through sliding block 195. Downward movement of spring sleeve 193 would compress coil spring 209 and, along with the upward movement of mandrel 151 and piston ring 157, reduce the available volume of the pressure chamber thereby exerting a downward force on balancing piston 219.
Mandrel 151, shifting linkages 141, 143, outer sleeve 183, spring sleeve 193, and spring 209, thus comprise operating means for moving the ball 111 between the open and closed positions responsive to pressure in the annulus.
Now, assume that while running into the well bore the pressure in the surrounding annulus is 2000 psi. There is thus a 2000 psi force acting toward on the bottom wall 173 of piston ring 157 tending to move mandrel 151 upward to open the ball 111. However, there is also a 3000 psi force exerted by the nitrogen gas in the pressure chamber acting on the top wall 211 of piston ring 157 which acts to hold the mandrel 151 in place and hold the ball 111 closed.
Assume now that a greater depth is reached and annulus pressure increases to 4000 psi. The 4000 psi pressure differential which acts on piston ring 157 would now act to cause upward movement of the mandrel 151 and rotate the ball 111 as has been described were it not for the annulus pressure which acts on balancing piston 219 through ports 92, passageways 83, 88 and 90, and flow passage 83. This pressure causes balancing piston 219 to move up in space 213 until pressure above and below piston 219 is equalized. Because the pressure acting on the bottom wall 173 of piston ring 157 is then equal to the pressure acting on the top wall 211 of piston ring 157, the pressure differential is eliminated thereby preventing movement of the mandrel 151.
Thus, as long as weight operated sleeve 33 is in the position shown in FIG. 5a, balancing piston 219 moves up and down in space 213 to compensate for fluctuations in annular pressure and prevent premature opening of ball 111.
TESTING
Assume now that the test tool has been placed in the well bore at the desired depth and that the oil producing formation has been sealed off by a packer located in the drill stem below the test tool. It is now desirable to shift the ball 111 to the open position to allow flow up the main tubular bore 103.
Weight is first applied to the drill stem causing weight operated sleeve 33 (FIG. 5b) to move downward with stop ring 291 being slidingly received within guide sleeve 43 and seals 95, 97 of seal ring 89 sealingly engaging the interior sidewall 53 of guide sleeve 43, thereby sealing off annular space 83 and ports 92 in stop ring 91 from communication with the well annulus. Weight operated sleeve 33 continues to move downwardly until splined lower extent 35 contacts shoulder 59 in bottom connection 46.
Now assume the annulus is enclosed at the surface and pressured up to 6000 psi. The 6000 psi force acts through port 171 and passageways 175, 177, and 179 on the bottom wall 173 of piston ring 157 forcing mandrel 151 upward. This 6000 psi upward force overcomes the lesser "locked in" pressure in the nitrogen chamber and causes the ball to shift to the open position as previously described.
When testing is completed, the annulus pressure is relieved and spring 209 acts through retainer ring 207, spring sleeve 193, outer sleeve 183 and second shifting linkage 143 to rotate the ball to the closed position.
As a safety measure, the ball can also be rotated to the closed position by an increase in annulus pressure acting on the upper end 78 (FIG. 5b) of seal ring 89 thereby overcoming the pressure in clearance 83 and passageway 90 causing shear screws 84 in stop ring 291 to shear. Once shear screws 84 are severed, seal ring 89 and stop ring 291 slide down annular clearance 83 thereby opening passageway 90 and ports 92 to the well annulus.
Balancing piston 219, spaces 210, 213, passageways 83, 88, 90 and flow passage 86, thus comprise a pressure balancing means which is movable between an active position responsive to pressures in the well annulus to prevent movement of the operating means and a static position to allow movement in the operating means. Weight operated sleeve 33, guide sleeve 43, stop ring 291, and seal ring 89 comprise an actuating means for moving the pressure balancing means between the active and static positions.
An invention has been provided with significant advantages. The present annulus operated test valve is pressure operated from the surface without rotating the drill string, making it especially suited for use in deviated well bores. A pressure balancing means compensates for fluctuations in annular pressure as the tool is being placed or retrieved from the well bore and prevents premature opening of the ball. The balancing means can be tailored to the particular well conditions by the choice of pressure in the nitrogen chamber, i.e., the nitrogen chamber can be charged to a greater initial pressure where testing will be carried out at greater depths. The spring which assists in closing the ball is located in the nitrogen chamber and is isolated from well bore fluids. By running the tool into the well bore with the ball closed, the tubing string is kept "dry." The ball rotation mechanism is simple in design and dependable in operation.
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 thus limited but is susceptible to various changes and modifications without departing from the spirit thereof. | A valve used in a drill stem test tool has a ball movable between an open position to allow flow through the drill string for testing and a closed position to block flow. Operating means move the ball between the open and closed positions in response to pressures in the well annulus. A nitrogen filled pressure chamber and pressure balancing piston compensate for variations in annular pressure as the tool is being lowered into position in the well. Actuating means including a weight operated sleeve are operated from the surface to overcome the compensating effect of the pressure balancing piston to allow the ball to be rotated to the open position. The ball is spring biased toward the closed position by a coil spring located inside the pressure chamber. Relieving pressure in the annulus causes the spring to close the ball. | 4 |
FIELD OF THE INVENTION
Disclosed herein is a gas generating composition suitable for use in an automobile air bag system.
BACKGROUND OF THE INVENTION
Automobile air bags systems are recognized as the best means to prevent trauma in an automobile accident. Designed to deploy when a vehicle travelling at velocities of 12 m.p.h. or greater experiences a sudden impact, the air bag inflates with a non-toxic gas to form a soft barrier, preventing occupant impact with the automobile interior or windshield. Thus, serious injuries are averted.
Air bags systems have been disclosed in patents as early as the 1950's. By the 1970's such systems were included in Ford, General Motors and Volvo automobiles. Passengers of those vehicles who became involved in accidents were spared serious injury by deployment of the system, conclusively proving the system's beneficence.
The typical air bag system is generally comprised of a sensor that sets off an explosive train, in which the last component is a gas generating device. The gas generating device contains a gas generating composition (a/k/a inflator). The sensor, which operates on mechanical or electro-mechanical principles, senses the energy generated by the crash. Energy is transferred to the sensor starts the explosion train. The gas generating composition rapidly inflates the bag with a non-toxic gas.
The two important components of the airbag system are the sensing device and the gas generating composition. The sensing device, which picks up the energy of the automobile crash and sets off the explosive train, can be either an electromechanical device with a diagnostic system or a mechanical device. A variety of gas generating compositions have been developed to fill the airbag. One of the earliest was that developed by Dow Chemical based on Oxamide as fuel and potassium perchlorate as the oxidizer, along with a coolant, which generated a gas containing 85% carbon dioxide and 13% nitrogen (Proceedings of 3rd International Pyrotechnics Seminar, Denver Res. Institute, Colorado 1972). A number of patents disclose the gas generating compositions, where the non-toxic gas filling the airbag is carbon dioxide. See e.g., U.S. Pat. Nos. 3,532,357, 3,647,353, 3,964,255 and 3,971,729. However, utilizing carbon-dioxide as the airbag-filling gas has not been accepted by the automobile industry, probably due to the fact that incipient oxidation may result in formation of carbon-monoxide, potentially a health hazard at 400 ppm levels. Hence, most of the development has been based on the use of metallic azides in combination with an oxidizer, where the gas generated to fill the airbag is nitrogen. There are numerous patents covering the use of metallic azides for gas generating compositions:
U.S. Pat. No. 3,741,585 discloses the use of metallic azides with metallic sulfides, iodides, oxides and sulfur to generate low temperature nitrogen gas generating composition.
U.S. Pat. No. 3,936,300 discloses the use of sodium azide as the fuel and potassium chlorate as the oxidizer, along with other additives, for the gas generating composition in airbags.
U.S. Pat. No. 3,947,300 discloses the use of sodium azide as the fuel, potassium nitrate as the oxidizer, along with silicon dioxide for slagging out the product of reaction for gas generating composition to be used in airbags. The preferred proportion in which the fuel, oxidizer and slagging agent are to be used are 5:1:2 to 10:1:5. The other oxidizers mentioned in the patent are sodium nitrate, magnesium nitrate, calcium nitrate, sodium perchlorate and potassium perchlorate and the other fuels mentioned are potassium azide and calcium azide.
U.S. Pat. No. 4,547,235 discloses the use of sodium azide in combination with potassium nitrate (an oxidizer) along with silicon dioxide, molybdenum sulfide and sulfur for the gas generating composition in airbags.
U.S. Pat. No. 4,604,151 discloses the use of an alkali metal azide, along with a mixture of metal oxides including manganese dioxide, iron oxide and nickel oxide. The combination of the metal oxides and ammonium perchlorate generate nitrogen gas for airbags.
U.S. Pat. No. 4,696,705 discloses the use of sodium azide in combination with iron oxide, sodium nitrate (as an oxidizer), bentonite, fumed silica, and graphite fibers to generate nitrogen gas to inflate airbags.
U.S. Pat. No. 4,734,141 discloses the use of sodium azide and an oxidizer consisting of bimetallic complexes containing copper or iron in combination with chromium, molybdenum or tungsten and a lubricant like magnesium stearate for generating non-toxic nitrogen gas for the airbags.
U.S. Pat. No. 4,806,180 discloses a gas generating composition for use in airbags consisting of a metal azide (30-50%) sodium nitrate or potassium perchlorate (40-60%) along with Boron 5-15%) and sodium silicate (1-15%).
SUMMARY OF THE INVENTION
Ideally, a gas generating composition should possess the following characteristics. It should be in solid form, capable of being formed into pellets. It should be easy to handle and non-toxic so as to provide a safe manufacturing process. It must not be hygroscopic, as it is likely that the system shall remain dormant for an extended time period. If moisture is absorbed the result can be de-sensitization of the system. The components must not be unduly toxic, thereby preventing safe handling during manufacture. Upon combustion, the composition should produce a predominantly non-toxic gas and the level of residual gaseous impurities must be acceptable when compared to industrial hygiene standards. Finally, the solid residue formed during the gas generating reaction should not form an aerosol of toxic nature, but should be capable of being arrested by the filters included in the inflator system.
It is an object of the present invention to provide a gas generating system which meets the above requirements.
It is a further object to provide a gas generating composition which can be used in the aforedescribed air bag systems.
The composition disclosed herein is comprised of a fuel that generates a non-toxic gas upon decomposition, an oxidizer which aids in igniting the fuel at low temperatures, and an additive that combines with the products of the fuel-oxidant reaction to form a solid slag that is captured by the filters in the housing that contains the gas generating composition. The fuel is a solid metal azide having greater than 60% by weight nitrogen. The oxidant is an alkali nitrate. The additive is a reactive form of silicon dioxide (SiO 2 ).
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The components of the generating composition described above uses, preferably, sodium azide as the fuel. Sodium azide is 63% nitrogen by weight, a non-toxic gas. By practicing reasonable safety habits it can be comminuted and easily handled in solid-solid mixers. The oxidant is potassium nitrate, non-hygroscopic alkali nitrate obtainable in a high degree of purity and does not contain residual heavy metals at levels which could form explosive heavy metallic azides. Diotomaceous earth is used as a slagging agent to prevent the formation of a toxic aerosol as a by-product of the fuel-oxidant reaction. The slagging agent is a solid, consisting essentially of silicon dioxide. It possesses a large surface area, facilitating rapid combination with the product of the fuel-oxidant reaction, forming a complex sodium potassium silicate. The formed slag is easily arrested by the filtering system in the inflator.
For an effective gas generating reaction, particle size of the fuel and the oxidant must be reduced. Preferably, the particles should be in the range of 10 to 30 microns. The slagging agent should also be of a reduced particle size, preferably in the range of 5 to 10 microns and have a surface area of 3000-4000 Cm 2 /gm.
The ingredients described above could be mixed effectively in mixers available in the industry for solids mixing, after comminuting them to the desired degree of fineness. Also, a suitable binder could be used to granulate the composition insuring a free flowing product for pelleting.
The method of assessing the gas generating composition for use in airbags has attracted the attention of manufacturers engaged in the development of this device. A standard method has been to fire the device into a static pressure tank of known volume and study the pressure-time variation, as well as the level of toxic residuals. The pressure-time study data can be correlated to its end use, such as the driver or the passenger side device. The pressure-time data referred to in this disclosure was compiled from tests occurring in a seventy (70) liter tank. The results set forth below can be correlated and compared to test situations where tanks of differing volumes are used.
The objectives and advantages of the invention become more apparent to those skilled in the art, as the invention is further disclosed in the examples to be given below:
EXAMPLE I
A mixture of sodium azide and potassium nitrate, both ground to a size of 15-20 microns and mixed with diatomaceous earth of particle size 5-10 microns and a surface area between 3000-4000 Cm 2 /gm, when mixed in a weight percent proportion of 3:1:1 to 3.5:1:1 of respectively fuel, oxidizer, and slagging agent will give a propellant with a slope of 1.00-1.10 PSI per millisecond in the test tank mentioned earlier and can be used effectively for airbags used on the driver's side, where lower levels of maximum pressure are preferred.
EXAMPLE II
A mixture of sodium azide and potassium nitrate, both ground to a size of 20-30 microns and mixed with diatomaceous earth of particle size of 5-10 microns and 3000-4000 Cm 2 /gm surface area, in a weight percent proportion of 3:1:1, will give a propellant with a slope of 1.10-1.30 PSI per millisecond in the test tank mentioned earlier and can be effectively used on airbags for the drivers side, where higher maximum pressures are desired.
EXAMPLE III
A mixture of sodium azide and potassium nitrate, both ground to a size of 15-20 microns and mixed with diatomaceous earth, 5-10 microns in size of 3000-4000 Cm 2 /gm surface area in a weight percent proportion of 3.3:1:1, gives a propellant that gives propellant with a slope of 1.30-1.65 PSI per millisecond and can be effectively used in airbags for the passenger side, in combination with the propellant from Example 1.
EXAMPLE IV
The flow properties of propellants in examples I through III can be very much improved for the pelleting operations by adding 0.5 to 1.0% of flow improvement additives like Magnesium oxide and Aluminum oxide which are available commercially. Examples of such additives are Magnasol, made by Reagent Chemical and Research Inc. and Aluminum oxide made by Deguissa Corp.
The scope and ambit of the invention is not limited to the pressure-time slope mentioned earlier, for effective use in airbags, as the design of the housing and filter system may vary. The compositions mentioned in the examples can be made to give different pressure-time profiles. Factors that could be used for getting such different profiles are varying the particle size of the fuel and oxidant and using pellets with different geometry as some of the parameters which could be utilized. | The invention disclosed herein is a gas generating composition suitable for use in air bag systems. The gas generating composition is comprised of a solid metal azide as a fuel, an alkali nitrate as an oxidizer, and diatomaceous earth as an additive. | 8 |
CROSS REFERENCE TO RELATED APPLICATION
Provisional Patent Application
Applicant filed a Provisional Application on this subject matter on Apr. 30, 1996, 60/016,580. Specific reference is made to that document.
BACKGROUND OF THE INVENTION
(1). Field of the Invention
This invention relates to cotton gins with a module feed.
(2). Description of the Related Art
A problem exists in cotton gins being fed from a module feeder. The problem is in the interaction of the module feeder and an inclined cleaner. The inclined cleaner is one of the first pieces of machinery to which the seed cotton is fed from a module feeder. The seed cotton may go through a cotton dryer, but this is not considered to be a piece of machinery because the cotton is carried in an air stream. The inclined cleaner is the first piece of machinery where the cotton is engaged by structure which will choke down if overfed. The module feeder inherently feeds cotton at an irregular rate.
In modern cotton gins, cotton will be fed into the inclined cleaner at a rate of about 1,000 lbs. per minute. The inclined cleaner operates at very close to its absolute capacity. If cotton is fed to the inclined cleaner at a rate faster than its capacity, the cotton builds up quicker than the picker rollers can move it over the grids. The cotton chokes up the grid, rotation slows down, additional cotton is fed that moves through the cleaner at a slower rate till the full choke up results. The rollers of the inclined feeder stops and the cotton continues to flow into it until it cuts off the suction.
SUMMARY OF THE INVENTION
This invention solves the problem by providing a storage hopper between the module feeder and the inclined cleaner. The storage hopper is set to disperse cotton at slightly lower rate than the absolute capacity of the cleaner. Therefore, if a surge of cotton from the module feeder enters the gin, the surge is held in the storage hopper for a short period of time until the surge is over. The cotton is fed regularly into the inclined cleaner. It is anticipated that the capacity of the storage hopper might well be no more than the amount of cotton to feed in one (1) minute, i.e. 1000 lbs.
OBJECTS OF THIS INVENTION
An object of this invention is to prevent surges of cotton from choking down the inclined cleaner of a cotton gin.
Further objects are to achieve the above with devices that are sturdy, compact, durable, lightweight, simple, safe, efficient, versatile, ecologically compatible, energy conserving, and reliable, yet inexpensive and easy to manufacture, install, operate, and maintain.
Other objects are to achieve the above with a method that is rapid, versatile, ecologically compatible, energy conserving, efficient, and inexpensive, and does not require highly skilled people to install, operate, and maintain.
The specific nature of the invention, as well as other objects, uses, and advantages thereof, will clearly appear from the following description and from the accompanying drawings, different views of which are not necessarily scale drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side sectional view of a prior art inclined cleaner.
FIG. 2 is a side elevational schematic view of an embodiment of this invention.
FIG. 3 is a sectional view of the dispersing unit.
CATALOGUE OF ELEMENTS
As an aid to correlating the terms to the exemplary drawing(s), the following catalog of elements is provided:
10 inclined cleaner
11 top
12 storage hopper or chamber
13 bottom
14 normal entry
16 suction pipe
17 module feeder
18 trash outlet
20 vacuum dropper
24 rollers
26 suction transit
28 down stream
30 elbow
32 variable speed mtr.
34 dispersing unit
36 feed rollers
38 dispersing spikes
40 wad buster
42 outlet transfer means
50 by-pass conduit
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings there may be seen an inclined cleaner 10. The cleaner, except for having an additional opening for chamber or storage hopper 12 is according to the prior art. It will have a normal entry 14 which before this invention was where all of the seed cotton and air was fed into the cleaner. The cotton and air was furnished to the cleaner by a extension of the suction pipe 16. This is referred to as an extension of the suction pipe 16, although actually it may be a pipe extending from a dryer. Stated otherwise the pipe 16 is a inlet transfer means for transferring seed cotton from a feed means for feeding seed cotton into the cotton gin. The feed means is represented in the drawings by module feeder 17.
The inclined cleaner will have a trash and air outlet 18 at the bottom as is conventional. The cotton from the inclined cleaner will be discharged from the vacuum dropper 20 into a conveyor as is conventional. An electric motor (not shown) will power the rollers 24 within the inclined cleaner.
Those in the skill of the ordinary art will understand that basically the equipment that is described to this point is conventional and well known except for the additional opening for the hopper.
According to this invention, transition 26 from the suction pipe 16 is located between the suction pipe 16 and the storage hopper 12 so that the inlet feed width is increased to the full width of the storage hopper 12 which is the width of the inclined cleaner 20. Elbow 30 extends from down stream end 28 of the transition 26.
In normal operation, most of the air and all of the seed cotton will flow through the elbow into the hopper 12. Feed rollers 36 are at the bottom of the hopper. The feed rollers are driven by variable speed motor 32. Wad buster cylinder 40 is located below the feed rollers. The wad buster cylinder will also be driven by the variable speed motor 32.
In operation if there is no sudden surge or slug of seed cotton fed, the cotton and air will flow through the hopper 12, through feed rollers and the wad buster cylinder into the inclined feeder. Experience has shown that the cotton drops into the inclined feeder at approximately the same location as if it were fed through the conventional opening 14 because of the angle of the conventional opening 14.
However, when a surge of seed cotton is fed, it will flow into the hopper faster than the variable speed feed rollers discharge it into the inclined feeder. Therefore, the hopper will fill partially with seed cotton. In as much as the air flow will not flow through the seed cotton readily, the air flow will be diverted back into by-pass conduit 50, which is connected from the inside of the elbow into the normal inlet 14 of the inclined feeder. When there is a slug of cotton in the hopper 12, the elbow 30 functions as an inertia separator. That is to say that the seed cotton because of its weight will be carried by inertia into the path that leads it into the hopper 12. However the air will be separated from the cotton and the air will go into the by-pass conduit 50.
In operation the feed rollers are set to feed the cotton as close to the maximum capacity of the inclined cleaner as possible without providing such a heavy feed that it causes the rollers to rotate at a slower speed, thus causing the problems. As soon as the surge of cotton is fed through, then the additional cotton is fed directly from the transition and elbow and the feed rollers do not impede the rate of flow of the cotton into the inclined feeder in any way. Stated otherwise, that the feed roller only impede the flow of the cotton into the inclined cleaner when there is a surge of cotton which would otherwise plug up or choke down the inclined feeder operation.
It will be understood that many variations of operations could be made. Although spiked feed rollers are preferred, it may be understood that other types of feeders could be used. The feed roller and the wad buster will have dispersing spikes 36 thereon. The rollers or wad buster perform as a means for moving the spikes along with the variable speed motor 32. It will be the spikes 36 which remove the seed cotton from the upright chamber 12 at a controlled rate.
The portion of the chamber 12 below the elbow 30 is considered the top 11 of the chamber and the portion above the feed rollers are considered the bottom 13 of the chamber. The chamber has a uniform cross-section between the top 11 and the bottom 13. That portion of the equipment which is below the bottom 13 of the chamber 12 is considered to be the dispersing unit 34. The portion of the equipment below the wad buster 40 is considered to be a outlet transfer means 42 which is for transferring the seed cotton. As seen the means 42 interconnects the dispersing unit to the seed cotton cleaner, also referred to as the inclined cleaner 10.
The suction 16 and transition 26 function as an inlet transfer means for transferring seed cotton into the chamber 12 by a blast of air in a conduit.
An additional advantage of this invention is that the cotton from the wad buster 40 in outlet transfer means 42 is spread evenly over the width of the inclined cleaner. This permits the inclined cleaner to operate at a higher rate than if the cotton is fed mainly along the center.
The storage hopper 12 with the separator comprising elbow 30 and by-pass 50, and also the dispersing unit 34 could operate A as a free standing unit. This free standing unit would be located after a module feeder and before the first seed cotton cleaner unit. The previously separated air blast would be reunited with the seed cotton at the free standing unit.
The embodiment shown and described above is only exemplary. I do not claim to have invented all the parts, elements or steps described. Various modifications can be made in the construction, material, arrangement, and operation, and still be within the scope of my invention.
The restrictive description and drawings of the specific examples above do not point out what an infringement of this patent would be, but are to enable one skilled in the art to make and use the invention. The limits of the invention and the bounds of the patent protection are measured by and defined in the following claims. | A storage hopper is placed upstream of an inclined cleaner to prevent a surge of cotton from choking down the inclined cleaner. The output of the storage hopper is limited by feed rollers. | 3 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This original non-provisional application claims priority to and the benefit of U.S. provisional application Ser. No. 61/962,017, filed Oct. 29, 2013, and entitled “Dental Apparatus and Method for the Digital Diagnosis, Computer Design and Manufacture of Dental Devices,” which is incorporated by reference herein.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] None.
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] This invention is related to dental recording devices, and more particularly to an intra oral dental recorder and related method for recording, scanning and digitizing the unique envelope of motion of a dental patient's jaw for use in the construction of dental devices.
[0005] 2. Description of the Related Art
[0006] For over two hundred years, most if not all dental devices have been made by hand using artisan type manual labor. Recently, digital methods of imaging patients using cone-beam computed tomography (CBCT), laser, light and ultra sound scanning and contact digitizing have transformed the process of making these devices. Three dimensional computer numerical control milling and additive manufacturing technologies are used extensively in dentistry and it appears that almost all devices in the future will be manufactured using digital techniques.
[0007] The human jaw is capable of complex motion because it is unique in that the mandible is rigidly attached to two moveable surfaces, or condyles. The movement of the jaw is not just a hinge motion; it can also have translation motion and rotation motion of the condyles in the glenoid fossae, the depression in the temporal bone that articulates with the condyles. This jaw motion is also constrained by ligaments, the meniscus and muscles. Due to these intricate factors, jaw motion is unique to each patient, and, as such, is complex and difficult to record and reproduce. These factors result in a unique three dimensional envelope of motion for any given patient.
[0008] In prior art, intra oral tracing devices have been used to shape moldable material with scribing or tracing pins to create what is known as a gothic arch tracing. A set of at least three such gothic arch tracings can accurately describe the unique three dimensional envelope of movement of a specific patient. These tracings were then used to mold material contacting the condylar surfaces of an articulator or to mold material on other types of cast holding devices to reproduce the patient's movement. With the advent of digital manufacturing, a physical articulator is not needed but accurate digital recording of a patient's jaw movement is.
[0009] Several new companies have developed processes to manufacture dentures using milling or additive manufacturing. However, a simple and cost effective method of recording jaw motion and a method of translating that recording into useful digital data have not yet been developed. All present digital recording devices are complex, expensive and do not allow for direct use in the digital manufacture of dental devices, such as dentures. There is a need for an economical device and method that faithfully and digitally records the position of the upper and lower impressions made with traditional impression materials or digital impressions (scans) of the patient and records the movement of the mandible and its neuro-muscular influences in a digital form.
BRIEF SUMMARY OF THE INVENTION
[0010] The present invention is an intra oral gothic arch tracing and dental motion recording device and method for recording the three dimensional envelope of motion of a patient and translating the recording into digital information which is used to diagnose, computer design and manufacture dental restorations. The dental device is comprised of upper and lower gothic arch tracing members having scribing or tracing pins on one member and complementary recording material on the other. The method includes forming a set of intra oral gothic arch tracings to define the three dimensional envelope of motion, converting the tracings to a digital data set that faithfully reproduces that motion, and using the data to create a virtual model of the patient and the jaw motion of the patient for constructing dentures. The data may also be used to mill articulator housings to faithfully reproduce jaw motion and to virtually position virtual teeth and shape them in conformity with the patient's jaw motion. The data can also be used to mill the completed dental prosthesis to insure the contacting surfaces of the teeth are in harmony with the patient's jaw motion.
[0011] It is an object of this invention to provide an improved method for constructing dentures.
[0012] It is another object of this invention to provide an improved apparatus for constructing dentures, including an intra oral tracing apparatus.
[0013] It is yet another object of this invention to provide a method and apparatus for constructing dentures, wherein movements of the jaw can be recorded and translated into digital data that identically reproduces that movement.
[0014] It is yet another object of this invention to provide a method and apparatus to join digital scan data from different scanning devices and systems to create a virtual computer model of the patient.
[0015] It is yet another object of this invention to use the digital data of a patient's jaw motion to mill condylar housings for a simple condylar articulator whereby the movement of the articulator may be confined to the envelope of motion, i.e., movement of the lower jaw as recorded in the sagittal (or vertical) and horizontal planes, of the patient.
[0016] It is yet another object of this invention to use the digital data about a patient's jaw motion to create a virtual upper and lower model of a patient's jaw that moves in an identical manner as the patient's jaw recording and to set virtual teeth to create a digital denture in harmony with the patient's jaw motion.
[0017] It is yet another object of this invention to digitally mill the surfaces of manufactured dentures such that the teeth are in harmony with the patient's jaw movement and the type of contacting occlusal relationship indicated for the patient.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0018] FIG. 1 is a top view of the lower gothic arch tracing member of the present invention.
[0019] FIG. 2 is a bottom view of the upper gothic arch tracing member of the present invention.
[0020] FIG. 3 is a rear elevated view of the intra oral gothic arch dental motion recording device of the present invention showing upper and lower gothic arch tracing members in an opposing complementary configuration.
[0021] FIG. 4 is an occlusal view of the lower gothic arch tracing member of FIG. 1 with recording material and illustrating the gothic arch tracings. The lower handle has been removed.
[0022] FIG. 5 shows an occlusal view of a single anterior gothic arch tracing from FIG. 4 made on the lower gothic arch tracing member.
[0023] FIG. 6 depicts the upper and lower gothic arch tracing members of the present invention in centric relation and the digital scans made therefrom.
[0024] FIG. 7 is a flow chart of the method of the present invention for recording jaw motion and scanning the tracing members.
[0025] FIG. 8A depicts an anterior gothic arch digital scan of the present invention in an .stl format.
[0026] FIG. 8B is a cross sectional view of FIG. 8A illustrating the channel created by the tracing pin of the present invention in an .stl format.
[0027] FIG. 9 depicts the three gothic arch tracings of FIG. 4 from the .stl scan of the lower gothic arch tracing member of the present invention.
[0028] FIG. 10 is an occlusal view of upper virtual teeth set in relation to the virtual upper impression of the present invention.
[0029] FIG. 11 is an occlusal view of a mandibular molar denture tooth.
[0030] FIG. 12 is a perspective view of a dental articulator.
DETAILED DESCRIPTION OF THE INVENTION
[0031] An intra oral gothic arch dental motion recording device 10 according to the present invention is comprised of lower gothic arch tracing member 12 and upper gothic arch tracing member 16 , as shown in FIGS. 1 and 2 . Referring now to FIG. 1 , lower gothic arch tracing member 12 has handle 20 removably attached to lower tray 15 . Handle 20 can be used to ideally position lower gothic arch tracing member 12 in a patient's mouth (not shown). Dental impression material 13 (see FIG. 3 ) is placed in lower tray 15 and positioned over the lower soft tissues and teeth to retain lower gothic arch tracing member 12 and to record the shape of the lower teeth and tissue. Dental impression material 13 may be polyvinyl siloxane or other suitable material. Handle 20 can easily be removed, if necessary.
[0032] Lower gothic arch tracing member 12 has at least three receiving areas 22 at various locations on and within lower tray 15 . Receiving areas 22 are depressions or recesses within lower tray 15 for the placement of recording material 18 (see FIG. 4 ). Threaded post 21 is centrally located within and traverses lower tray 15 . Threaded post 21 can be moved up or down to record movement at the correct amount of jaw opening which has previously been determined. At least three radiographic fiducial markers 40 are attached to lower tray 15 at locations adjacent to receiving areas 22 .
[0033] Referring now to FIG. 2 , upper tray 17 of upper gothic arch tracing member 16 has contact plate 24 which contacts threaded post 21 when upper tray 17 is in the mouth (not shown). The configuration of contact plate 24 may be flat, curved or arched and still be within the contemplated invention. Upper handle 23 removably attached to and extending distally from upper tray 17 is used to position upper tray 17 in the mouth (not shown) with dental impression material 13 to stabilize upper gothic arch tracing member 16 and to record the shape of the upper tissue or teeth.
[0034] Three or more scribing or tracing pins 25 are rigidly attached to upper tray 17 in a triangular configuration. For example, one tracing pin may be located at an anterior position of the mouth while the other two tracing pins are located at posterior positions on either side of the mouth. The plurality of tracing pins 25 are used to cut and shape recording material 18 located on lower intra oral gothic arch tracing member 12 (see FIG. 4 ) to record the three dimensional border movements, i.e., envelope of motion, of the patient's mandible.
[0035] In the preferred embodiment, threaded pin 21 is on lower tray 15 and contact plate 24 on upper tray 17 . However, the two components (i.e., threaded pin 21 and contact plate 24 ) can be reversed such that threaded pin 21 is on upper tray 17 and contact plate 24 is on lower tray 15 , if preferred. The same is true for tracing pins 25 and receiving areas 22 . In the preferred embodiment, tracing pins 25 are on upper tray 17 and receiving areas 22 on lower tray 15 but the positions can be reversed with receiving areas 22 on upper tray 17 and tracing pins 25 on lower tray 15 . Finally, radiographic fiducial markers 40 are located on lower tray 15 but can also be on upper tray 17 to accomplish the same purpose.
[0036] Fiducial markers 40 have a shape, e.g., round, that can be precisely located in a digital scan of lower gothic arch tracing member 12 with light, laser, cone-beam computed tomography (CBCT) or contact digitizing. Only fiducial markers 40 are radiolucent and will be detected with radiographic imaging. The remaining portions of upper gothic arch tracing member 16 and lower gothic arch tracing member 12 of intra oral gothic arch dental motion recording device 10 are radiolucent and will not distort radiographic images. In the preferred embodiment, intra oral gothic arch dental motion recording device 10 is made of a radiolucent plastic, such as carbon fiber or other similar material.
[0037] FIG. 3 is a rear view of intra oral gothic arch dental motion recording device 10 illustrating how upper and lower gothic arch tracing members 12 , 16 would appear and be aligned relative to each other in the mouth. Upper gothic arch tracing member 16 and lower gothic arch tracing member 12 are aligned in centric position relation with respect to each other. Centric relation is the position of the mandible in relation to the maxilla when the condyles are situated as far anteriorly and superiorly as possible within the glenoid fossa. At centric relation, the condyles are both simultaneously seated most superiority in their respective glenoid fossa.
[0038] Upper tray 17 of upper gothic arch tracing member 16 is stabilized in the mouth with impression material 13 , such as polyvinyl siloxane or other suitable material, that conforms to and records the shape of the upper oral tissue.
[0039] Contact plate 24 provides a vertical stop for threaded post 21 at the proper vertical dimension of occlusion (VDO) for any given patient. At the proper VDO, the patent's teeth are in maximum intercuspation, i.e., where the cusps of the teeth of both the top set and the bottom set of teeth are fully interposed with each other. Adjustments in the vertical contact position may be made by turning threaded post 21 in a manner similar to turning a screw. For example, turning threaded post 21 in a clockwise direction extends threaded post 21 further from lower tray 15 , expanding the distance between upper gothic arch tracing member 16 and lower gothic arch tracing member 12 . Conversely, rotating threaded post 21 in a counterclockwise rotation minimizes the distance between upper gothic arch tracing member 16 and lower gothic arch tracing member 12 .
[0040] Lower tray 15 of lower gothic arch tracing member 12 is also stabilized with impression material 13 which conforms to and records the shape of the lower oral tissues. Upper tracing pins 25 capture the right lateral, left lateral and protrusive mandibular movements, i.e., envelope of motion, in recording material 18 . Recording material 18 is applied at the same locations where receiving areas 22 (not shown) are located (see FIG. 1 ). Recording material 18 may be methyl-methacrylate resin, dental modeling compound, plaster, wax, light curable composite or any other suitable recording material.
[0041] Intra oral gothic arch dental motion recording device 10 of the present invention is universally sized, e.g., small, medium and large, to accommodate and be used with patients of various ages and sizes from children to adults.
[0042] In a procedure well known in the dental art, the patient is guided in mandibular movements to cut border movements in the recording material. When the dental professional, e.g., a dentist, is guiding the patient in this procedure, the patient is asked to move the jaw forward and backward, as well as to the left and to the right. The result is a gothic arch tracing with the centric relation position at the apex of the gothic arch tracing. It is useful in the process of making dentures to record this centric position by requesting the patient to move back until the apex position is reproduced and a locking material 14 , such as polyvinyl siloxane or other similar bite registration material, is injected into space 29 between upper contact plate 24 and lower threaded post 21 , as shown in FIGS. 3 and 6 .
[0043] In the preferred embodiment, the patient can have a CBCT scan made with upper gothic arch tracing member 16 and lower gothic arch tracing member 12 locked in this centric position (see FIG. 6 ). Radiographic fiducial markers 40 can then be located in the CBCT scan as well as in the scanning of upper and lower gothic arch tracing members 12 , 16 out of the mouth. This makes it possible to join data from the CT scan with the jaw movement recording of upper and lower gothic arch tracing members 12 , 16 .
[0044] FIG. 4 is a top occlusal view of lower gothic arch tracing member 12 illustrating anterior gothic arch tracing 19 a , right posterior gothic arch tracing 19 b , and left posterior gothic arch tracing 19 c cut into recording material 18 . Each gothic arch tracing 19 a - c has an arrowhead shape with the apex being the centric relation position. These gothic arch tracings 19 a - c are cut into recording material 18 by tracing pins 25 (see FIGS. 2 and 3 ) and have a complex three dimensional shape that reflects the precise border and protrusive movements of the mandible.
[0045] FIG. 5 is a top view of anterior gothic arch tracing 19 a cut into recording material 18 . Centric relation point 34 is located at the point where the individual mandibular movements making up the envelope of motion converge, i.e., the apex of the protrusive 28 , right lateral 26 and left lateral 27 movements.
[0046] FIG. 6 illustrates the steps in scanning the tracing members. Physical combination 43 of upper and lower gothic arch tracing members 16 , 12 —which are locked in centric position using locking material 14 —of intra oral gothic arch dental motion recording device 10 is first scanned (noted by solid arrow 108 pointing right) with contact, CT, laser or light to produce accurate three dimensional digital images (e.g., .stl file) of upper tissue surface 104 from impression material 13 (resulting in virtual upper impression 41 ) and lower tissue surface 106 from impression material 13 (resulting in virtual lower impression 42 ) in centric relation. Various light scanners from, for example, 3Shape, Dental Wings, and MEDIT are commercially available to perform the scan. In additional, other commercially available scanners may also be used.
[0047] Upper gothic arch tracing member 16 from physical combination 43 is then separated and scanned (noted by solid arrow 110 pointing up) separately to create a three dimensional digital image (e.g., .stl file) of upper tissue surface 104 from upper impression material 13 and occlusal surface 100 with tracing pins 25 , resulting in virtual upper tissue surface 44 . Lower gothic arch tracing member 12 from physical combination 43 is also separated and scanned (noted by solid arrow 112 pointing down) to create a three dimensional digital image (e.g., .stl file) of lower tissue surface 106 from lower impression material 13 and occlusal surface 102 , resulting in virtual lower tissue surface 45 , including fiducial markers 40 , threaded post 21 , and the plurality of gothic arch tracings 19 a - c . Once scanning is complete, intra oral gothic arch dental motion recording device 10 is no longer needed and may be discarded.
[0048] Referring now to FIG. 7 , flow diagram 300 of the method of the present invention is provided illustrating the steps used to record jaw motion and to scan lower gothic arch tracing member 12 and upper gothic arch tracing member 16 of intra oral gothic arch dental motion recording device 10 . Beginning with step 302 , the dental professional inserts upper and lower gothic arch tracing members 16 , 12 with impression material 13 in the patient's mouth. The height of threaded post 21 is set to proper vertical dimension of occlusion in step 304 . Proper spacing for tracing pins 25 is checked and recording material 18 is added to lower tray 15 , as indicated in step 306 . The dental professional then guides the patient through protrusive, right lateral and left lateral jaw movements while recording same in step 308 . Once the envelope of motion has been recorded, the dental professional then guides the patient into placing the patient's jaw into centric relation position. The dental professional then proceeds to inject locking material 14 between the upper and lower gothic tracing members 12 , 16 , as indicated in step 310 . A cone-beam computed tomography scan is made, if indicated, in step 312 . The dental professional then sends the upper and lower gothic tracing members 12 , 16 and locking material 14 to a proper facility, such as a laboratory, to be scanned, as indicated in step 314 . The upper and lower gothic tracing members 12 , 16 are then scanned together in centric relation and then scanned separately to create 3D digital data files (see FIG. 6 ), as indicated in step 316 .
[0049] FIG. 8A is an .stl image and digital scan 30 of anterior gothic arch 19 a . FIG. 8B is a cross sectional view and .stl image 116 of channel 114 within anterior gothic arch 19 a —across 116 - 116 of FIG. 8 A—created by tracing pin 25 (see FIG. 2 ) in recording material 18 (see FIG. 4 ). In FIG. 8B , .stl image 116 is cut in a cross section along the x-axis to view the .stl file (.stl image 116 ) which describes raw unstructured triangulated surface 118 by the unit normal and vertices (ordered by the right-hand rule) of the triangles using a three-dimensional Cartesian coordinate system. Simple mathematical algorithms can sort all triangle vertices to select only the lowest points, such as low point 31 , which describe the path of tracing pin 25 through recording material 18 . Simple mathematical algorithms can also sort and use the low points, e.g., low point 31 , in channel 114 to create a polyline or spline of the path of the tracing pin in the recording material. FIG. 8A illustrates 3D splines 32 of anterior gothic arch tracing 19 a.
[0050] The gothic arch tracing process can very accurately record jaw movement but the exact timing is not known. However, the starting point and the end point of each movement are known. For example, referring to FIG. 8A , centric relation point 34 is the common starting point for all three mandibular movements (i.e., protrusive, right lateral and left lateral). End point 35 is the end point of the movements, though the end point will be at different locations for each movement.
[0051] FIG. 9 illustrates the three gothic arch tracings 19 a - c showing right lateral movement 33 created by tracing pin 25 (see FIG. 2 ) in recording material 18 (see FIG. 4 ). These three gothic arch tracings 19 a - c are from the .stl scan of lower gothic arch tracing member 12 . To illustrate the method of the present invention for using scan data to digitally record movement and to create a virtual computer model of the patient, right lateral movement 33 in FIG. 9 will be used for illustration purposes. However, the same process may be used for the protrusive and left lateral movements.
[0052] Many methods are used in computer science to move one virtual object in relation to another. Since three points define any object in space, they can be used in computer-aided design (CAD) software to move an object in computer space to another position in computer space precisely.
[0053] Still referring to FIG. 9 , the splines of right lateral movement 33 for each of anterior gothic arch splines A, right posterior gothic arch splines B and left posterior gothic arch splines C are all of a different length. An excellent estimate of the position of the tracing pin along each of right lateral splines A, B, C can be obtained by bisecting each spline and locating midpoint 36 along the spline. This process of mathematically dividing the spline proportionally will generate Cartesian coordinate points to correctly move the virtual upper and lower impressions in computer space. This process may also be used to move virtual denture teeth to reproduce the motion that exists in the patient. This process may further still be used to mill manufactured dentures to be in conformity with a given patient jaw motion.
[0054] Still referring to FIG. 9 , three gothic arch tracings corresponding to various locations within the patient's jaw are shown. Centric positions 34 of anterior gothic arch tracing A, right posterior gothic arch tracing B and left posterior gothic arch tracing C—i.e., three points—define the position of virtual upper impression 41 in relation to virtual lower impression 42 (see FIG. 6 ). To find the position of virtual upper impression 41 in relation to virtual lower impression 42 at the middle of right lateral movement or tracing 33 , centric points 34 at anterior gothic arch tracing A, right posterior gothic arch tracing B and left posterior gothic arch tracing C may be used to make virtual upper impression 41 move from centric points 34 to bisector points 33 of anterior gothic arch tracing A, right posterior gothic arch tracing B and left posterior gothic arch tracing C. If end points 35 of anterior gothic arch tracing A, right posterior gothic arch tracing B and left posterior gothic arch tracing C—i.e., three points—are used to make virtual centric points 34 and virtual upper impression 41 move in computer space to a new position, the movement of the upper jaw to the end of the right lateral recording or movement 33 will be faithfully reproduced.
[0055] Simple moves from centric point 34 , bisector point 33 , and end point 35 have been used to illustrate the method of precisely creating virtual movement of the jaws in computer space. If the splines are divided further into smaller proportional divisions such as ¼, ⅙, 1/50 or 1/100 of the spline, then an even more accurate record of virtual movement may be made. If needed, the points (XYZ) can be translated into data as a sequence of six (6) degrees of freedom (X, Y, Z translations, and Rx, Ry, Rz Euler angles) as measured at some specific point on the mandible or maxillae.
[0056] FIG. 10 is an occlusal view (i.e., toward the biting surface of posterior teeth) of upper virtual teeth set 120 in relation to virtual upper impression 41 (not shown). Virtual teeth 37 are set in centric relation position in relation to virtual lower impression 42 (not shown). Virtual teeth 38 have been moved in computer space to the bisected position along the right lateral spline. Virtual teeth 39 represent a virtual move of the teeth and virtual upper impression 41 to the end of the right lateral spline.
[0057] The arrows in FIG. 10 represent the direction of movement in the occlusal view, demonstrating that though the teeth travel together the same distance, the teeth do not necessarily travel in the same direction. This recording of movement can also be used to precisely refine the occlusal contacts (i.e., contacts between the upper and lower teeth when the jaw is in a closed position) of the digitally manufactured dentures.
[0058] Teeth that are used in the manufacture of dentures have predetermined contours and contact relationships that may not be in harmony with the patient's jaw movement. Frequently, in the construction of dentures, it is necessary to have the denture teeth contact in a lingualized relationship with bilateral balance. FIG. 11 illustrates a left mandibular molar denture tooth 46 . Upper lingual cusp 47 fits properly in the central fossae of lower left mandibular molar denture tooth 46 but has protrusive 48 , right lateral 49 and left lateral 50 interferences when the mandible moves in these border motion positions that have been measured using the dental motion recording device of the present invention. By using the digital information obtained from the dental motion recording device of the present invention, the interferences can be removed using a number controlled mill to create bilateral balance in the molar occlusal relationship. The same process can be used to mill all the teeth in the processed denture to create bilateral balance or any other type of occlusal relationship.
[0059] Referring now to FIG. 12 , a typical arcon type semi-adjustable articulator 122 used in dentistry is shown. Articulator 122 is called “semi-adjustable” because this type of articulator cannot follow a patient's jaw motion but is an approximation to that movement. The present invention provides an inexpensive method of reproducing a patient's exact jaw movement by milling 58 the condylar housing 51 to allow condylar ball 52 of articulator 122 to travel in the same motion as the patient. It is also possible to mill anterior pin stop 57 such that incisal pin 59 of articulator 122 travels along a milled surface that has protrusive contour 54 , right lateral contour 55 , and left lateral contour 56 that will reproduce the exact movement of the patient's jaw.
[0060] The various embodiments described herein may be used singularly or in conjunction with other similar devices. The present disclosure includes preferred or illustrative embodiments of specifically described apparatuses, assemblies, methods and systems. Alternative embodiments of such apparatuses, assemblies, methods and systems can be used in carrying out the invention as claimed and such alternative embodiments are limited only by the claims themselves. Other aspects and advantages of the present invention may be obtained from a study of this disclosure and the drawings, along with the appended claims. | An intra oral dental device and method for recording the 3D envelope of motion of a patient and translating the recording into digital information used to diagnose, computer design and manufacture dental restorations. The dental device is comprised of upper and lower tracing members having tracing pins on one member and complementary recording material on the other. The method includes forming a set of intra oral gothic arch tracings to define the 3D envelope of motion, converting the tracings to a digital data set reproducing the motion, and using the data to create a virtual model of the patient and the jaw motion. The data is used to mill articulator housings to reproduce jaw motion, to virtually position and shape virtual teeth in conformity with the patient's jaw motion, and to mill the completed dental prosthesis insuring teeth contacting surfaces are in harmony with the patient's jaw motion. | 0 |
This is a Continuation Application of application Ser. No. 09/026,896, filed Feb. 20, 1998, now abandoned.
FIELD OF THE INVENTION
The present invention relates to vaccine formulations comprising papilloma virus proteins, either as fusion proteins, truncated proteins, or truncated fusion proteins The invention further embraces methods for producing capsomeres of the formulations, as well as prophylactic and therapeutic methods for their use.
BACKGROUND
Infections with certain high-risk strains of genital papilloma viruses in humans (HPV)—for example. HPV 16, 18, or 45—are believed to be the main risk factor for the formation of malignant tumors of the anogenital tract. Of the possible malignancies, cervical carcinoma is by far the most frequent: according to an estimate by the World Health Organization (WHO), almost 500,000 new cases of the disease occur annually. Because of the frequency with which this pathology occurs, the connection between HPV infection and cervical carcinoma has been extensively examined, leading to numerous generalizations.
For example, precursor lesions of cervical intraepithelial neoplasia (CIN) are known to be caused by papilloma virus infections [Crum, New Eng. J. Med. 310:880-883 (1984)]. DNA from the genomes of certain HPV types, including for example, strains 16, 18, 33, 35, and 45, have been detected in more than 95% of tumor biopsies from patients with this disorder, as well as in primary cell lines cultured from the tumors. Approximately 50 to 70% of the biopsied CIN tumor cells have been found to include DNA derived only from HPV 16.
The protein products of the HPV 16 and HPV 18 early genes E6 and E7 have been detected in cervical carcinoma cell lines as well as in human keratinocytes transformed in vitro [Wettstein, et al., in PAPRILLOMA VIRUSES AND HUMAN CANCER, Pfister (Ed.), CRC Press: Boca Raton, Fla. 1990 pp 155-179] and a significant percentage of patients with cervical carcinoma have anti-E6 or anti-E7 antibodies. The E6 and E7 proteins have been shown to participate in induction of cellular DNA synthesis in human cells, transformation of human keratinocytes and other cell types, and tumor formation in transgenic mice [Arbelt. et al., J. Virol, 68:4358-14364 (1994): Auewarakul, et al., Mol. Cell. Biol. 14:8250-8258 (1994); Barbosa. et al., J. Virol. 65:292-298 (1991); Kaur, et al., J. Gen. Virol. 70: 1261-1266(1989): Schlegel. et al., EMBO J., 7:3181-3187 (1988)]. The constitutive expression of the E6/E7 proteins appears to be necessary to maintain the transformed condition of HPV-positive tumors.
Despite the capacity of some HPV strains to induce neoplastic phenotypes in vivo and in vitro, still other HPV types cause benign genital warts such as condylomata acuminata and are only rarely associated with malignant tumors [Ikenberg,. In Gross, et al., (eds.) GENITAL PAPILLOMAVIRUS INFECTIONS. Springer Verlag: Berlin, pp., 87-112]. Low risk strains of this type include, for example, HPV 6 and 11.
Most often, genital papilloma viruses are transmitted between humans during intercourse which in many instances leads to persistent infection in the anogenital mucous membrane. While this observation suggests that either the primary infection induces an inadequate immune response or that the virus has developed the ability to avoid immune surveillance, other observations suggest that the immune system is active during primary manifestation as well as during malignant progression of papilloma virus infections [Altmann et al. in VIRUSES AND CANCER, Minson et al., (eds.) Cambridge University Press, (1994) pp. 71-80].
For example, the clinical manifestation of primary infection by rabbit and bovine papilloma virus can be prevented by vaccination with wart extracts or viral structural proteins [Altmann, et al., supra; Campo, Curr. Top. In Microbiol and Immunol. 186:255-266 (1994); Yindle and Frazer, Curr. Top. In Microbiol. and Immunol. 186;217-253 (1994)]. Rodents previously vaccinated with vaccinia recombinants encoding HPV 16 early proteins E6 or E7, or with synthetic E6 or E7 peptides, are similarly protected from tumor formation after inoculation of HPV 16 transformed autologous cells [Altman. et al., supra; Campo, et al., supra; Yindle and Frazer, et al. supra]. Regression of warts can be induced by the transfer of lymphocytes from regressor animals following infection by animal papilloma viruses. Finally, in immunosuppressed patients, such as, for example, recipients of organ transplants or individuals infected with HIV, the incidence of genital warts. CIN. and anogenital cancer is elevated.
To date, no HPV vaccinations have been described which comprise human papilloma virus late L1 protein in the form of capsomeres which are suitable both for prophylactic and therapeutic purposes. Since the L1 protein is not present in malignant genital lesions, vaccination with L1 protein does not have any therapeutic potential for these patients. Construction of chimeric proteins, comprising amino acid residues from L1 protein and, for example E6 or E7 protein, which give rise to chimeric capsomeres, combines prophylactic and therapeutic functions of a vaccine. A method for high level production of chimeric capsomeres would therefore be particularly desirable, in view of the possible advantages offered by such a vaccine for prophylactic and therapeutic intervention.
Thus there exists a need in the art to provide vaccine formulations which can prevent or treat HPV infection. Methods to produce vaccine formulations which overcome problems known in the art to be associated with recombinant HPV protein expression and purification would manifestly be useful to treat the population of individuals already infected with HPV as well as useful to immunize the population of individuals susceptible to HPV infection.
SUMMARY OF THE INVENTION
The present invention provides therapeutic and prophylactic vaccine formulations comprising chimeric human papilloma capsomeres. The invention also provides therapeutic methods for treating patients infected with an HPV as well as prophylactic methods for preventing HPV infection in a susceptible individual. Methods for production and purification of capsomeres and proteins of the invention are also contemplated.
In one aspect of the invention, prophylactic vaccinations for prevention of HPV infection are considered which incorporate the structural proteins L1 and L2 of the papilloma virus. Development of a vaccine of this type faces significant obstacles because papilloma viruses cannot be propagated to adequate titers in cell cultures or other experimental systems to provide the viral proteins in sufficient quantity for economical vaccine production. Moreover, recombinant methodologies to express the proteins are not always straightforward and often results in low protein yield. Recently, virus-like particles (VLPs), similar in make up to viral capsid structures, have been described which are formed in Sf-9 insect cells upon expression of the viral proteins L1 and L2 (or L1 on its own) using recombinant vaccinia or baculovirus. Purification of the VLPs can be achieved very simply by means of centrifugation in CsCl or sucrose gradients [Kimbauer. et al., Proc. Natl. Acad. Sic. ( USA ), 99:12180-12814 (1992): Kimbaurer. et al., J. Virol. 67:6929-6936 (1994); Proso, et al., J. Virol. 6714:1936-1944 (1992): Sasagawa. et al., Virology 2016:126-195 (1995): Volpers, et al., J. Virol. 69:3258-3264 (1995); Zhou, et al., J. Gen. Virol. 74:762-769 (1993): Zhou, et al., Virology 185:251-257 (1991)]. WO 93/02184 describes a method in which papilloma virus-like particles (VLPs) are used for diagnostic applications or as a vaccine against infections caused by the papilloma virus. WO 94/00152 describes recombinant production of L1 protein which mimics the conformational neutralizing epitope on human and animal papilloma virions.
In another aspect of the invention, therapeutic vaccinations are provided to relieve complications of, for example, cervical carcinoma or precursor lesions resulting from papilloma virus infection, and thus represent an alternative to prophylactic intervention. Vaccinations of this type may comprise early papilloma virus proteins, principally E6 or E7, which are expressed in the persistently infected cells. It is assumed that following administration of a vaccination of this type, cytotoxic T-cells might be activated against persistently infected cells in genital lesions. The target population for therapeutic intervention is patients with HPV-associated pre-malignant or malignant genital lesions. PCT patent application WO 93/20844 discloses that the early protein E7 and antigenic fragments thereof of the papilloma virus from HPV or BPV is therapeutically effective in the regression, but not in the prevention of papilloma virus tumors in mammals. While early HPV proteins have been produced by recombinant expression in E. coli or suitable eukaryotic cell types, purification of the recombinant proteins has proven difficult due to inherent low solubility and complex purification procedures which generally require a combination of steps, including ion exchange chromatography, gel filtration and affinity chromatography.
According to the present invention vaccine formulations comprising papilloma virus capsomeres are provided which comprise either: (i) a first protein that is an intact viral protein expressed as a fusion protein comprised in part of amino acid residues from a second protein; (ii) a truncated viral protein; (iii) a truncated viral protein expressed as a fusion protein comprised in part of amino acid residues from a second protein, or (iv) some combination of the three types of proteins. According to the invention, vaccine formulations are provided comprising capsomeres of bovine papilloma virus (BPV) and human papilloma virus. Preferred bovine virus capsomeres comprise protein from bovine papilloma virus type I. Preferred human virus capsomeres comprise proteins from any one of human papilloma virus strains HPV6, HPV11, HPV16, HPV18, HPV33, HPV35, and HPV45. The most preferred vaccine formulations comprise capsomeres comprising proteins from HPV16.
In one aspect, capsomere vaccine formulations of the invention comprise a first intact viral protein expressed as a fusion protein with additional amino acid residues from a second protein. Preferred intact viral proteins are the structural papilloma viral proteins L1 and L2. Capsomeres comprised of intact viral protein fusions may be produced using the L1 and L2 proteins together or the L1 protein alone. Preferred capsomeres are made up entirely of L1 fusion proteins, the amino acid sequence of which is set out in SEQ ID NO: 2 and encoded by the polynucleotide sequence of SEQ ID NO: 1. Amino acids of the second protein can be derived from numerous sources (including amino acid residues from the first protein) as long as the addition of the second protein amino acid residues to the first protein permits formation of capsomeres. Preferably, addition of the second protein amino acid residues inhibits the ability of the intact viral protein to form virus-like particle structures; most preferably, the second protein amino acid residues promote capsomere formation. In one embodiment of the invention, the second protein may be any human tumor antigen, viral antigen, or bacterial antigen which is important in stimulating an immune response in neoplastic or infectious disease states. In a preferred embodiment, the second protein is also a papilloma virus protein. It also preferred that the second protein be the expression product of papilloma virus early gene. It is also preferred. however, that the second protein be selected from group of E1, E2, E3, E4, E5, E6, and E7—early gene products encoded in the genome of papilloma virus strains HVP6. HPV11, HPV18, HPV33, HPV35, or HPV45. It is most preferred that the second protein be encoded by the HPV16 E7 gene, the open reading frame of which is set out in SEQ ID NO: 3. Capsomeres assembled from fusion protein subunits are referred to herein as chimeric capsomeres. In one embodiment, the vaccine formulation of the invention is comprised of chimeric capsomeres wherein L1 protein amino acid residues make up approximately 50 to 99% of the total fusion protein amino acid residues. In another embodiment, L1 amino acid residues make up approximately 60 to 90% of the total fusion protein amino acid residues; in a particularly preferred embodiment, L1 amino acids comprise approximately 80% of the fusion protein amino acid residues.
In another aspect of the invention, capsomere vaccine formulations are provided that are comprised of truncated viral proteins having a deletion of one or more amino acid residues necessary for formation of a virus-like particle. It is preferred that the amino acid deletion not inhibit formation of capsomeres by the truncated protein, and it is most preferred that the deletion favor capsomere formation. Preferred vaccine formulations of this type include capsomeres comprised of truncated L1 with or without L2 viral proteins. Particularly preferred capsomeres are comprised of truncated L1 proteins. Truncated proteins contemplated by the invention include those having one or more amino acid residues deleted from the carboxy terminus of the protein, or one or more amino acid residues deleted from the amino terminus of the protein, or one or more amino acid residues deleted from an internal region (i.e., not from either terminus) of the protein. Preferred capsomere vaccine formulations are comprised of proteins truncated at the carboxy terminus. In formulations including L1 protein derived from HPV16, it is preferred that from 1 to 34 carboxy terminal amino acid residues are deleted. Relatively shorter deletions are also contemplated which offer the advantage of minor modification of the antigenic properties of the L1 proteins and the capsomeres formed thereof. It is most preferred, however, that 34 amino acid residues be deleted from the L1 sequence, corresponding to amino acids 472 to 505 in HPV16 set out in SEQ ID NO: 2, and encoded by the polynucleotide sequence corresponding to nucleotides 1414 to 1516 in the human HPV16 L1 coding sequence set out in SEQ ED NO: 1.
When a capsomere vaccine formulation is made up of proteins bearing an internal deletion, it is preferred that the deleted amino acid sequence comprise the nuclear localization region of the protein. In the L1 protein of HPV 16, the nuclear localization signal is found from about amino acid residue 499 to about amino acid residue 505. Following expression of L1 proteins wherein the NLS has been deleted, assembly of capsomere structures occurs in the cytoplasm of the host cell. Consequently, purification of the capsomeres is possible from the cytoplasm instead of from the nucleus where intact L1 proteins assemble into capsomeres. Capsomeres which result from assembly of truncated proteins wherein additional amino acid sequences do not replace the deleted protein sequences are necessarily not chimeric in nature.
In still another aspect of the invention, capsomere vaccine formulations are provided comprising truncated viral protein expressed as a fusion protein adjacent amino acid residues from a second protein. Preferred truncated viral proteins of the invention are the structural papilloma viral proteins L1 and L2. Capsomeres comprised of truncated viral protein fusions may he produced using L1 and L2 protein components together or L1 protein alone. Preferred capsomeres are those comprised of L1 protein amino acid residues. Truncated viral protein components of the fusion proteins include those having one or more amino acid residues deleted from the carboxy terminus of the protein, or one or more amino acid residues deleted from the amino terminus of the protein, or one or more amino acid residues deleted from an internal region (i.e., not from either terminus) of the protein. Preferred capsomere vaccine formulations are comprised of proteins truncated at the carboxy terminus. In those formulations including L1 protein derived from HPV16, it is preferred that from 1 to 34 carboxy terminal amino acid residues are deleted. Relatively shorter deletions are also contemplated that offer the advantage of minor modification of the antigenic properties of the L1 protein component of the fusion protein and the capsomeres formed thereof. It is most preferred, however, that 34 amino acid residues be deleted from the L1 sequence, corresponding to amino acids 472 to 505 in HPV16 set out in SEQ ID NO: 2, and encoded by the polynucleotide sequence corresponding to nucleotides 1414 to 1516 in the human HPV16 L1 coding sequence set out in SEQ ID NO: 1. When the vaccine formulation is comprised of capsomeres made up of proteins bearing an internal deletion, it is preferred that the deleted amino acid sequence comprise the nuclear localization region, or sequence, of the protein.
Amino acids of the second protein can be derived from numerous sources as tong as the addition of the second protein amino acid residues to the first protein permits formation of capsomeres. Preferably, addition of the second protein amino acid residues promotes or favors capsomere formation. Amino acid residues of the second protein can be derived from numerous sources, including amino acid residues from the first protein. In a preferred embodiment, the second protein is also a papilloma virus protein. It also preferred that the second protein be the expression product of papilloma virus early gene. It is most preferred, however, that the second protein be selected from group of early gene products encoding by papilloma virus E1, E2, E3, E4, E5, E6, and E7 genes. In one embodiment, the vaccine formulation of the invention is comprised of chimeric capsomeres wherein L1 protein amino acid residues make up approximately 50 to 99% of the total fusion protein amino acid residues. In another embodiment, L1 amino acid residues make up approximately 60 to 90% of the total fusion protein amino acid residues; in a particularly preferred embodiment, L1 amino acids comprise approximately 80% of the fusion protein amino acid residues.
In a preferred embodiment of the invention, proteins of the vaccine formulations are produced by recombinant methodologies, but in formulations comprising intact viral protein, the proteins may be isolated from natural sources. Intact proteins isolated from natural sources may be modified in vitro to include additional amino acid residues to provide a fusion protein of the invention using covalent modification techniques well known and routinely practiced in the art. Similarly, in formulations comprising truncated viral proteins, the proteins may be isolated from natural sources as intact proteins and hydrolyzed in vitro using chemical hydrolysis or enzymatic digestion with any of a number of site-specific or general proteases, the truncated protein subsequently modified to include additional amino acid resides as described above to provide a truncated fusion protein of the invention.
In producing capsomeres, recombinant molecular biology techniques can be utilized to produce DNA encoding either the desired intact protein, the truncated protein, or the truncated fusion protein. Recombinant methodologies required to produce a DNA encoding a desired protein are well known and routinely practiced in the art. Laboratory manuals, for example Sambrook. et al., (eds.), MOLECULAR CLONING: A LABORATORY MANUAL. Cold Spring Harbor Press: Cold Spring Harbor, N.Y. (1989) and Ausebel et al., (eds.). PROTOCOLS IN MOLECULAR BIOLOGY. John Wiley & Sons. Inc. (1994-1997), describe in detail techniques necessary to carry out the required DNA manipulations. For large-scale production of chimeric capsomeres, protein expression can be carried out using either viral or eukaryotic vectors. Preferable vectors include any of the well known prokaryotic expression vectors, recombinant baculoviruses, COS cell specific vectors, vaccinia recombinants, or yeast-specific expression constructs. When recombinant proteins are used to provide capsomeres of the invention, the proteins may first be isolated from the host cell of its expression and thereafter incubated under conditions which permit self-assembly to provide capsomeres. Alternatively, the proteins may be expressed under conditions wherein capsomeres are formed in the host cell.
The invention also contemplates processes for producing capsomeres of the vaccine formulations. In one method, L1 proteins are expressed from DNA encoding six additional histidines at the carboxy terminus of the L1 protein coding sequence. L1 proteins expressed with additional histidines (His L1 proteins) are most preferably expressed in E. coli and the His L1 proteins can be purified using nickel affinity chromatography His L1 proteins in cell lysate are suspended in a denaturation buffer, for example. 6 M guanidine hydrochloride or a buffer of equivalent denaturing capacity, and then subjected to nickel chromatography. Protein eluted from the nickel chromatography step is renatured, for example in 150 mM NaCl. 1 mM CaCl 2 , 0.01% Triton-X 100, 10 mM HEPES (N-2-hydroxyethyl pipenizine-N′-2 ethane sulfonic acid), pH 7.4. According to a preferred method of the invention, assembly of capsomeres takes place after dialysis of the purified proteins, preferably after dialysis against 150 mM NaCl. 25 mM Ca 2+ , 10% DMSO (dimethyl sulfoxide). 0.1% Triton-X 100. 10 mM Tris [tris-(hydroxymethyl) aminomethane] acetic acid with a pH value of 5.0.
Formation of capsomeres can be monitored by electron microscopy, and, in instances wherein capsomeres are comprised of fusion proteins, the presence of various protein components in the assembled capsomere can be confirmed by Western blot analysis using specific antisera.
According to the present invention, methods are provided for therapeutic treatment of individuals infected with HPV comprising the step of administering to a patient in need thereof an amount of a vaccine formulation of the invention effective to reduce the level of HPV infection. The invention also provide methods for prophylactic treatment of individuals susceptible to HPV infection comprising the step of administering to an individual susceptible to HPV infection an amount of a vaccine formulation of the invention effective to prevent HPV infection. While infected individuals can be easily identified using standard diagnostic techniques, susceptible individuals may be identified, for example, as those engaged in sexual relations with an infected individual. However, due to the high frequency of HPV infection, all sexually active persons are susceptible to papilloma virus infection.
Administration of a vaccine formulation can include one or more additional components such as pharmaceutically acceptable carriers, diluents, adjuvants, and/or buffers. Vaccines may be administered at a single time or at multiple times. Vaccine formulation of the invention may be delivered by various routes including, for example, oral, intravenous, intramuscular, nasal, rectal, transdermal, vaginal, subcutaneous, and intraperitoneal administration.
Vaccine formulations of the invention offer numerous advantages when compared to conventional vaccine preparations. As part of a therapeutic vaccination, capsomeres can promote elimination of persistently infected cells in, for example, patients with CIN or cervical carcinoma. Additionally, therapeutic vaccinations of this type can also serve a prophylactic purpose in protecting patients with CIN lesions from re-infection. As an additional advantage, capsomeres can escape neutralization by pre-existing anticapsid antibodies and thereby posses longer circulating half-life as compared to chimeric virus-like particles.
Vaccine formulations comprising chimeric capsomeres can provide the additional advantage of increased antigenicity of both protein components of the fusion protein from which the capsomere is formed. For example, in a VLP, protein components of the underlying capsomere may be buried in the overall structure as a result of internalized positioning within the VLP itself. Similarly, epitopes of the protein components may be sterically obstructed as a result of capsomere-to-capsomere contact, and therefore unaccessible for eliciting an immune response. Preliminary results using L1/E7 fusion proteins to produce VLPs support this position in that no antibody response was detected against the E7 component. This observation is consistent with previous results which indicate that the carboxy terminal region of L1 forms inter-pentameric arm structures that chromatography. Protein eluted from the nickel chromatography step is allow assembly of capsomeres into capsids [Garcia, et al., J. Virol. 71: 2988-2995 (1997)]. Presumably in a chimeric capsomere structure, both protein components of the fusion protein substructure are accessible to evoke an immune response. Capsomere vaccines would therefore offer the additional advantage of increased antigenicity against any protein component, including, for example, neutralizing epitopes from other virus proteins, expressed as a fusion with L1 amino acid sequences.
DETAILED DESCRIPTION OF THE INVENTION
The present invention is illustrated by the following examples. Example 1 describes construction of expression vectors to produce fusion, or chimeric, viral proteins. Example 2 relates to generation of recombinant baculoviruses for expression of viral proteins. Example 3 addresses purification of capsomeres. Example 4 describes an immunization protocol for production of antisera and monoclonal antibodies. Example 5 provides a peptide ELISA to quantitate capsomere formation. Example 6 describes an antigen capture ELISA to quantitate capsomere formation. Example 7 provides a hemagglutinin assay to assay for the induction of neutralizing antibodies.
EXAMPLE 1
Construction of Chimeric L1 Genes
DNA encoding the HPV 16 L1 open reading frame was excised from plasmid 16-114/k-L1/L2-pSynxtVI − [Kirnbauer et al, J. Virol. 67:6929-6936 (1994)] using BglII and the resulting fragment subcloned into pUC19 (New England Biolabs, Beverly, Mass. previously linearized at the unique BamHI restriction site. Two basic expression constructs were first generated to permit subsequent insertion of DNA to allow fusion protein expression. One construct encoded HPV 16 L1Δ310 having a nine amino acid deletion: the deleted region was known to show low level homology with all other papilloma virus L1 proteins. The second construct, HPV 16 L1 ΔC, encoded a protein having a 34 amino acid deletion of the carboxy terminal L1 residues. Other constructs include an EcoRV restriction site at the position of the deletion for facilitated insertion of DNA encoding other protein sequences. Addition of the EcoRV site encodes two non-L1 protein amino acids, aspartate and isoleucine.
A. Generation of an HPV 16 L1Δ310 Expression Construct
Two primers (SEQ ID NOs: 5 and 6) were designed to amplify the pUC19 vector and the complete HPV 16 L1 coding sequence, except nucleotides 916 through 942 in SEQ ID NO: 1. Primers were synthesized to also introduce a unique EcoRV restriction site (underlined in SEQ ID NOs: 5 and 6) at the termini of the amplification product.
CCCC GATATC GCCTTTAATGTATAAATCGTCTGG
SEQ ID NO:5
CCCC GATATC TCAAATTATTTTCCTACACCTAGTG
SEQ ID NO:6
The resulting PCR product was digested with EcoRV to provide complementary ends and the digestion product circularized by ligation. Ligated DNA was transformed into E. coli using standard techniques and plasmids from resulting colonies were screened for the presence of an EcoRV restriction site. One clone designated HPV 16 L1 Δ310 was identified as having the appropriate twenty-seven nucleotide deletion and this construct was used to insert DNA fragments encoding other HPV 16 proteins at the EcoRV site as discussed below.
B. Generation of an HPV 16 L1 ΔC Expression Constructs
Two primers (SEQ ID NOs: 7 and 8) were designed complementary to the HPV 16 L1 open reading frame such that the primers abutted each other to permit amplification in reverse directions on the template DNA comprising HPV 16 L1-encoding sequences in pUC19 described above.
SEQ ID NO:7
AAA GATATC TTGTAGTAAAAATTTGCGTCCTAAAGGAAAC
SEQ ID NO:8
AAA GATATC TAATCTACCTCTACAACTGCTAAACGCAAAAAACG
Each primer introduced an EcoRV restriction site at the terminus of the amplification product. In the downstream primer (SEQ ID NO: 8), the EcoRV site was followed by a TAA translational stop codon positioned such that the amplification product, upon ligation of the EcoRV ends to circularize, would include deletion of the 34 carboxy terminal L1 amino acids. PCR was performed to amplify the partial L1 open reading frame and the complete vector. The amplification product was cleaved with EcoRV, circularized with T4 DNA ligase, and transformed into E. coli DH5 α cells. Plasmids from viable clones were analyzed for the presence of an EcoRV site which would linearize the plasmid. One positive construct designated pUCHPV16L1ΔC was identified and used to insert DNA from other HPV 16 proteins utilizing the EcoRV site.
C. Insertion of DNA Fragments into HPV 16 L1 Δ310 and HPV16L1ΔC
DNA fragments of HPV 16 E7 encoding amino acids 1-50, 1-60, 1-98, 25-75, 40-98, 50-98 in SEQ ID NO: 4 were amplified using primers that introduced terminal 5′ EcoRV restriction sites in order to facilitate insertion of the fragment into either HPV 16 L1 Δ310 and HPV16L1ΔC modified sequence. In the various amplification reactions, primer E7.1 (SEQ ID NO: 9) was used in combination with primer E7.2 (SEQ ID NO: 10) to generate a DINA fragment encoding E7 amino acids 1-50: with primer E7.3 (SEQ ID NO: 11) generate a DNA fragment encoding E7 amino acids 1-60: or with primer E7.4 (SEQ ID NO: 12) generate a DNA fragment encoding E7 amino acids 1-98. In other amplification reactions, primer pairs E7.5 (SEQ ID NO: 13) and E7.6 (SEQ ID NO: 14) were used to amplify a DNA fragment encoding E7 amino acids 25-75: E7.7 (SEQ ID NO: 15) and E7.4 (SEQ ID NO: 12) were used to amplify a DNA fragment encoding E7 amino acids 40-98; and E7.8 (SEQ ID NO: 16) and E7.4 (SEQ ID NO: 12) were used to amplify a DNA fragment encoding E7 amino acids 50-98.
Primer E7.1
SEQ ID NO:9
AAAA GATATC ATGCATGGAGATACACCTACATTGC
Primer E7.2
SEQ ID NO:10
TTTT GATATC GGCTCTGTCCGGTTCTGCTTGTCC
Primer E7.3
SEQ ID NO:11
TTTT GATATC CTTGCAACAAAAGGTTACAATATTGTAATGGGCC
Primer E7.4
SEQ ID NO:12
AAAA GATATC TGGTTTCTGAGAACAGATGGGGCAC
Primer E7.5
SEQ ID NO:13
TTTT GATATC GATTATGAGCAATTAAATGACAGCTCAG
Primer E7.6
SEQ ID NO:14
TTTT GATATC GTCTACGTGTGTGCTTTGTACGCAC
Primer E7.7
SEQ ID NO:15
TTTATC GATATC GGTCCAGCTGGACAAGCAGAACCGGAC
Primer E7.8
SEQ ID NO:16
TTTT GATATC GATGCCCATTACAATATTGTAACCTTTTG
Similarly, nucleotides from DNA encoding the influenza matrix protein (SEQ ID NO: 17) was amplified using the primer pair set out in SEQ ID NOs: 19 and 20. Both primers introduced an EcoRV restriction site in the amplification product.
SEQ ID NO:19
TTTT GATATC GATATGGAATGGCTAAAGACAAGACCAATC
SEQ ID NO:20
TTTT GATATC GTTGTTTGGATCCCCATTCCCATTG
PCR products from each amplification reaction were cleaved with EcoRV and inserted into the EcoRV site of either the HPV 16 L1 Δ310 and HPV16L1ΔC sequences previously linearized with the same enzyme. In order to determine the orientation of inserts in plasmids encoding E7 amino acids 25-75 and 50-98 and plasmid including influenza matrix protein, ClaI digestion was employed, taking advantage of a restriction site overlapping the newly created EcoRV restriction site ( GATATC GAT) and included in the upstream primer. For the three expression constructs including the initiating methionine of HPV16 E7, insert orientation was determined utilizing a NSlI restriction site within the E7 coding region.
Once expression constructs having appropriate inserts were identified, the protein coding region for both L1 and inserted amino acids was excised as a unit using restriction enzymes XbaI and SmaI and the isolated DNA ligated into plasmid pVL1393 (Invitrogen) to generate recombinant baculoviruses.
D. Elimination of EcoRV Restriction Sites in Expression Constructs
The HPV 16 L1 ΔC sequence includes DNA from the EcoRV site that results in translation of amino acids not normally found in wild-type L1 polypeptides. Thus, a series of expression constructions was designed in which the artificial EcoRv site was eliminated. The L1 sequence for this series of expression constructs was designated HPV 16L1ΔC*.
To generate an expression construct containing the HPV 16L1ΔC* sequence, two PCR reactions were performed to amplify two overlapping fragments from the pUC-HPV16 L1ΔC encoding E7 amino acids 1-50. The resulting DNA fragments overlapped at the position of the L1/E7 boundary but did not contain the two EcoRV restriction sites. Fragment 1 was generated using primers P1 (SEQ ID NO: 21) and P2 (SEQ ID NO: 22) and fragment 2 using primers P3 (SEQ ID NO: 23) and P4 (SEQ ID NO: 24).
Primer P1
GTTATGACATACATACATTCTATG
SEQ ID NO:21
Primer P2
CCATGCATTCCTGCTTGTAGTAAAAATTTGCGTCC
SEQ ID NO:22
Primer P3
CTACAAGCAGGAATGCATGGAGATACACC
SEQ ID NO:23
Primer P4
CATCTGAAGCTTAGTAATGGGCTCTGTCCGGTTCTG
SEQ ID NO:24
Following the first two amplification reactions, the two purified products were used as templates in another PCR reaction using primers P1 and P4 only. The resulting amplification product was digested with enzymes EcoNI and HindIII inserted into the HPV 16L1ΔC expression construct described above following digestion with the same enzymes. The resulting expression construct differed from the original HPV16L1ΔC construct with DNA encoding L1 and E7 amino acids 1-50 by loss of the two internal EcoRV restriction sites. The first EcoRV site was replaced by DNA encoding native L1 alanine and glycine amino acids in this position and the second was replaced by a translational stop signal. In addition, the expression construct, designated HPV 16 L1ΔC* E7 1-52, contained the first 52 amino acids of HPV 16 E7 as a result of using primer P4 which also encodes E7 amino acids residues histidine at position 51 and tyrosine at position 52. HPV 16 L1ΔC* E7 1-52 was then used to generate additional HPV 16 L1ΔC expression constructs further including DNA encoding E7 amino acids 1-55 using primer P1 (SEQ ID NO: 21) in combination with primer P5 (SEQ ID NO: 25), E7 amino acids 1-60 with primer pair P1 and P6 (SEQ ID NO: 26), and E7 amino acids 1-65 with primer pair P1 and P7 (SEQ ID NO: 27). The additional amino acid-encoding DNA sequences in the amplification products arose from design of the primers to include additional nucleotides for the desired amino acids.
Primer P5
SEQ ID NO:25
CATCTGAAGCTTAACAATATTGTAATGGGC-
TCTGTCCG
Primer P6
SEQ ID NO:26
CATCTGAAGCTTACTTGCAACAAAAGGTTA-
CAATATTGTAATGGGCTCTGTCCG
Primer P7
SEQ ID NO:27
CATCTGAAGCTTAAAGCGTAGAGTCACACTTGCAAC-
AAAAGGTTACAATATTGTAATGGGCTCTGTCCG
Similarly, HPV 16 L1ΔC* E7 1-70 was generated using template DNA encoding HPV 16 L1ΔC* E7 1-66 and the primer pair P1 and P8 (SEQ ID NO: 28).
Primer P8
SEQ ID NO:28
CATCTGAAGCTTATTGTACGCACAAC-
CGAAGCGTAGAGTCACACTTG
Following each PCR reaction, the amplification products were digested with EcoNI and HindIII and inserted into HPV16L1ΔC previously digested with the same enzymes. Sequences of each constructs were determined using an Applied Biosystems Prism 377 sequencing instrument with fluorescent chain terminating dideoxynucleotides [Prober et al., Science 238:336-341 (1987)].
EXAMPLE 2
Generation of Recombinant Baculoviruses
Spodoptera frugiperda (Sf9) cells were grown in suspension or monolayer cultures at 27° in TNMFH medium (Sigma) supplemented with 10% fetal calf serum and 2 mM glutamine. For HPV 16 L1-based recombinant baculovirus construction, Sf9 cells were transfected with 10 μg of transfer plasmid together with 2 μg of linearized Baculo-Gold DNA (PharMingen, San Diego, Calif.). Recombinant viruses were purified by according to manufacturer's suggested protocol.
To test for expression of HPV 16 L1 protein, 10 5 Sf9 cells were infected with baculovirus recombinant at a multiplicity of infection (m.o.i) of 5 to 10. After incubation for three to four days at 28° C., media was removed and cells were washed with PBS. The cells were lysed in SDS sample buffer and analyzed by SDS-PAGE and Western blotting using anti-HPV16 L1 and anti-HPV16 E7 antibodies.
In order to determine which of the chimeric L1 protein expression constructs would preferentially produce capsomeres, extracts from transfected cells were subjected to gradient centrifugation. Fractions obtained from the gradient were analyzed for L1 protein content by Western blotting and for VLP formation by electron microscopy. The results are shown in Table 1.
The intact HPV L1 protein, as well as the expression products HPV 16 L1Δ310 and HPV 16 L1ΔC. each were shown to produce capsomeres and virus-like particles in equal proportions. When E7 coding sequences were inserted into the HPV 16 L1Δ310 vector, only fusion proteins including E7 amino acids 1 to 50 produced cave rise to detectable capsomere formation.
When E7 encoding DNA was inserted into the HPV 16 L1ΔC vector, all fusion proteins were found to produce capsomeres; chimeric proteins including E7 amino acid residues 40-98 produced the highest level of exclusively capsomere structures. Chimeric proteins including E7 amino acids 1-98 and 25-75 both produced predominantly capsomeres, even thorough virus-like particle formation was also observed. The chimeric protein including E7 amino acids 1-60 resulted in nearly equal levels of capsomere and virus-like particle production.
When E7 sequences were inserted into the HPV 16 L1Δ*C vector, all fusion proteins were shown to produce capsomeres. Insertion of DNA encoding E7 residues 1-52, 1-55 and 1-60 produced the highest level of capsomeres, but equal levels of virus-like particle production were observed. While insertion of DNA encoding E7. DNA for residues 1-65, 1-70, 25-75, 40-98, and 1-98 resulted in comparatively lower levels or undetectable levels of capsid, capsomeres were produced in high quantities.
TABLE 1
Capsomeree and Capsid Forming Capacity of
Chimeric HPV L1 Proteins
L1 Expression
Capsomere
Capsid
Construct
Insert
Yield
Yield
HVP 16 L1
None
+++++
+++++
HPV 16 L1Δ310
None
+++
++
HPV 16 L1ΔC
None
++++
++++
HPV 16 L1Δ310
E7 1-98
−
−
HPV 16 L1Δ310
E7 1-50
++
−
HPV 16 L1Δ310
E7 25-75
−
−
HPV 16 L1Δ310
E7 50-98
−
−
HPV 16 L1ΔC
E7 1-98
+++
+
HPV 16 L1ΔC
E7 25-75
+++
+
HPV 16 L1ΔC
E7 50-98
+
+
HPV 16 L1ΔC
E7 1-60
+++++
+++++
HPV 16 L1ΔC
E7 40-98
++++
−
HPV 16 L1ΔC
Influenza
+++
+
HPV 16 L1Δ*C
E7 1-52
+++++
+++++
HPV 16 L1Δ*C
E7 1-55
+++++
+++++
HPV 16 L1Δ*C
E7 1-60
+++
++++
HPV 16 L1Δ*C
E7 1-65
++
−
HPV 16 L1Δ*C
E7 1-70
++
−
EXAMPLE 3
Purification of Capsomeres
Trichopulsia ni (TN) High Five cells were grown to a density of approximately 2×10 6 cells/ml in Ex-Cell 405 serum-free medium (JRH Biosciences). Approximately 2×10 8 cells were pelleted by centrifugation at 1000×g for 15 minutes, resuspended in 20 ml of medium, and infected with recombinant baculoviruses at m.o.i of 2 to 5 for 1 hour at room temperature. After addition of 200 ml medium, cells were plated and incubated for 3 to 4 days at 27° C. Following incubation, cells were harvested, pelleted, and resuspended in 10 ml of extraction buffer.
The following steps were performed at 4° C. Cells were sonicated for 45 seconds at 60 watts and the resulting cell lysate was centrifuged at 10,000 rpm in a Sorval SS34 rotor. The supernatant was removed and retained while the resulting pellet was resuspended in 6 ml of extraction buffer, sonicated for an additional 3 seconds at 60 watts, and centrifuged again. The two supernatants were combined, layered onto a two-step gradient containing 14 ml of 40% sucrose on top of 8 ml of CsCl solution (4.6 g CsCl per 8 ml in extraction buffer), and centrifuged in a Sorval AH629 swinging bucket rotor for 2 hours at 27,000 rpm at 10° C. The interface region between the CsCl and the sucrose along with the CsCl complete layer were collected into 13.4 ml Quickseal tubes (Beckman) and extraction buffer added to adjust the volume 13.4 ml. Samples were centrifuged overnight at 50,000 rpm at 20° C. in a Beckman 70 TI rotor. Gradients were fractionated (1 ml per fraction) by puncturing tubes on top and bottom with a 21-gauge needle. Fractions were collected from each tube and 2.5 μl of each fraction were analyzed by a 10% SDS-polyacrylamide gel and Western blotting using an anti-HPV16 L1 antibody.
Virus-like particles and capsomeres were separated from the fractions identified above by sedimentation on 10 to 50% sucrose gradients. Peak fractions from CsCl gradients were pooled and dialyzed for 2 hours against 5 mM HEPES (pH 7.5). Half of the dialysate was used to produce capsomeres by disassembly of intact VLPs overnight by adding EDTA (final concentration 50 mM), EGTA (50 mM), DTT (30 mM). NaCl (100 mM), and Tris/HCl, pH 8.0, (10 mM). As control, NaCl and Tris/HCl only were added to the other half.
For analysis of capsomeres produced from disassembled VLPs, EDTA, EGTA, and DTT (final concentration 5 mM each) were added to the sucrose cushions which were centrifuged at 250,000×g for 2 to 4 hours at 4° C. Fractions were collected by puncturing tubes from the bottom. A 1:10 dilution of each fraction was then analyzed by antigen capture ELISA.
EXAMPLE 4
Immunization Protocol for Production of Polyclonal Antisera and Monoclonal Antibodies
Balb/c mice are immunized subcutaneously three times, every four weeks with approximately 60 μl of HPV chimeric capsomeres mixed 1:1 with complete or incomplete Freund's Adjuvants in a total volume of 100 μl. Six weeks after the third immunization, mice are sacrificed and blood is collected by cardiac puncture.
EXAMPLE 5
Peptide ELISA to Quantitate Capsomere Formation
Microtiter plates (Dynatech) are coated overnight with 50 μl of peptide E701 [Muller et al., 1982] at a concentration of 10 μ/ml in PBS. Wells are blocked for 2 hour at 37° C. with 100 μl of buffer containing 5% BSA and 0.05% Tween 20 in PBS and washed three times with PBS containing 0.05% Tween 20. After the third wash. 50 μl of sera diluted 1:5000 in BSA/Tween 20/PBS is added to each well and incubation carried out for 1 hour. Plates are washed again as before and 50 μl of goat-anti-mouse peroxidase conjugate is added at a 1:5000 dilution. After 1 hour, plates are washed and stained using ABTS substrate (0.2 mg/ml. 2.2′-Azino-bis(3-ethylbenzhiazoline-β-sulfonic acid in 0.1 M Na-Acetate-Phosphate buffer (pH 4.2) with 4 μl 30% H 2 O 2 per 10 ml). Extinction is measured after 1 hour at 490 nm in a Dynatech automated plate reader.
EXAMPLE 6
Antigen Capture ELISA to Quantitate Capsomere Formation
To allow relative quantification of virus-like particles and capsomeres in fractions of CsCl gradients, an antigen capture ELISA was utilized. Microtiter plates were coated overnight with 50 μl/well of a 1:500 dilution (final concentration of 2 μg per ml, in PBS) with a protein A purified mouse monoclonal antibody immunospecific for HPV 16 L1 (antibodies 25/C, MM07 and Ritti 1 were obtained from mice immunized with HPV 16 VLPs). Plates were blocked with 5% milk/PBS for 1 hour and 50 μl of fractions of CsCl gradients were added for 1 hour at 37° C. using a 1:300 dilution (in 5% milk/PBS). After three washings with PBS/0.05% Tween 20, 50 μl of a polyclonal rabbit antiserum (1:3000 dilution in milk/PBS), raised against HPV 16 VLPs was added and plates were incubated at 37° for 1 hour. Plates were washed again and further incubated with 50 μl of a goat-anti-rabbit peroxidase conjugate (Sigma) diluted 1:5000 in PBS containing 5% milk for 1 hour. After final washing, plates were stained with ABTS substrate for 30 minutes and extinction measured at 490 nm in a Dynatech automated plate reader. As a negative control, the assay also included wells coated only with PBS.
To test monoclonal antibodies for capsomere specificity, VLPs with EDTA/DTT to disassemble particles. Treated particle preparations were assayed in the antigen-capture ELISA and readings compared to untreated controls. For disassembly, 40 μl of VLPs was incubated overnight at 4° C. in 500 μl of disruption buffer containing 30 mM DTT, 50 mM EGTA, 60 mM EDTA, 100 mM NaCl, and 100 mM Tris/HCl. pH 8.0. Aliquots of treated and untreated particles were used in the above capture ELISA in a 1:20-1:40 dilution.
EXAMPLE 7
Hemagglutinin Inhibition Assay
In order to determine the extent to which chimeric capsomere vaccines evoke production of neutralizing antibodies, a hemagglutination inhibition assay is carried out as briefly described below. This assay is based on previous observations that virus-like particles are capable of hemagglutinizing red blood cells.
Mice are immunized with any of a chimeric capsomere vaccine and sera is collected as described above in Example 4. As positive controls, HPV16 L1 virus like particles (VLPs) and bovine PVI (BPV) L1 VLPs are assayed in parallel with a chimeric capsomere preparation. To establish a positive baseline, the HPV16 or BPV1 VLPs are first incubated with or without sera collected from immunized mice after which red blood cells are added. The extent to which preincubation with mouse cera inhibits red blood cell hemagglutinization is an indication of the neutralizing capacity of the mouse sera. The experiments are then repeated using chimeric capsomeres in order to determine the neutralizing effect of the mouse sera on the vaccine. A brief protocol for the hemagglutination inhibition assay is described below.
One hundred microliters of heparin (1000 usp units/ml) are added to 1 ml fresh mouse blood. Red blood cells are washed three times with PBS followed by centrifugation and resuspension in a volume of 10 ml. Next, erythrocytes are resuspended in 0.5 ml PBS and stored at 4° C. for up to three days. For the hemagglutinin assay. 70 μl of the suspension is used per well on a 96-well plate.
Chimeric capsomere aliquots from CsCl gradients are dialyzed for one hour against 10 mM Hepes (pH 7.5) and 100 μl of two-fold serial dilutions in PBS are added to mouse erythrocytes in round-bottom 96-well microtiter plates which are further incubated for 3-16 hours at 4° C. For hemagglutination inhibition, capsomeres are incubated with dilutions of antibodies in PBS for 60 minutes at room temperature and then added to the erythrocytes. The level of erythrocyte hemagglutination, and therefore the presence of neutralizing antibodies, is determined by standard methods.
In preliminary results, mouse sera generated against chimeric capsomeres comprising HPV16L1ΔC protein in association with E7 amino acid residues 1-98 was observed to inhibit hemagglutination by HPV16 VLPs, but not by BPV VLPs. The mouse sera was therefore positive for neutralizing antibodies against the human VLPs and this differential neutralization was most likely the result of antibody specificity for epitopes against which the antibodies were raised.
Numerous modifications and variations in the invention as set forth in the above illustrative examples are expected to occur to those skilled in the art. Consequently only such limitations as appear in the appended claims should be placed on the invention.
# SEQUENCE LISTING
(1) GENERAL INFORMATION:
(iii) NUMBER OF SEQUENCES: 28
(2) INFORMATION FOR SEQ ID NO: 1:
(i) SEQUENCE CHARACTERISTICS:
(A) LENGTH: 1518 base
#pairs
(B) TYPE: nucleic acid
(C) STRANDEDNESS: single
(D) TOPOLOGY: linear
(ii) MOLECULE TYPE: DNA (genomic)
(ix) FEATURE:
(A) NAME/KEY: CDS
(B) LOCATION: 1..1515
(xi) SEQUENCE DESCRIPTION: SEQ ID NO:
#1:
ATG TCT CTT TGG CTG CCT AGT GAG GCC ACT GT
#C TAC TTG CCT CCT GTC 48
Met Ser Leu Trp Leu Pro Ser Glu Ala Thr Va
#l Tyr Leu Pro Pro Val
1 5
# 10
# 15
CCA GTA TCT AAG GTT GTA AGC ACG GAT GAA TA
#T GTT GCA CGC ACA AAC 96
Pro Val Ser Lys Val Val Ser Thr Asp Glu Ty
#r Val Ala Arg Thr Asn
20
# 25
# 30
ATA TAT TAT CAT GCA GGA ACA TCC AGA CTA CT
#T GCA GTT GGA CAT CCC 144
Ile Tyr Tyr His Ala Gly Thr Ser Arg Leu Le
#u Ala Val Gly His Pro
35
# 40
# 45
TAT TTT CCT ATT AAA AAA CCT AAC AAT AAC AA
#A ATA TTA GTT CCT AAA 192
Tyr Phe Pro Ile Lys Lys Pro Asn Asn Asn Ly
#s Ile Leu Val Pro Lys
50
# 55
# 60
GTA TCA GGA TTA CAA TAC AGG GTA TTT AGA AT
#A CAT TTA CCT GAC CCC 240
Val Ser Gly Leu Gln Tyr Arg Val Phe Arg Il
#e His Leu Pro Asp Pro
65
# 70
# 75
# 80
AAT AAG TTT GGT TTT CCT GAC ACC TCA TTT TA
#T AAT CCA GAT ACA CAG 288
Asn Lys Phe Gly Phe Pro Asp Thr Ser Phe Ty
#r Asn Pro Asp Thr Gln
85
# 90
# 95
CGG CTG GTT TGG GCC TGT GTA GGT GTT GAG GT
#A GGT CGT GGT CAG CCA 336
Arg Leu Val Trp Ala Cys Val Gly Val Glu Va
#l Gly Arg Gly Gln Pro
100
# 105
# 110
TTA GGT GTG GGC ATT AGT GGC CAT CCT TTA TT
#A AAT AAA TTG GAT GAC 384
Leu Gly Val Gly Ile Ser Gly His Pro Leu Le
#u Asn Lys Leu Asp Asp
115
# 120
# 125
ACA GAA AAT GCT AGT GCT TAT GCA GCA AAT GC
#A GGT GTG GAT AAT AGA 432
Thr Glu Asn Ala Ser Ala Tyr Ala Ala Asn Al
#a Gly Val Asp Asn Arg
130
# 135
# 140
GAA TGT ATA TCT ATG GAT TAC AAA CAA ACA CA
#A TTG TGT TTA ATT GGT 480
Glu Cys Ile Ser Met Asp Tyr Lys Gln Thr Gl
#n Leu Cys Leu Ile Gly
145 1
#50 1
#55 1
#60
TGC AAA CCA CCT ATA GGG GAA CAC TGG GGC AA
#A GGA TCC CCA TGT ACC 528
Cys Lys Pro Pro Ile Gly Glu His Trp Gly Ly
#s Gly Ser Pro Cys Thr
165
# 170
# 175
AAT GTT GCA GTA AAT CCA GGT GAT TGT CCA CC
#A TTA GAG TTA ATA AAC 576
Asn Val Ala Val Asn Pro Gly Asp Cys Pro Pr
#o Leu Glu Leu Ile Asn
180
# 185
# 190
ACA GTT ATT CAG GAT GGT GAT ATG GTT GAT AC
#T GGC TTT GGT GCT ATG 624
Thr Val Ile Gln Asp Gly Asp Met Val Asp Th
#r Gly Phe Gly Ala Met
195
# 200
# 205
GAC TTT ACT ACA TTA CAG GCT AAC AAA AGT GA
#A GTT CCA CTG GAT ATT 672
Asp Phe Thr Thr Leu Gln Ala Asn Lys Ser Gl
#u Val Pro Leu Asp Ile
210
# 215
# 220
TGT ACA TCT ATT TGC AAA TAT CCA GAT TAT AT
#T AAA ATG GTG TCA GAA 720
Cys Thr Ser Ile Cys Lys Tyr Pro Asp Tyr Il
#e Lys Met Val Ser Glu
225 2
#30 2
#35 2
#40
CCA TAT GGC GAC AGC TTA TTT TTT TAT TTA CG
#A AGG GAA CAA ATG TTT 768
Pro Tyr Gly Asp Ser Leu Phe Phe Tyr Leu Ar
#g Arg Glu Gln Met Phe
245
# 250
# 255
GTT AGA CAT TTA TTT AAT AGG GCT GGT GCT GT
#T GGT GAA AAT GTA CCA 816
Val Arg His Leu Phe Asn Arg Ala Gly Ala Va
#l Gly Glu Asn Val Pro
260
# 265
# 270
GAC GAT TTA TAC ATT AAA GGC TCT GGG TCT AC
#T GCA AAT TTA GCC AGT 864
Asp Asp Leu Tyr Ile Lys Gly Ser Gly Ser Th
#r Ala Asn Leu Ala Ser
275
# 280
# 285
TCA AAT TAT TTT CCT ACA CCT AGT GGT TCT AT
#G GTT ACC TCT GAT GCC 912
Ser Asn Tyr Phe Pro Thr Pro Ser Gly Ser Me
#t Val Thr Ser Asp Ala
290
# 295
# 300
CAA ATA TTC AAT AAA CCT TAT TGG TTA CAA CG
#A GCA CAG GGC CAC AAT 960
Gln Ile Phe Asn Lys Pro Tyr Trp Leu Gln Ar
#g Ala Gln Gly His Asn
305 3
#10 3
#15 3
#20
AAT GGC ATT TGT TGG GGT AAC CAA CTA TTT GT
#T ACT GTT GTT GAT ACT 1008
Asn Gly Ile Cys Trp Gly Asn Gln Leu Phe Va
#l Thr Val Val Asp Thr
325
# 330
# 335
ACA CGC AGT ACA AAT ATG TCA TTA TGT GCT GC
#C ATA TCT ACT TCA GAA 1056
Thr Arg Ser Thr Asn Met Ser Leu Cys Ala Al
#a Ile Ser Thr Ser Glu
340
# 345
# 350
ACT ACA TAT AAA AAT ACT AAC TTT AAG GAG TA
#C CTA CGA CAT GGG GAG 1104
Thr Thr Tyr Lys Asn Thr Asn Phe Lys Glu Ty
#r Leu Arg His Gly Glu
355
# 360
# 365
GAA TAT GAT TTA CAG TTT ATT TTT CAA CTG TG
#C AAA ATA ACC TTA ACT 1152
Glu Tyr Asp Leu Gln Phe Ile Phe Gln Leu Cy
#s Lys Ile Thr Leu Thr
370
# 375
# 380
GCA GAC GTT ATG ACA TAC ATA CAT TCT ATG AA
#T TCC ACT ATT TTG GAG 1200
Ala Asp Val Met Thr Tyr Ile His Ser Met As
#n Ser Thr Ile Leu Glu
385 3
#90 3
#95 4
#00
GAC TGG AAT TTT GGT CTA CAA CCT CCC CCA GG
#A GGC ACA CTA GAA GAT 1248
Asp Trp Asn Phe Gly Leu Gln Pro Pro Pro Gl
#y Gly Thr Leu Glu Asp
405
# 410
# 415
ACT TAT AGG TTT GTA ACC TCC CAG GCA ATT GC
#T TGT CAA AAA CAT ACA 1296
Thr Tyr Arg Phe Val Thr Ser Gln Ala Ile Al
#a Cys Gln Lys His Thr
420
# 425
# 430
CCT CCA GCA CCT AAA GAA GAT CCC CTT AAA AA
#A TAC ACT TTT TGG GAA 1344
Pro Pro Ala Pro Lys Glu Asp Pro Leu Lys Ly
#s Tyr Thr Phe Trp Glu
435
# 440
# 445
GTA AAT TTA AAG GAA AAG TTT TCT GCA GAC CT
#A GAT CAG TTT CCT TTA 1392
Val Asn Leu Lys Glu Lys Phe Ser Ala Asp Le
#u Asp Gln Phe Pro Leu
450
# 455
# 460
GGA CGC AAA TTT TTA CTA CAA GCA GGA TTG AA
#G GCC AAA CCA AAA TTT 1440
Gly Arg Lys Phe Leu Leu Gln Ala Gly Leu Ly
#s Ala Lys Pro Lys Phe
465 4
#70 4
#75 4
#80
ACA TTA GGA AAA CGA AAA GCT ACA CCC ACC AC
#C TCA TCT ACC TCT ACA 1488
Thr Leu Gly Lys Arg Lys Ala Thr Pro Thr Th
#r Ser Ser Thr Ser Thr
485
# 490
# 495
ACT GCT AAA CGC AAA AAA CGT AAG CTG TAA
#
# 1518
Thr Ala Lys Arg Lys Lys Arg Lys Leu
500
# 505
(2) INFORMATION FOR SEQ ID NO: 2:
(i) SEQUENCE CHARACTERISTICS:
(A) LENGTH: 505 amino
#acids
(B) TYPE: amino acid
(D) TOPOLOGY: linear
(ii) MOLECULE TYPE: protein
(xi) SEQUENCE DESCRIPTION: SEQ ID NO:
#2:
Met Ser Leu Trp Leu Pro Ser Glu Ala Thr Va
#l Tyr Leu Pro Pro Val
1 5
# 10
# 15
Pro Val Ser Lys Val Val Ser Thr Asp Glu Ty
#r Val Ala Arg Thr Asn
20
# 25
# 30
Ile Tyr Tyr His Ala Gly Thr Ser Arg Leu Le
#u Ala Val Gly His Pro
35
# 40
# 45
Tyr Phe Pro Ile Lys Lys Pro Asn Asn Asn Ly
#s Ile Leu Val Pro Lys
50
# 55
# 60
Val Ser Gly Leu Gln Tyr Arg Val Phe Arg Il
#e His Leu Pro Asp Pro
65
# 70
# 75
# 80
Asn Lys Phe Gly Phe Pro Asp Thr Ser Phe Ty
#r Asn Pro Asp Thr Gln
85
# 90
# 95
Arg Leu Val Trp Ala Cys Val Gly Val Glu Va
#l Gly Arg Gly Gln Pro
100
# 105
# 110
Leu Gly Val Gly Ile Ser Gly His Pro Leu Le
#u Asn Lys Leu Asp Asp
115
# 120
# 125
Thr Glu Asn Ala Ser Ala Tyr Ala Ala Asn Al
#a Gly Val Asp Asn Arg
130
# 135
# 140
Glu Cys Ile Ser Met Asp Tyr Lys Gln Thr Gl
#n Leu Cys Leu Ile Gly
145 1
#50 1
#55 1
#60
Cys Lys Pro Pro Ile Gly Glu His Trp Gly Ly
#s Gly Ser Pro Cys Thr
165
# 170
# 175
Asn Val Ala Val Asn Pro Gly Asp Cys Pro Pr
#o Leu Glu Leu Ile Asn
180
# 185
# 190
Thr Val Ile Gln Asp Gly Asp Met Val Asp Th
#r Gly Phe Gly Ala Met
195
# 200
# 205
Asp Phe Thr Thr Leu Gln Ala Asn Lys Ser Gl
#u Val Pro Leu Asp Ile
210
# 215
# 220
Cys Thr Ser Ile Cys Lys Tyr Pro Asp Tyr Il
#e Lys Met Val Ser Glu
225 2
#30 2
#35 2
#40
Pro Tyr Gly Asp Ser Leu Phe Phe Tyr Leu Ar
#g Arg Glu Gln Met Phe
245
# 250
# 255
Val Arg His Leu Phe Asn Arg Ala Gly Ala Va
#l Gly Glu Asn Val Pro
260
# 265
# 270
Asp Asp Leu Tyr Ile Lys Gly Ser Gly Ser Th
#r Ala Asn Leu Ala Ser
275
# 280
# 285
Ser Asn Tyr Phe Pro Thr Pro Ser Gly Ser Me
#t Val Thr Ser Asp Ala
290
# 295
# 300
Gln Ile Phe Asn Lys Pro Tyr Trp Leu Gln Ar
#g Ala Gln Gly His Asn
305 3
#10 3
#15 3
#20
Asn Gly Ile Cys Trp Gly Asn Gln Leu Phe Va
#l Thr Val Val Asp Thr
325
# 330
# 335
Thr Arg Ser Thr Asn Met Ser Leu Cys Ala Al
#a Ile Ser Thr Ser Glu
340
# 345
# 350
Thr Thr Tyr Lys Asn Thr Asn Phe Lys Glu Ty
#r Leu Arg His Gly Glu
355
# 360
# 365
Glu Tyr Asp Leu Gln Phe Ile Phe Gln Leu Cy
#s Lys Ile Thr Leu Thr
370
# 375
# 380
Ala Asp Val Met Thr Tyr Ile His Ser Met As
#n Ser Thr Ile Leu Glu
385 3
#90 3
#95 4
#00
Asp Trp Asn Phe Gly Leu Gln Pro Pro Pro Gl
#y Gly Thr Leu Glu Asp
405
# 410
# 415
Thr Tyr Arg Phe Val Thr Ser Gln Ala Ile Al
#a Cys Gln Lys His Thr
420
# 425
# 430
Pro Pro Ala Pro Lys Glu Asp Pro Leu Lys Ly
#s Tyr Thr Phe Trp Glu
435
# 440
# 445
Val Asn Leu Lys Glu Lys Phe Ser Ala Asp Le
#u Asp Gln Phe Pro Leu
450
# 455
# 460
Gly Arg Lys Phe Leu Leu Gln Ala Gly Leu Ly
#s Ala Lys Pro Lys Phe
465 4
#70 4
#75 4
#80
Thr Leu Gly Lys Arg Lys Ala Thr Pro Thr Th
#r Ser Ser Thr Ser Thr
485
# 490
# 495
Thr Ala Lys Arg Lys Lys Arg Lys Leu
500
# 505
(2) INFORMATION FOR SEQ ID NO: 3:
(i) SEQUENCE CHARACTERISTICS:
(A) LENGTH: 297 base
#pairs
(B) TYPE: nucleic acid
(C) STRANDEDNESS: single
(D) TOPOLOGY: linear
(ii) MOLECULE TYPE: DNA (genomic)
(ix) FEATURE:
(A) NAME/KEY: CDS
(B) LOCATION: 1..294
(xi) SEQUENCE DESCRIPTION: SEQ ID NO:
#3:
ATG CAT GGA GAT ACA CCT ACA TTG CAT GAA TA
#T ATG TTA GAT TTG CAA 48
Met His Gly Asp Thr Pro Thr Leu His Glu Ty
#r Met Leu Asp Leu Gln
1 5
# 10
# 15
CCA GAG ACA ACT GAT CTC TAC TGT TAT GAG CA
#A TTA AAT GAC AGC TCA 96
Pro Glu Thr Thr Asp Leu Tyr Cys Tyr Glu Gl
#n Leu Asn Asp Ser Ser
20
# 25
# 30
GAG GAG GAG GAT GAA ATA GAT GGT CCA GCT GG
#A CAA GCA GAA CCG GAC 144
Glu Glu Glu Asp Glu Ile Asp Gly Pro Ala Gl
#y Gln Ala Glu Pro Asp
35
# 40
# 45
AGA GCC CAT TAC AAT ATT GTA ACC TTT TGT TG
#C AAG TGT GAC TCT ACG 192
Arg Ala His Tyr Asn Ile Val Thr Phe Cys Cy
#s Lys Cys Asp Ser Thr
50
# 55
# 60
CTT CGG TTG TGC GTA CAA AGC ACA CAC GTA GA
#C ATT CGT ACT TTG GAA 240
Leu Arg Leu Cys Val Gln Ser Thr His Val As
#p Ile Arg Thr Leu Glu
65
# 70
# 75
# 80
GAC CTG TTA ATG GGC ACA CTA GGA ATT GTG TG
#C CCC ATC TGT TCT CAG 288
Asp Leu Leu Met Gly Thr Leu Gly Ile Val Cy
#s Pro Ile Cys Ser Gln
85
# 90
# 95
AAA CCA TAA
#
#
# 297
Lys Pro
(2) INFORMATION FOR SEQ ID NO: 4:
(i) SEQUENCE CHARACTERISTICS:
(A) LENGTH: 98 amino
#acids
(B) TYPE: amino acid
(D) TOPOLOGY: linear
(ii) MOLECULE TYPE: protein
(xi) SEQUENCE DESCRIPTION: SEQ ID NO:
#4:
Met His Gly Asp Thr Pro Thr Leu His Glu Ty
#r Met Leu Asp Leu Gln
1 5
# 10
# 15
Pro Glu Thr Thr Asp Leu Tyr Cys Tyr Glu Gl
#n Leu Asn Asp Ser Ser
20
# 25
# 30
Glu Glu Glu Asp Glu Ile Asp Gly Pro Ala Gl
#y Gln Ala Glu Pro Asp
35
# 40
# 45
Arg Ala His Tyr Asn Ile Val Thr Phe Cys Cy
#s Lys Cys Asp Ser Thr
50
# 55
# 60
Leu Arg Leu Cys Val Gln Ser Thr His Val As
#p Ile Arg Thr Leu Glu
65
# 70
# 75
# 80
Asp Leu Leu Met Gly Thr Leu Gly Ile Val Cy
#s Pro Ile Cys Ser Gln
85
# 90
# 95
Lys Pro
(2) INFORMATION FOR SEQ ID NO: 5:
(i) SEQUENCE CHARACTERISTICS:
(A) LENGTH: 34 base
#pairs
(B) TYPE: nucleic acid
(C) STRANDEDNESS: single
(D) TOPOLOGY: linear
(ii) MOLECULE TYPE: other nucleic acid
(A) DESCRIPTION: /desc
#= “Primer”
(xi) SEQUENCE DESCRIPTION: SEQ ID NO:
#5:
CCCCGATATC GCCTTTAATG TATAAATCGT CTGG
#
# 34
(2) INFORMATION FOR SEQ ID NO: 6:
(i) SEQUENCE CHARACTERISTICS:
(A) LENGTH: 35 base
#pairs
(B) TYPE: nucleic acid
(C) STRANDEDNESS: single
(D) TOPOLOGY: linear
(ii) MOLECULE TYPE: other nucleic acid
(A) DESCRIPTION: /desc
#= “Primer”
(xi) SEQUENCE DESCRIPTION: SEQ ID NO:
#6:
CCCCGATATC TCAAATTATT TTCCTACACC TAGTG
#
# 35
(2) INFORMATION FOR SEQ ID NO: 7:
(i) SEQUENCE CHARACTERISTICS:
(A) LENGTH: 40 base
#pairs
(B) TYPE: nucleic acid
(C) STRANDEDNESS: single
(D) TOPOLOGY: linear
(ii) MOLECULE TYPE: other nucleic acid
(A) DESCRIPTION: /desc
#= “Primer”
(xi) SEQUENCE DESCRIPTION: SEQ ID NO:
#7:
AAAGATATCT TGTAGTAAAA ATTTGCGTCC TAAAGGAAAC
#
# 40
(2) INFORMATION FOR SEQ ID NO: 8:
(i) SEQUENCE CHARACTERISTICS:
(A) LENGTH: 44 base
#pairs
(B) TYPE: nucleic acid
(C) STRANDEDNESS: single
(D) TOPOLOGY: linear
(ii) MOLECULE TYPE: other nucleic acid
(A) DESCRIPTION: /desc
#= “Primer”
(xi) SEQUENCE DESCRIPTION: SEQ ID NO:
#8:
AAAGATATCT AATCTACCTC TACAACTGCT AAACGCAAAA AACG
#
# 44
(2) INFORMATION FOR SEQ ID NO: 9:
(i) SEQUENCE CHARACTERISTICS:
(A) LENGTH: 35 base
#pairs
(B) TYPE: nucleic acid
(C) STRANDEDNESS: single
(D) TOPOLOGY: linear
(ii) MOLECULE TYPE: other nucleic acid
(A) DESCRIPTION: /desc
#= “Primer”
(xi) SEQUENCE DESCRIPTION: SEQ ID NO:
#9:
AAAAGATATC ATGCATGGAG ATACACCTAC ATTGC
#
# 35
(2) INFORMATION FOR SEQ ID NO: 10:
(i) SEQUENCE CHARACTERISTICS:
(A) LENGTH: 34 base
#pairs
(B) TYPE: nucleic acid
(C) STRANDEDNESS: single
(D) TOPOLOGY: linear
(ii) MOLECULE TYPE: other nucleic acid
(A) DESCRIPTION: /desc
#= “Primer”
(xi) SEQUENCE DESCRIPTION: SEQ ID NO:
#10:
TTTTGATATC GGCTCTGTCC GGTTCTGCTT GTCC
#
# 34
(2) INFORMATION FOR SEQ ID NO: 11:
(i) SEQUENCE CHARACTERISTICS:
(A) LENGTH: 44 base
#pairs
(B) TYPE: nucleic acid
(C) STRANDEDNESS: single
(D) TOPOLOGY: linear
(ii) MOLECULE TYPE: other nucleic acid
(A) DESCRIPTION: /desc
#= “Primer”
(xi) SEQUENCE DESCRIPTION: SEQ ID NO:
#11:
TTTTGATATC CTTGCAACAA AAGGTTACAA TATTGTAATG GGCC
#
# 44
(2) INFORMATION FOR SEQ ID NO: 12:
(i) SEQUENCE CHARACTERISTICS:
(A) LENGTH: 35 base
#pairs
(B) TYPE: nucleic acid
(C) STRANDEDNESS: single
(D) TOPOLOGY: linear
(ii) MOLECULE TYPE: other nucleic acid
(A) DESCRIPTION: /desc
#= “Primer”
(xi) SEQUENCE DESCRIPTION: SEQ ID NO:
#12:
AAAAGATATC TGGTTTCTGA GAACAGATGG GGCAC
#
# 35
(2) INFORMATION FOR SEQ ID NO: 13:
(i) SEQUENCE CHARACTERISTICS:
(A) LENGTH: 38 base
#pairs
(B) TYPE: nucleic acid
(C) STRANDEDNESS: single
(D) TOPOLOGY: linear
(ii) MOLECULE TYPE: other nucleic acid
(A) DESCRIPTION: /desc
#= “Primer”
(xi) SEQUENCE DESCRIPTION: SEQ ID NO:
#13:
TTTTGATATC GATTATGAGC AATTAAATGA CAGCTCAG
#
# 38
(2) INFORMATION FOR SEQ ID NO: 14:
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(xi) SEQUENCE DESCRIPTION: SEQ ID NO:
#14:
TTTTGATATC GTCTACGTGT GTGCTTTGTA CGCAC
#
# 35
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(xi) SEQUENCE DESCRIPTION: SEQ ID NO:
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TTTATCGATA TCGGTCCAGC TGGACAAGCA GAACCGGAC
#
# 39
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(xi) SEQUENCE DESCRIPTION: SEQ ID NO:
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TTTTGATATC GATGCCCATT ACAATATTGT AACCTTTTG
#
# 39
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(xi) SEQUENCE DESCRIPTION: SEQ ID NO:
#17:
ATG AGT CTT CTA ACC GAG GTC GAA ACG CTT AC
#C AGA AAC GGA TGG GAG 48
Met Ser Leu Leu Thr Glu Val Glu Thr Leu Th
#r Arg Asn Gly Trp Glu
1 5
# 10
# 15
TGC AAA TGC AGC GAT TCA AGT GAT CCT CTC AT
#T ATC GCA GCG AGT ATC 96
Cys Lys Cys Ser Asp Ser Ser Asp Pro Leu Il
#e Ile Ala Ala Ser Ile
20
# 25
# 30
ATT GGG ATC TTG CAC TTG ATA TTG TGG ATT TT
#T TAT CGT CTT TTC TTC 144
Ile Gly Ile Leu His Leu Ile Leu Trp Ile Ph
#e Tyr Arg Leu Phe Phe
35
# 40
# 45
AAA TGC ATT TAT CGT CGC CTT AAA TAC GGT TT
#G AAA AGA GGG CCT TCT 192
Lys Cys Ile Tyr Arg Arg Leu Lys Tyr Gly Le
#u Lys Arg Gly Pro Ser
50
# 55
# 60
ACG GAA GGA GCG CCT GAG TCT ATG AGG GAA GA
#A TAT CGG CAG GAA CAG 240
Thr Glu Gly Ala Pro Glu Ser Met Arg Glu Gl
#u Tyr Arg Gln Glu Gln
65
# 70
# 75
# 80
CAG AGT GCT GTG GAT GTT GAC GAT GTT CAT TT
#T GTC AAC ATA GAG CTG 288
Gln Ser Ala Val Asp Val Asp Asp Val His Ph
#e Val Asn Ile Glu Leu
85
# 90
# 95
GAG TAA
#
#
# 294
Glu
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Met Ser Leu Leu Thr Glu Val Glu Thr Leu Th
#r Arg Asn Gly Trp Glu
1
#5
#10
#15
Cys Lys Cys Ser Asp Ser Ser Asp Pro Leu
#Ile Ile Ala Ala Ser Ile
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# 25
# 30
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# 55
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Thr Glu Gly Ala Pro Glu Ser Met Arg Glu
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# 70
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Gln Ser Ala Val Asp Val Asp Asp Val His
#Phe Val Asn Ile Glu Leu
#85
#90
#95
Glu
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(xi) SEQUENCE DESCRIPTION: SEQ ID NO:
#19:
TTTTGATATC GATATGGAAT GGCTAAAGAC AAGACCAATC
#
# 40
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(xi) SEQUENCE DESCRIPTION: SEQ ID NO:
#20:
TTTTGATATC GTTGTTTGGA TCCCCATTCC CATTG
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# 35
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# 24
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CCATGCATTC CTGCTTGTAG TAAAAATTTG CGTCC
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# 29
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# 36
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CTCTGTCCG
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CATCTGAAGC TTATTGTACG CACAACCGAA GCGTAGAGTC ACACTTG
# 47 | Vaccine formulations comprising viral capsomeres are disclosed along with methods for their production. Therapeutic and prophylactic methods of use for the vaccine formulations are also disclosed. | 8 |
RELATED APPLICATIONS
[0001] This application is a divisional of U.S. patent application Ser. No. 11/243,387 filed on Oct. 4, 2005. This application claims the benefit of Japanese Patent Application No. 2004-294585 filed Oct. 7, 2004, 2004-294588 filed Oct. 7, 2004, 2004-294589 filed Oct. 7, 2004, and 2005-196411 filed Jul. 5, 2005. The disclosures of the above applications are incorporated herein by reference.
BACKGROUND
[0002] 1. Technical Field
[0003] The present invention relates to a system, a device, an apparatus, and a program that perform an output process through authentication, and more particularly, to an authentication output system, a device using apparatus, a network device, an output data managing program, an output control program, an output system, an authentication output method, and an output method capable of allowing only an authorized user to acquire an output matter and of protecting the secrecy of output contents by preventing the output process from being performed beyond an output permission range.
[0004] 2. Related Art
[0005] When confidential documents are printed by a network printer, serving as a network device, it is preferable to protect the secrecy of a printed matter such that the printed matter is not viewed by unauthorized users. Also, it is preferable to protect literary works, such as documents and images, read over a network.
[0006] For example, an image forming apparatus disclosed in JP-A-2002-149385 and a printing control apparatus disclosed in JP-A-2002-189578 have been known as techniques for protecting the secrecy of printed matters.
[0007] According to the technique disclosed in JP-A-2002-149385, in a case in which a print job of a confidential print mode is received, when printing is currently inexecutable, the print job is transmitted to another network printer. In this case, only when another network printer, a destination of the print job, which is positioned close to the currently used printer, is in an immediately printable state, the print job is transmitted in a forced print mode. Meanwhile, when the network printer which is a destination of the print job is positioned far away from the currently used printer, or is not in the immediately printable state although it is positioned close thereto, the print job is transmitted again in a confidential print mode. In this way, even when a problem, such as a paper jam, occurs in a network printer receiving a printing request, it is possible to reliably acquire a printed matter by using another network printer.
[0008] According to the technique disclosed in JP-A-2002-189578, a print job received from a host terminal, a source of the print job which is serving as a device using apparatus is transmitted to a network printer which is previously set as a destination of the print job. Then, when an NW port of the network printer detects problems, such as a jam of a printing engine unit and the abnormality of a PDL analysis, by communicating with a PDL port, the network printer, which is a destination of the print job, is instructed to start a page analyzing process of the print job. In this way, it is possible to rapidly process the print job in the network printer, which is a destination of the job print, without transmitting the print job to another network printer.
[0009] Meanwhile, for example, a document managing method disclosed in JP-A-10-320289 has been known as a technique for protecting a literary work.
[0010] The invention disclosed in JP-A-10-320289 includes a copyright management information setting unit, a document storage unit, a copyright management information storage unit, a copyright management information checking unit, and a document generating unit. The copyright management information setting unit sets copyright management information in constituent units of the documents stored in the document storage unit, and associates the set copyright management information with information indicating the constituent units of the set copyright management information to store it in the copyright management information storage unit. When the document generating unit requires using a predetermined portion of another document stored in the document storage unit during the creation of documents, the copyright management information checking unit determines an available portion in the predetermined portion, on the basis of the copyright management information stored in the copyright management information storage unit in the constituent unit that overlaps the predetermined portion.
[0011] However, according to the invention disclosed in JP-A-2002-149385, in a case in which the remaining print job exists in a network printer, is a source of the data, capable of reliably acquiring a printed matter, when the network printer gets out of trouble, the same printed matter as that printed in a transmission destination may be printed out.
[0012] Further, according to the invention disclosed in JP-A-2002-189578, a plurality of network printers capable of reliably and rapidly acquiring printed matters are simultaneously instructed to start the page analysis process, printed matters larger than a necessary number of copies may be printed.
[0013] Therefore, the inventions disclosed in JP-A-2002-149385 and JP-A-2002-189578 have a problem in that unauthorized users may view the contents of a printed matter.
[0014] Meanwhile, in the invention disclosed in JP-A-10-320289, when it is necessary to use a predetermined portion of another document, an available portion in the predetermined portion is determined on the basis of the copyright management information in the constituent unit that overlaps the predetermined portion. Therefore, it is possible to restrict the change of documents by using the relationship with other documents, but the document can be relatively freely printed. As a result, literary works may be printed without restriction, and thus the structure disclosed in JP-A-10-320289 has a problem in that the literary works can not be reliably protected.
[0015] The problem of the insufficient protection of the literary works may also arise in a case in which a display device, such as a projector or an LCD (liquid crystal display device), is connected to a network to display an image, as well as in the printing process.
SUMMARY
[0016] A first advantage of some aspects of the invention is that it provides an authentication output system, a device using apparatus, a network device, an output data managing program, an output control program, an output system, an authentication output method, and an output method capable of allowing only an authorized user to acquire an output matter and of protecting the secrecy of output contents by preventing an output process from being performed beyond an output permission range. In addition, a second advantage of some aspects of the invention is that it provides an output system, a network device, an output control program, and an output method capable of allowing only an authorized user to acquire an output matter and of protecting literary works and the secrecy of output contents by preventing an output process from being performed beyond an output permission range.
[0017] According to a first aspect of the invention, an authentication output system includes a plurality of network devices each of which performs an output process on the basis of output data; and a device using apparatus that uses the network devices, the device using apparatus being connected to the network devices so as to communicate therewith. When authentication succeeds, the network devices perform the output process. The device using apparatus includes an output data storage unit that stores the output data; a job ticket storage unit that stores job tickets specifying contents related to whether to permit or restrict the use of the output data; and an output data utilization managing unit that manages the use of the output data. When the authentication succeeds, the output data utilization managing unit supplies the output data stored in the output data storage unit to any one of the plurality of network devices, and prohibits the supply of the output data until a print completion notice is received. When the print completion notice is received, the output data utilization managing unit updates the job tickets stored in the job ticket storage unit. When it is determined that the contents of the job tickets satisfy predetermined conditions, the output data utilization managing unit prohibits the supply of the output data. Each of the network devices includes an output data receiving unit that receives the output data; and an output control unit that performs output control on the basis of the output data received by the output data receiving unit. The output control unit transmits the print completion notice to the device using apparatus when the network device completely outputs the output data.
[0018] According to this structure, in the device using apparatus, when the authentication succeeds, the output data utilization managing unit supplies the output data to any one of the plurality of network devices, and then prohibits the supply of the output data until the print completion notice is received.
[0019] In the network device, when the output data receiving unit receives the output data, the output control unit performs the output control on the basis of the received output data. Then, when the output of the output data is completed, the print completion notice is transmitted to the device using apparatus.
[0020] In the device using apparatus, when the print completion notice is received, the output data utilization managing unit updates the job tickets.
[0021] Further, in the device using apparatus, when it is determined that the contents of the job tickets satisfy the predetermined conditions, the output data utilization managing unit prohibits the supply of the output data.
[0022] In this way, when the output of the output data is completed, the job tickets are updated. Therefore, even when the output of the output data from the network device is interrupted due to a trouble, it is possible to obtain output contents by using another network device. Thus, only an authorized user can obtain an output matter.
[0023] Furthermore, since the output data is supplied to any one of the network devices, it is possible to prevent the same output content from being simultaneously output from the plurality of network devices. In addition, even when the network device is restored from a disable state to a normal state, it is possible to prevent the output content from being output from the network device since the use of the output data is prohibited. Further, it is possible to prevent the output process from being performed beyond an output permission range, and thus to more reliably protect the secrecy of the output content.
[0024] Moreover, since the output data and the job tickets are collectively managed by the device using apparatus, it is possible to more strictly manage the output data and the job tickets, compared with a case in which the output data and the job tickets are managed by different apparatuses.
[0025] Further, when it is determined that the contents of the job tickets satisfy predetermined conditions, the supply of the output data is prohibited. In this case, prohibiting the supply and use of the output data includes, for example, removing the output data, rejecting a request for the supply or use of the output data, rewriting the attribute of the output data into ‘unavailable’, and encoding the output data such that the output data cannot be read. The above is similarly applied to an authentication output system according to a third aspect, device using apparatuses according to sixteenth and eighteenth aspects, a network device according to a twenty-third aspect, output data managing programs according to thirty-fourth and thirty-sixth aspects, an output control program according to a forty-first aspect, and authentication output methods according to fifty-second and fifty-fourth aspects.
[0026] Furthermore, the supply of the output data is prohibited until the print completion notice is received. In this case, prohibiting the supply of the output data includes, for example, rejecting a request for the supply of the output data, rewriting the attribute of the output data into ‘unavailable’, and encoding the output data such that the output data cannot be read. The above is similarly applied to the authentication output system according to the third aspect, the device using apparatuses according to the sixteenth and eighteenth aspects, the output data managing programs according to the thirty-fourth and thirty-sixth aspects, and the authentication output methods according to the fifty-second and fifty-fourth aspects.
[0027] Further, updating the job tickets includes, for example, prescribing the number of supplies of the output data and decrementing the number of supplies of the output data whenever the supply is performed and incrementing the number of supplies of the output data whenever the supply is performed. The above is similarly applied to an authentication output system according to a fourth aspect, device using apparatuses according to seventeenth and nineteenth aspects, output data managing programs according to thirty-fifth and thirty-seventh aspects, and authentication output methods according to fifty-third and fifty-fifth aspects.
[0028] Furthermore, the output control unit has any structure as long as it can perform output control on the basis of the output data. For example, the output control unit may perform the output control on a printing unit that performs a printing process on the basis of print data, a display unit that performs display on the basis of display data, or a voice output unit that outputs a voice on the basis of audio data. For example, a projector or an LCD is used as the display unit. The above is similarly applied to authentication output systems according to fourth, ninth, eleventh, sixty-seventh, sixth-eighth, seventy-third, and seventy-fourth aspects, network devices according to twenty-fourth, twenty-seventh, twenty-ninth, eighty-fifth, eighty-eighth, eighty-ninth, one-hundred twenty-seventh and one-hundred twenty-eighth aspects, and output systems according to one-hundred twenty-first and one-hundred twenty-second aspects.
[0029] Moreover, the output data storage unit stores the output data. Alternatively, the output data may be previously stored in the output data storage unit, or the output data may be stored in the output data storage unit by input from the outside during the operation of the present system. This is similarly applied to a case in which the job tickets are stored in the job ticket storage unit. The above is similarly applied to the authentication output systems according to the fourth, ninth, eleventh, sixty-seventh, sixth-eighth, seventy-third, and seventy-fourth aspects, device using apparatuses according to seventeenth, nineteenth, seventy-ninth, and eightieth aspects, the network devices according to the twenty-seventh, twenty-ninth, eighty-fifth, eighty-eighth, eighty-ninth, one-hundred twenty-seventh and one-hundred twenty-eighth aspects, and the output systems according to the one-hundred twenty-first and one-hundred twenty-second aspects.
[0030] Further, obtaining authentication includes, for example, obtaining the authentication by an authenticating unit and acquiring authentication result information indicating an authentication result. The authenticating unit may be provided in a network device, a device using apparatus, and other apparatuses connected to the network. The above is similarly applied to the authentication output systems according to the fourth, ninth, eleventh, sixty-seventh, sixth-eighth, seventy-third, and seventy-fourth aspects, the device using apparatuses according to the seventeenth, nineteenth, seventy-ninth, and eightieth aspects, the network devices according to the twenty-seventh, twenty-ninth, eighty-eighth, and eighty-ninth aspects.
[0031] Further, using the network device means utilizing the functions of the network device. This is similarly applied to the other aspects.
[0032] In addition, utilization restriction includes the output restriction of the output data, the movement restriction of the output data, and copy restriction, and utilization permission includes the output permission of the output data, the movement permission of the output data, and copy permission. Further, specifying the contents related to whether to permit or restrict the use of the output data includes, for example, specifying the number of supplies of the output data. The above is similarly applied to the other aspects.
[0033] Furthermore, the management by the output data utilization managing unit includes, for example, the output permission of data, the output restriction of data, and the update of the job tickets. This is similarly applied to the other aspects.
[0034] In addition, the supply of the output data includes, for example, transmitting the output data and storing the output data in a storage unit, such as a memory. This is similarly applied to the other aspects.
[0035] Further, the predetermined conditions include, for example, a condition for specifying a utilization restriction range and a condition for specifying a utilization permission range. This is similarly applied to the other aspects.
[0036] Moreover, the job tickets include, for example, information on content management, such as the number of output permissions (for example, time and the number of times) or the remaining number of output permissions, output permission target information, a place where output is permitted, the number of copies, and output exclusive control information. This is similarly applied to the other aspects.
[0037] According to a second aspect of the invention, in the authentication output system of the first aspect, the output data utilization managing unit prohibits the supply of the output data until the print completion notice or a print interruption notice is received. In addition, when the output of the output data from the network devices is interrupted, the output control unit prohibits the use of the output data and transmits the print interruption notice to the device using apparatus.
[0038] According to this structure, in the device using apparatus, the supply of the output data is prohibited until the print completion notice or the print interruption notice is received.
[0039] In the network device, when the output of the output data is interrupted, the use of the output data is prohibited, and the print interruption notice is transmitted to the device using apparatus.
[0040] Here, in the case in which the output is interrupted and the use of the output data is prohibited, prohibiting the supply or use of the output data includes, for example, removing the output data, rejecting a request for the supply or use of the output data, rewriting the attribute of the output data into ‘unavailable’, and encoding the output data such that the output data cannot be read. The above is similarly applied to the authentication output system according to the fourth aspect, the device using apparatuses according to the seventeenth and nineteenth aspects, the network device according to the twenty-fourth aspect, the output data managing programs according to thirty-fifth and thirty-seventh aspects, an output control program according to a forty-second aspect, and authentication output methods according to fifty-third and fifty-fifth aspects.
[0041] Further, in the case in which the supply of the output data is prohibited until the print completion notice or a print interruption notice is received, prohibiting the supply of the output data includes, for example, rejecting a request for the supply of the output data, rewriting the attribute of the output data into ‘unavailable’, and encoding the output data such that the output data cannot be read. This is similarly applied to the authentication output system according to the fourth aspect, the device using apparatuses according to the seventeenth and nineteenth aspects, the output data managing programs according to thirty-fifth and thirty-seventh aspects, and the authentication output methods according to the fifty-third and fifty-fifth aspects.
[0042] According to a third aspect of the invention, an authentication output system includes a plurality of network devices each of which performs an output process on the basis of output data; and a device using apparatus that uses the network devices, the device using apparatus being connected to the network devices so as to communicate therewith. When authentication succeeds, the network devices perform the output process. The device using apparatus includes an output data storage unit that stores the output data; a job ticket storage unit that stores job tickets specifying contents related to whether to permit or restrict the use of the output data; and an output data utilization managing unit that manages the use of the output data. When the authentication succeeds, the output data utilization managing unit supplies the output data stored in the output data storage unit to any one of the plurality of network devices, updates the job tickets stored in the job ticket storage unit, and prohibits the supply of the output data until a print completion notice is received. When it is determined that the contents of the job tickets satisfy predetermined conditions, the output data utilization managing unit prohibits the supply of the output data. Each of the network devices includes an output data receiving unit that receives the output data; and an output control unit that performs output control on the basis of the output data received by the output data receiving unit. The output control unit transmits the print completion notice to the device using apparatus when the network device completely outputs the output data.
[0043] According to this structure, in the device using apparatus, when the authentication succeeds, the output data utilization managing unit supplies the output data to any one of the plurality of network devices, and updates the job tickets. Then, the output data utilization managing unit prohibits the supply of the output data until the print completion notice is received.
[0044] In the network device, when the output data receiving unit receives the output data, the output control unit performs the output control on the basis of the received output data. Then, when the output of the output data is completed, the print completion notice is transmitted to the device using apparatus.
[0045] In the device using apparatus, when it is determined that the contents of the job tickets satisfy the predetermined conditions, the output data utilization managing unit prohibits the supply of the output data.
[0046] In this way, when the output of the output data is completed, the job tickets are updated. Therefore, even when the output of the output data from the network device is interrupted due to a trouble, it is possible to obtain output contents by using another network device. Thus, only an authorized user can obtain an output matter.
[0047] Furthermore, since the output data is supplied to any one of the network devices, it is possible to prevent the same output content from being simultaneously output from the plurality of network devices. In addition, even when the network device is restored from a disable state to a normal state, it is possible to prevent the output content from being output from the network device since the use of the output data is prohibited. Further, it is possible to prevent the output process from being performed beyond an output permission range, and thus to more reliably protect the secrecy of the output content.
[0048] Moreover, since the output data and the job tickets are collectively managed by the device using apparatus, it is possible to more strictly manage the output data and the job tickets, compared with a case in which the output data and the job tickets are managed by different apparatuses.
[0049] According to a fourth aspect of the invention, in the authentication output system of the third aspect, the output data utilization managing unit prohibits the supply of the output data until the print completion notice or a print interruption notice is received. When the print interruption notice is received, the output data utilization managing unit restores the contents of the job tickets to the original states before the update. When the output of the output data from the network devices is interrupted, the output control unit prohibits the use of the output data and transmits the print interruption notice to the device using apparatus.
[0050] According to this structure, in the device using apparatus, the supply of the output data is prohibited until the print completion notice or the print interruption notice is received.
[0051] In the network device, when the output of the output data is interrupted, the use of the output data is prohibited, and the print interruption notice is transmitted to the device using apparatus.
[0052] In the device using apparatus, when the print interruption notice is received, the output data utilization managing unit restores the contents of the job tickets to the original states before the update.
[0053] According to a fifth aspect of the invention, in the authentication output system of the second aspect or the fourth aspect, the device using apparatus further includes an authentication information receiving unit that receives authentication information used for the authentication; and an authenticating unit. Each of the network devices further includes an authentication information acquiring unit that acquires the authentication information; and an authentication information transmitting unit that transmits the authentication information acquired by the authentication information acquiring unit to the device using apparatus. The authenticating unit authenticates the use of the output data on the basis of the authentication information received by the authentication information receiving unit. When it is determined that the use of the output data is authenticated by the authenticating unit, the output data utilization managing unit supplies the output data to one of the plurality of network device, which is a source of the authentication information.
[0054] According to this structure, in the network device, when the authentication information acquiring unit acquires the authentication information, the authentication information transmitting unit transmits the acquired authentication information to the device using apparatus.
[0055] In the device using apparatus, when the authentication information receiving unit receives the authentication information, the authenticating unit authenticates the use of the output data on the basis of the received authentication information. As a result, when it is determined that the use of the output data is authenticated by the authenticating unit, the output data utilization managing unit supplies the output data to one of the plurality of network device, which is a source of the authentication information.
[0056] In this way, when a user inputs proper authentication information to a desired network device, the user can obtain output contents from the network device.
[0057] Here, the authentication information acquiring unit has any structure as long as it can acquire the authentication information. For example, the authentication information acquiring unit may receive the authentication information from an input device, or it may acquire or receive the authentication information from, for example, an external terminal. Alternatively, the authentication information acquiring unit reads out the authentication information from, for example, a storage device or a storage media. The storage device and the storage media may be combined with each other, or may be separated from each other. In addition, acquiring includes, for example, at least, input, obtaining, receiving, and reading. The above is similarly applied to authentication output systems according to twelfth, sixty-ninth, and seventy-fifth aspects, network devices according to twenty-fifth, thirtieth, eighty-sixth, eightieth, and one-hundred twenty-ninth aspects, and an output system according to a one-hundred twenty-third aspect.
[0058] According to a sixth aspect of the invention, in the authentication output system of the fifth aspect, when it is determined that the use of the output data is authenticated by the authenticating unit and that the job tickets can be updated, the output data utilization managing unit supplies the output data, and prohibits the update of the job tickets until the print interruption notice or the print completion notice is received.
[0059] According to this structure, in the device using apparatus, when it is determined that the use of the output data is authenticated by the authenticating unit and that the job tickets can be updated, the output data utilization managing unit supplies the output data. Then, the output data utilization managing unit prohibits the update of the job tickets until the print interruption notice or the print completion notice is received. Therefore, even when the authentication information is received, the output data is not supplied until the print interruption notice or the print completion notice is received.
[0060] Here, prohibiting the update includes, for example, prohibiting the update of the job tickets by the request of other network devices. This is similarly applied to the other aspects.
[0061] Further, according to a seventh aspect of the invention, in the authentication output system according to any one of the second, fourth to sixth aspects, the device using apparatus further includes a utilization history information generating unit that creates utilization history information indicating a utilization history of the output data, on the basis of the result supplied by the output data utilization managing unit.
[0062] According to this structure, in the device using apparatus, the utilization history information generating unit creates utilization history information indicating a utilization history of the output data, on the basis of the result supplied by the output data utilization managing unit.
[0063] In this way, it is possible to see how the output data has been used by referring to the utilization history information.
[0064] Thus, it is possible to manage a copyright. In addition, it is possible to confirm that a permitted number of copies are output or only an authorized user performs an output process.
[0065] Furthermore, according to an eighth aspect of the invention, an authentication output system includes first and second network devices each of which performs an output process on the basis of output data; and a device using apparatus that uses the network devices, the device using apparatus being connected to the network devices so as to communicate therewith. When authentication succeeds, the network devices perform the output process. The device using apparatus includes an output data transmitting unit that transmits the output data to the first network device. The first network device includes an output data storage unit; a first output data receiving unit that receives the output data; an output data holding unit that stores the output data received by the first output data receiving unit in the output data storage unit; a job ticket storage unit that stores job tickets specifying contents related to whether to permit or restrict the use of the output data; an output data utilization managing unit that manages the use of the output data; and a first output control unit that performs output control on the basis of the output data stored in the output data storage unit. When the authentication succeeds, the output data utilization managing unit supplies the output data stored in the output data storage unit to the second network device, and prohibits the supply and use of the output data until a print completion notice is received. Alternatively, the output data utilization managing unit requires the first output control unit to output the output data, prohibits the supply of the output data until the output of the output data from the first network device is completed, updates the job tickets stored in the job ticket storage unit when the print completion notice is received or when the output of the output data from the first network device is completed, and prohibits the supply and use of the output data when it is determined that the contents of the job tickets satisfy predetermined conditions. The first output control unit performs the output process on the basis of the output data, according to the output request. The second network device includes a second output data receiving unit that receives the output data; and a second output control unit that performs output control on the basis of the output data received by the second output data receiving unit. When the output of the output data from the second network device is completed, the second output control unit transmits the print completion notice to the first network device.
[0066] According to this structure, in the device using apparatus, the output data transmitting unit transmits the output data to the first network device.
[0067] In the first network device, when the first output data receiving unit receives the output data, the output data holding unit stores the received output data in the output data storage unit. Then, when the authentication succeeds, the output data utilization managing unit supplies the output data to the second network device, or requests the first network device to output the output data. In the former case, the supply and use of the output data are prohibited until the print completion notice is received.
[0068] In the second network device, when the second output data receiving unit receives the output data, the second output control unit performs output control on the basis of the received output data. When the output of the output data is completed, the print completion notice is transmitted to the first network device.
[0069] In the first network device, when the print completion notice is received, the output data utilization managing unit updates the job tickets.
[0070] Meanwhile, in the first network device, when the output request is performed on the first output control unit, the first output control unit performs the output process on the basis of the output data. Then, the output data utilization managing unit prohibits the supply of the output data until the output of the output data is completed. When the output of the output data is completed, the job tickets are updated.
[0071] Further, in the first network device, the output data utilization managing unit prohibits the supply and use of the output data when it is determined that the contents of the job tickets satisfy predetermined conditions.
[0072] In this way, when the output of the output data is completed, the job tickets are updated. Therefore, even when the output of the output data from one of the first and second network devices is interrupted due to a trouble, it is possible to obtain output contents from the other network device. In addition, only an authorized user can obtain an output matter.
[0073] In addition, the output data is supplied to the second network device, or the output data is used for the first network device. Therefore, it is possible to prevent the same output content from being simultaneously output from the first and second network devices. In addition, even when the network device is restored from a disable state to a normal state, it is possible to prevent the output content from being output from the network device since the use of the output data is prohibited. Further, it is possible to prevent the output process from being performed beyond an output permission range, and thus to more reliably protect the secrecy of the output content.
[0074] Moreover, since the output data and the job tickets are collectively managed by the first network device, it is possible to more strictly manage the output data and the job tickets, compared with a case in which the output data and the job tickets are managed by different apparatuses.
[0075] Further, when it is determined that the contents of the job tickets satisfy predetermined conditions, the supply of the output data is prohibited. In this case, prohibiting the supply and use of the output data includes, for example, removing the output data, rejecting a request for the supply or use of the output data, rewriting the attribute of the output data into ‘unavailable’, and encoding the output data such that the output data cannot be read. The above is similarly applied to an authentication output system according to a tenth aspect, network devices according to twenty-sixth and twenty-eighth aspects, output control programs according to forty-fourth and forty-sixth aspects, and authentication output methods according to fifty-ninth and sixty-first aspects.
[0076] Furthermore, in the case in which the supply and use of the output data are prohibited until the print completion notice is received or the supply of the output data is prohibited until the output of the output data is completed, prohibiting the supply or use of the output data includes, for example, rejecting a request for the supply or use of the output data, rewriting the attribute of the output data into ‘unavailable’, and encoding the output data such that the output data cannot be read. The above is similarly applied to the authentication output system according to the tenth aspect, the network devices according to the twenty-sixth and twenty-eighth aspects, the output control programs according to the forty-fourth and forty-sixth aspects, and the authentication output methods according to the fifty-ninth and sixty-first aspects.
[0077] Further, updating the job tickets includes, for example, prescribing the number of supplies or utilizations of the output data, decrementing the number of supplies or utilizations of the output data whenever the supply or utilization is performed, and incrementing the number of supplies or utilizations of the output data whenever the supply or utilization is performed. The above is similarly applied to the authentication output system according to the eleventh, aspect, the network devices according to the twenty-seventh, twenty-ninth, one-hundred twenty-seventh, and one-hundred twenty-eighth aspects, output control programs according to forty-fifth, forty-seventh, one-hundred thirty-third, and one-hundred thirty-fourth aspects, authentication output methods according to sixtieth and sixty-second aspects, the output systems according to one-hundred twenty-first and one-hundred twenty-second aspects, and output method according to one-hundred thirty-ninth and one-hundred fortieth.
[0078] Further, according to a ninth aspect of the invention, in the authentication output system of the eighth aspect, the output data utilization managing unit prohibits the supply and use of the output data until the print completion notice or a print interruption notice is received. Alternatively, the output data utilization managing unit prohibits the supply of the output data until the output of the output data from the first network device is interrupted or completed. When the output of the output data from the second network device is interrupted, the second output control unit prohibits the use of the output data and transmits the print interruption notice to the first network device.
[0079] According to this structure, in the first network device, when the authentication succeeds, the output data utilization managing unit supplies the output data to the second network device, or requests the first network device to output the output data. In the former case, the supply and use of the output data are prohibited until the print interruption notice or the print completion notice is received.
[0080] In the second network device, when the output of the output data is interrupted, the use of the output data is prohibited, and the print interruption notice is transmitted to the first network device.
[0081] Meanwhile, in the first network device, the output data utilization managing unit prohibits the supply of the output data until the output of the output data is interrupted or completed.
[0082] Here, when the output of the output data is interrupted, the use of the output data is prohibited. In this case, prohibiting the supply and use of the output data includes, for example, removing the output data, rejecting a request for the supply or use of the output data, rewriting the attribute of the output data into ‘unavailable’, and encoding the output data such that the output data cannot be read. This is similarly applied to the authentication output system according to the eleventh, aspect, the network devices according to the twenty-seventh and twenty-ninth aspects, the output control programs according to the forty-fifth and forty-seventh aspects, and the authentication output methods according to the sixtieth and sixty-second aspects.
[0083] Further, in the case in which the supply and use of the output data are prohibited until the print interruption notice or the print completion notice is received or the supply of the output data is prohibited until the output of the output data is interrupted or completed, prohibiting the supply or use of the output data includes, for example, rejecting a request for the supply or use of the output data, rewriting the attribute of the output data into ‘unavailable’, and encoding the output data such that the output data cannot be read. This is similarly applied to the authentication output system according to the eleventh aspect, the network devices according to the twenty-seventh, twenty-ninth, one-hundred twenty-seventh, and one-hundred twenty-eighth aspects, the output control programs according to the forty-fifth, forty-seventh, one-hundred thirty-third, and one-hundred thirty-fourth aspects, the authentication output methods according to the sixtieth and sixty-second aspects, the output systems according to the one-hundred twenty-first and one-hundred twenty-second aspects, and the output methods according to the one-hundred thirty-ninth and one-hundred fortieth aspects.
[0084] Further, according to a tenth aspect of the invention, an authentication output system includes first and second network devices each of which performs an output process on the basis of output data; and a device using apparatus that uses the network devices, the device using apparatus being connected to the network devices so as to communicate therewith. When authentication succeeds, the network devices perform the output process. The device using apparatus includes an output data transmitting unit that transmits the output data to the first network device. The first network device includes an output data storage unit; a first output data receiving unit that receives the output data; an output data holding unit that stores the output data received by the first output data receiving unit in the output data storage unit; a job ticket storage unit that stores job tickets specifying contents related to whether to permit or restrict the use of the output data; an output data utilization managing unit that manages the use of the output data; and a first output control unit that performs output control on the basis of the output data stored in the output data storage unit. When the authentication succeeds, the output data utilization managing unit supplies the output data stored in the output data storage unit to the second network device, updates the job tickets stored in the job ticket storage unit, and prohibits the supply and use of the output data until a print completion notice is received. Alternatively, the output data utilization managing unit requires the first output control unit to output the output data, updates the job tickets stored in the job ticket storage unit, prohibits the supply of the output data until the output of the output data from the first network device is completed, and prohibits the supply and use of the output data when it is determined that the contents of the job tickets satisfy predetermined conditions. The first output control unit performs the output process on the basis of the output data, according to the output request. The second network device includes a second output data receiving unit that receives the output data; and a second output control unit that performs output control on the basis of the output data received by the second output data receiving unit. When the output of the output data from the second network device is completed, the second output control unit transmits the print completion notice to the first network device.
[0085] According to this structure, in the device using apparatus, the output data transmitting unit transmits the output data to the first network device.
[0086] In the first network device, when the first output data receiving unit receives the output data, the output data holding unit stores the received output data in the output data storage unit. Then, when the authentication succeeds, the output data utilization managing unit supplies the output data to the second network device, or requests the first network device to output the output data. In the former case, the job tickets are updated, and the supply and use of the output data are prohibited until the print completion notice is received.
[0087] In the second network device, when the second output data receiving unit receives the output data, the second output control unit performs output control on the basis of the received output data. When the output of the output data is completed, the print completion notice is transmitted to the first network device.
[0088] In the first network device, when an output request is performed on the first network device, the output data utilization managing unit updates the job tickets, and the first control unit performs the output process on the basis of the output data. Then, the output data utilization managing unit prohibits the supply of the output data until the output of the output data is completed.
[0089] Further, in the first network device, the output data utilization managing unit prohibits the supply and use of the output data when it is determined that the contents of the job tickets satisfy predetermined conditions.
[0090] In this way, when the output of the output data is completed, the job tickets are updated. Therefore, even when the output of the output data from one of the first and second network devices is interrupted due to a trouble, it is possible to obtain output contents from the other network device. In addition, only an authorized user can obtain an output matter.
[0091] In addition, the output data is supplied to the second network device, or the output data is used for the first network device. Therefore, it is possible to prevent the same output content from being simultaneously output from the first and second network devices. In addition, even when the network device is restored from a disable state to a normal state, it is possible to prevent the output content from being output from the network device since the use of the output data is prohibited. Further, it is possible to prevent the output process from being performed beyond an output permission range, and thus to more reliably protect the secrecy of the output content.
[0092] Moreover, since the output data and the job tickets are collectively managed by the first network device, it is possible to more strictly manage the output data and the job tickets, compared with a case in which the output data and the job tickets are managed by different apparatuses.
[0093] Further, according to the eleventh aspect of the invention, in the authentication output system of the tenth aspect, the output data utilization managing unit prohibits the supply and use of the output data until the print completion notice or a print interruption notice is received. Alternatively, the output data utilization managing unit prohibits the supply of the output data until the output of the output data from the first network device is interrupted or completed, and restores the contents of the job tickets to the original states before the update when the print interruption notice is received or when the output of the output data from the first network device is interrupted. When the output of the output data from the second network device is interrupted, the second output control unit prohibits the use of the output data and transmits the print interruption notice to the first network device.
[0094] According to this structure, in the first network device, when the authentication succeeds, the output data utilization managing unit supplies the output data to the second network device, or requests the first network device to output the output data. In the former case, the job tickets are updated, and the supply and use of the output data are prohibited until the print interruption notice or the print completion notice is received.
[0095] In the second network device, when the output of the output data is interrupted, the use of the output data is prohibited, and the print interruption notice is transmitted to the first network device.
[0096] In the first network device, when the print interruption notice is received, the output data utilization managing unit restores the contents of the job tickets to the original state before the update.
[0097] Meanwhile, in the first network device, the output data utilization managing unit prohibits the supply of the output data until the output of the output data is interrupted or completed. When the output is interrupted, the contents of the job tickets are restored to the state before the update.
[0098] According to the twelfth aspect of the invention, in the authentication output system of the ninth aspect or the eleventh aspect, the first network device further includes an authentication information receiving unit that receives authentication information used for the authentication; a first authentication information acquiring unit that acquires the authentication information; and an authenticating unit. The second network device further includes a second authentication information acquiring unit that acquires the authentication information; and an authentication information transmitting unit that transmits the authentication information acquired by the second authentication information acquiring unit to the first network device. The authenticating unit authenticates the use of the output data on the basis of the authentication information received by the authentication information receiving unit and the authentication information acquired by the first authentication information acquiring unit. When it is determined that the use of the output data is authenticated by the authenticating unit, on the basis of the authentication information received by the authentication information receiving unit, the output data utilization managing unit supplies the output data to the second network device. In addition, when it is determined that the use of the output data is authenticated by the authenticating unit on the basis of the authentication information acquired by the first authentication information acquiring unit, the output data utilization managing unit requires the first output control unit to output the output data.
[0099] According to this structure, in the second network device, when the authentication information is acquired by the second authentication information acquiring unit, the authentication information transmitting unit transmits the acquired authentication information to the first network device.
[0100] In the first network device, when the authentication information is received by the authentication information receiving unit, the use of the output data is authenticated by the authenticating unit on the basis of the received authentication information. As a result, when it is determined that the use of the output data is permitted, the output data utilization managing unit supplies the output data to the second network device.
[0101] Further, in the first network device, when the first authentication information acquiring unit acquires the authentication information, the use of the output data is authenticated on the basis of the acquired authentication information. As a result, when the use of the output data is permitted, the output data utilization managing unit requests the first network device to output the output data.
[0102] In this way, the same effects as those in the fifth aspect are obtained.
[0103] Furthermore, according to a thirteenth aspect of the invention, in the authentication output system of the twelfth aspect, when it is determined that the use of the output data is authenticated by the authenticating unit on the basis of the authentication information received by the authentication information receiving unit and that the job tickets can be updated, the output data utilization managing unit supplies the output data, and prohibits the update of the job tickets until the print interruption notice or the print completion notice is received. In addition, when it is determined that the use of the output data is authenticated by the authenticating unit, on the basis of the authentication information acquired by the first authentication information acquiring unit and that the job tickets can be updated, the output data utilization managing unit performs an output request and prohibits the update of the job tickets until the output of the output data from the first network device is interrupted or completed.
[0104] According to this structure, in the first network device, when it is determined that the use of the output data is authenticated by the authenticating unit on the basis of the received authentication information and that the job tickets can be updated, the output data utilization managing unit supplies the output data to the second network device, and prohibits the update of the job tickets until the print interruption notice or the print completion notice is received.
[0105] In addition, in the first network device, when it is determined that the use of the output data is authenticated on the basis of the acquired authentication information and that the job tickets can be updated, the output data utilization managing unit requests the first network device to output the output data, and prohibits the update of the job tickets until the output of the output data is interrupted or completed.
[0106] Therefore, until the print interruption notice or the print completion notice is received or until the output of the output data is interrupted or completed, the output data is not supplied even though the authentication information is received, and the output of the output data is not performed even though the authentication information is acquired.
[0107] Further, according to a fourteenth aspect of the invention, in the authentication output system according to any one of the ninth, eleventh to thirteenth aspects, the first network device further includes a utilization history information generating unit that creates utilization history information indicating a utilization history of the output data, on the basis of a utilization result and a supply result of the output data utilization managing unit.
[0108] According to this structure, in the first network device, the utilization history information generating unit creates the utilization history information indicating the utilization history of the output data, on the basis of the utilization result and the supply result of the output data utilization managing unit.
[0109] In this way, the same effects as those in the seventh aspect are obtained.
[0110] Moreover, according to a fifth aspect of the invention, in the authentication output system according to any one of the second aspect, the fourth to seventh aspects, the ninth aspect, and the eleventh to fourteenth aspects, when it is determined that the contents of the job tickets satisfy the predetermined conditions, the output data utilization managing unit removes the output data and the job tickets.
[0111] According to this structure, when it is determined that the contents of the job tickets satisfy the predetermined conditions, the output data utilization managing unit removes the output data and the job tickets.
[0112] In this way, it is possible to prevent the output data and the job tickets from being illegally used, and thus to reliably protect the secrecy of the output contents.
[0113] According to the sixteenth aspect of the invention, there is provided a device using apparatus that uses a plurality of network devices. The device using apparatus includes an output data storage unit that stores output data; a job ticket storage unit that stores job tickets specifying contents related to whether to permit or restrict the use of the output data; and an output data utilization managing unit that manages the use of the output data. In the device using apparatus, when authentication succeeds, the output data utilization managing unit supplies the output data stored in the output data storage unit to any one of the plurality of network devices, and prohibits the supply of the output data until a print completion notice is received. When the print completion notice is received, the output data utilization managing unit updates the job tickets stored in the job ticket storage unit. When it is determined that the contents of the job tickets satisfy predetermined conditions, the output data utilization managing unit prohibits the supply of the output data.
[0114] According to this structure, the same operations as those in the device using apparatus of the authentication output system according to the first aspect are obtained. Thus, the same effects as those in the authentication output system according to the first aspect are obtained.
[0115] Further, according to the seventh aspect of the invention, in the device using apparatus of the sixteenth aspect, the output data utilization managing unit prohibits the supply of the output data until the print completion notice or the print interruption notice is received.
[0116] According to this structure, the same operations as those in the device using apparatus of the authentication output system according to the second aspect are obtained. Thus, the same effects as those in the authentication output system according to the second aspect are obtained.
[0117] Furthermore, according to the eighteenth aspect of the invention, there is provided a device using apparatus that uses a plurality of network devices. The device using apparatus includes an output data storage unit that stores output data; a job ticket storage unit that stores job tickets specifying contents related to whether to permit or restrict the use of the output data; and an output data utilization managing unit that manages the use of the output data. In the device using apparatus, when authentication succeeds, the output data utilization managing unit supplies the output data stored in the output data storage unit to any one of the plurality of network devices, updates the job tickets stored in the job ticket storage unit, and prohibits the supply of the output data until a print completion notice is received. When it is determined that the contents of the job tickets satisfy predetermined conditions, the output data utilization managing unit prohibits the supply of the output data.
[0118] According to this structure, the same operations as those in the device using apparatus of the authentication output system according to the third aspect are obtained. Thus, the same effects as those in the authentication output system according to the third aspect are obtained.
[0119] Further, according to the nineteenth aspect of the invention, in the device using apparatus of the eighteenth aspect, the output data utilization managing unit prohibits the supply of the output data until the print completion notice or a print interruption notice is received. When the print interruption notice is received, the output data utilization managing unit restores the contents of the job tickets to the original states before the update.
[0120] According to this structure, the same operations as those in the device using apparatus of the authentication output system according to the fourth aspect are obtained. Thus, the same effects as those in the authentication output system according to the fourth aspect are obtained.
[0121] Moreover, according to a twentieth aspect of the invention, the authentication output system of the seventeenth aspect or the nineteenth aspect further includes an authentication information receiving unit that receives authentication information used for the authentication; and an authenticating unit. The authenticating unit authenticates the use of the output data on the basis of the authentication information received by the authentication information receiving unit. When it is determined that the use of the output data is authenticated by the authenticating unit, the output data utilization managing unit supplies the output data to one of the plurality of network device, which is a source of the authentication information.
[0122] According to this structure, the same operations as those in the device using apparatus of the authentication output system according to the fifth aspect are obtained. Thus, the same effects as those in the authentication output system according to the fifth aspect are obtained.
[0123] Further, according to a twenty-first aspect of the invention, in the device using apparatus of the twentieth aspect, when it is determined that the use of the output data is authenticated by the authenticating unit and that the job tickets can be updated, the output data utilization managing unit supplies the output data, and prohibits the update of the job tickets until the print interruption notice or the print completion notice is received.
[0124] According to this structure, the same operations as those in the device using apparatus of the authentication output system according to the sixth aspect are obtained. Thus, the same effects as those in the authentication output system according to the sixth aspect are obtained.
[0125] Furthermore, according to a twenty-second aspect of the invention, the device using apparatus according to any one of the seventeen, nineteenth to twenty-first aspects further includes a utilization history information generating unit that creates utilization history information indicating a utilization history of the output data, on the basis of the result supplied by the output data utilization managing unit.
[0126] According to this structure, the same operations as those in the device using apparatus of the authentication output system according to the seventh aspect are obtained. Thus, the same effects as those in the authentication output system according to the seventh aspect are obtained.
[0127] Moreover, according to the twenty-third aspect of the invention, there is provided a network device that performs an output process on the basis of output data. The network device includes an output data receiving unit that receives the output data; and an output control unit that performs output control on the basis of the output data received by the output data receiving unit. When the network device completely outputs the output data, the output control unit transmits a print completion notice to a device using apparatus.
[0128] According to this structure, the same operations as those in the network device of the authentication output system according to the first aspect are obtained. Thus, the same effects as those in the authentication output system according to the first aspect are obtained.
[0129] Furthermore, according to the twenty-fourth aspect of the invention, in the network device of the twenty-third aspect, when the output of the output data from the network devices is interrupted, the output control unit prohibits the use of the output data and transmits the print interruption notice to the device using apparatus.
[0130] According to this structure, the same operations as those in the network device of the authentication output system according to the second aspect are obtained. Thus, the same effects as those in the authentication output system according to the second aspect are obtained.
[0131] Moreover, according to a twenty-fifth aspect of the invention, the network device of the twenty-fourth aspect includes an authentication information acquiring unit that acquires the authentication information; and an authentication information transmitting unit that transmits the authentication information acquired by the authentication information acquiring unit to the device using apparatus.
[0132] According to this structure, the same operations as those in the network device of the authentication output system according to the fifth aspect are obtained. Thus, the same effects as those in the authentication output system according to the fifth aspect are obtained.
[0133] Further, according to a twenty-sixth aspect of the invention, there is provided a network device that performs an output process on the basis of output data. The network device includes an output data storage unit; an output data receiving unit that receives the output data; an output data holding unit that stores the output data received by the output data receiving unit in the output data storage unit; a job ticket storage unit that stores job tickets specifying contents related to whether to permit or restrict the use of the output data; an output data utilization managing unit that manages the use of the output data; and an output control unit that performs output control on the basis of the output data stored in the output data storage unit. In the network device, when the authentication succeeds, the output data utilization managing unit supplies the output data stored in the output data storage unit to another network device, and prohibits the supply and use of the output data until a print completion notice is received. Alternatively, the output data utilization managing unit requires the output control unit to output the output data, prohibits the supply of the output data until the output of the output data from the network device is completed, updates the job tickets stored in the job ticket storage unit when the print completion notice is received or when the output of the output data from the network device is completed, and prohibits the supply and use of the output data when it is determined that the contents of the job tickets satisfy predetermined conditions. The output control unit performs the output process on the basis of the output data, according to the output request.
[0134] According to this structure, the same operations as those in the first network device of the authentication output system according to the eighth aspect are obtained. Thus, the same effects as those in the authentication output system according to the eighth aspect are obtained.
[0135] Further, according to the twenty-seventh aspect of the invention, in the network device of the twenty-sixth aspect, the output data utilization managing unit prohibits the supply and use of the output data until the print completion notice or a print interruption notice is received, or the output data utilization managing unit prohibits the supply of the output data until the output of the output data from the network device is interrupted or completed.
[0136] According to this structure, the same operations as those in the first network device of the authentication output system according to the ninth aspect are obtained. Thus, the same effects as those in the authentication output system according to the ninth aspect are obtained.
[0137] Furthermore, according to a twenty-eighth aspect of the invention, there is provided a network device that performs an output process on the basis of output data. The network device includes an output data storage unit; an output data receiving unit that receives the output data; an output data holding unit that stores the output data received by the output data receiving unit in the output data storage unit; a job ticket storage unit that stores job tickets specifying contents related to whether to permit or restrict the use of the output data; an output data utilization managing unit that manages the use of the output data; and an output control unit that performs output control on the basis of the output data stored in the output data storage unit. In the network device, when authentication succeeds, the output data utilization managing unit supplies the output data stored in the output data storage unit to another network device, updates the job tickets stored in the job ticket storage unit, and prohibits the supply and use of the output data until a print completion notice is received. Alternatively, the output data utilization managing unit requires the output control unit to output the output data, updates the job tickets stored in the job ticket storage unit, prohibits the supply of the output data until the output of the output data from the first network device is completed, and prohibits the supply and use of the output data when it is determined that the contents of the job tickets satisfy predetermined conditions. The output control unit performs the output process on the basis of the output data, according to the output request.
[0138] According to this structure, the same operations as those in the first network device of the authentication output system according to the tenth aspect are obtained. Thus, the same effects as those in the authentication output system according to the tenth aspect are obtained.
[0139] Moreover, according to the twenty-ninth aspect of the invention, in the network device of the twenty-eighth aspect, the output data utilization managing unit prohibits the supply and use of the output data until the print completion notice or a print interruption notice is received. Alternatively, the output data utilization managing unit prohibits the supply of the output data until the output of the output data from the network device is interrupted or completed, and restores the contents of the job tickets to the original states before the update when the print interruption notice is received or when the output of the output data from the first network device is interrupted.
[0140] According to this structure, the same operations as those in the first network device of the authentication output system according to the eleventh aspect are obtained. Thus, the same effects as those in the authentication output system according to the eleventh aspect are obtained.
[0141] Further, according to a thirtieth aspect of the invention, the network device of the twenty-seventh aspect or the twenty-ninth aspect includes an authentication information receiving unit that receives authentication information used for the authentication; an authentication information acquiring unit that acquires the authentication information; and an authenticating unit. The authenticating unit authenticates the use of the output data on the basis of the authentication information received by the authentication information receiving unit and the authentication information acquired by the authentication information acquiring unit. When it is determined that the use of the output data is authenticated by the authenticating unit, on the basis of the authentication information received by the authentication information receiving unit, the output data utilization managing unit supplies the output data to another network device. When it is determined that the use of the output data is authenticated by the authenticating unit on the basis of the authentication information acquired by the authentication information acquiring unit, the output data utilization managing unit requires the output control unit to output the output data.
[0142] According to this structure, the same operations as those in the first network device of the authentication output system according to the twelfth aspect are obtained. Thus, the same effects as those in the authentication output system according to the twelfth aspect are obtained.
[0143] Furthermore, according to a thirty-first aspect of the invention, in the network device of the thirtieth aspect, when it is determined that the use of the output data is authenticated by the authenticating unit on the basis of the authentication information received by the authentication information receiving unit and that the job tickets can be updated, the output data utilization managing unit supplies the output data, and prohibits the update of the job tickets until the print interruption notice or the print completion notice is received. When it is determined that the use of the output data is authenticated by the authenticating unit, on the basis of the authentication information acquired by the authentication information acquiring unit and that the job tickets can be updated, the output data utilization managing unit performs an output request and prohibits the update of the job tickets until the output of the output data from the network device is interrupted or completed.
[0144] According to this structure, the same operations as those in the first network device of the authentication output system according to the thirteenth aspect are obtained. Thus, the same effects as those in the authentication output system according to the thirteenth aspect are obtained.
[0145] Moreover, according to a thirty-second aspect of the invention, the network device according to any one of the twenty-seventh, twenty-ninth to thirty-first aspects further includes a utilization history information generating unit that creates utilization history information indicating a utilization history of the output data, on the basis of a utilization result and a supply result of the output data utilization managing unit.
[0146] According to this structure, the same operations as those in the first network device of the authentication output system according to the fourteenth aspect are obtained. Thus, the same effects as those in the authentication output system according to the fourteenth aspect are obtained.
[0147] Further, according to a thirty-third aspect of the invention, in the network device according to any one of the twenty-fourth, twenty-fifth, twenty-seventh, twenty-ninth to thirty-second aspects, when it is determined that the contents of the job tickets satisfy the predetermined conditions, the output data utilization managing unit removes the output data and the job tickets.
[0148] According to this structure, the same operations as those in the first network device of the authentication output system according to the fifteenth aspect are obtained. Thus, the same effects as those in the authentication output system according to the fifteenth aspect are obtained.
[0149] Furthermore, according to the thirty-fourth aspect of the invention, there is provided an output data managing program that manages output data used for a plurality of network devices. The output data managing program includes a program that allows a computer to execute a process including an output data utilization managing step of managing the use of the output data. In the output data utilization managing step, when authentication succeeds in an authenticating step, the output data stored in an output data storage unit that stores the output data is supplied to any one of the plurality of network devices, and the supply of the output data is prohibited until a print completion notice is received. When the print completion notice is received, job tickets stored in a job ticket storage unit that stores the job tickets specifying contents related to whether to permit or restrict the use of the output data are updated. When it is determined that the contents of the job tickets satisfy predetermined conditions, the supply of the output data is prohibited.
[0150] According to this configuration, when the computer reads out the program to perform the process according to the read program, the same operations and effects as those in the device using apparatus according to the sixteenth aspect are obtained.
[0151] Moreover, according to a thirty-fifth aspect of the invention, in the output data managing program of the thirty-fourth aspect, in the output data utilization managing step, the supply of the output data is prohibited until the print completion notice or a print interruption notice is received.
[0152] According to this configuration, when the computer reads out the program to perform the process according to the read program, the same operations and effects as those in the device using apparatus according to the seventeenth aspect are obtained.
[0153] Further, according to the thirty-sixth aspect of the invention, there is provided an output data managing program that manages output data used for a plurality of network devices. The output data managing program includes a program that allows a computer to execute a process including an output data utilization managing step of managing the use of the output data. In the output data utilization managing step, when authentication succeeds in an authenticating step, the output data stored in an output data storage unit that stores the output data is supplied to any one of the plurality of network devices, job tickets stored in a job ticket storage unit that stores the job tickets specifying contents related to whether to permit or restrict the use of the output data are updated, and the supply of the output data is prohibited until a print completion notice is received. When it is determined that the contents of the job tickets satisfy predetermined conditions, the supply of the output data is prohibited.
[0154] According to this configuration, when the computer reads out the program to perform the process according to the read program, the same operations and effects as those in the device using apparatus according to the eighteenth aspect are obtained.
[0155] Furthermore, according to the thirty-seventh aspect of the invention, in the output data managing program of the thirty-sixth aspect, in the output data utilization managing step, the supply of the output data is prohibited until a print interruption notice or the print completion notice is received. When the print interruption notice is received, the contents of the job tickets are restored to the original states before the update.
[0156] According to this configuration, when the computer reads out the program to perform the process according to the read program, the same operations and effects as those in the device using apparatus according to the nineteenth aspect are obtained.
[0157] Moreover, according to a thirty-eighth aspect of the invention, the output data managing program of the thirty-fifth aspect or the thirty-seventh aspect includes a program that allows a computer to execute a process composed of an authentication information receiving step of receiving authentication information used for authentication and the authenticating step. In the authenticating step, the use of the output data is authenticated on the basis of the authentication information received in the authentication information receiving step. In the output data utilization managing step, when it is determined that the use of the output data is authenticated in the authenticating step, the output data is supplied to one of the plurality of network device, which is a source of the authentication information.
[0158] According to this configuration, when the computer reads out the program to perform the process according to the read program, the same operations and effects as those in the device using apparatus according to the twentieth aspect are obtained.
[0159] Further, according to a thirty-ninth aspect of the invention, in the output data managing program of the thirty-eighth aspect, in the output data utilization managing step, when it is determined that the use of the output data is authenticated in the authenticating step and that the job tickets can be updated, the output data is supplied, and the update of the job tickets is prohibited until the print interruption notice or the print completion notice is received.
[0160] According to this configuration, when the computer reads out the program to perform the process according to the read program, the same operations and effects as those in the device using apparatus according to the twenty-first aspect are obtained.
[0161] Furthermore, according to a fortieth aspect of the invention, the output data managing program according to any one of the thirty-fifth, thirty-seventh to thirty-ninth aspects further includes a program that allows a computer to execute a process composed of a utilization history information generating step of generating utilization history information indicating a utilization history of the output data, on the basis of the result supplied in the output data utilization managing step.
[0162] According to this configuration, when the computer reads out the program to perform the process according to the read program, the same operations and effects as those in the device using apparatus according to the twenty-second aspect are obtained.
[0163] Moreover, according to the forty-first aspect of the invention, there is provided an output control program that performs an output process on the basis of output data. The output control program includes a program that allows a computer to execute a process including an output data receiving step of receiving the output data and an output control step of performing output control on the basis of the output data received in the output data receiving step. In the output control step, when the output of the output data is completed, a print completion notice is transmitted to a device using apparatus.
[0164] According to this configuration, when the computer reads out the program to perform the process according to the read program, the same operations and effects as those in the network device according to the twenty-third aspect are obtained.
[0165] In this configuration, in the output control step, the output control may be performed on the output data, and the output control step includes, for example, performing the output control on a printing unit that performs a printing process on the basis of print data, a display unit that performs display on the basis of display data, or a voice output unit that outputs a voice on the basis of audio data. This is similarly applied to output control programs according to forty-fourth, forty-sixth, hundredth, one-hundred third, one-hundred fourth, one-hundred thirty-third, and one-hundred thirty-fourth aspects, authentication output methods according to fifty-second, fifty-fourth, fifty-ninth, sixty-first, one-hundred ninth, one-hundred tenth, one-hundred fifteenth, and one-hundred sixteenth aspects, and output methods according to one-hundred thirty-ninth and one-hundred fortieth aspects.
[0166] Further, according to the forty-second aspect of the invention, in the output control program of the forty-first aspect, in the output control step, when the output of the output data is interrupted, the use of the output data is prohibited, and the print interruption notice is transmitted to the device using apparatus.
[0167] According to this configuration, when the computer reads out the program to perform the process according to the read program, the same operations and effects as those in the network device according to the twenty-fourth aspect are obtained.
[0168] Furthermore, according to a forty-third aspect of the invention, the output control program of the forty-second aspect further includes a program that allows a computer to execute a process composed of an authentication information acquiring step of acquiring the authentication information; and an authentication information transmitting step of transmitting the authentication information acquired in the authentication information acquiring step to the device using apparatus.
[0169] According to this configuration, when the computer reads out the program to perform the process according to the read program, the same operations and effects as those in the network device according to the twenty-fifth aspect are obtained.
[0170] Here, the authentication information acquiring step has any configuration as long as the authentication information can be acquired. For example, the authentication information may be input from an input device, or the authentication information may be acquired or received from, for example, an external terminal. Alternatively, the authentication information may be read out from, for example, a storage device or a storage media. The storage device and the storage media may be combined with each other, or may be separated from each other. In addition, acquiring includes, for example, at least, input, obtaining, receiving, and reading. This is similarly applied to output control programs according to forty-eight, one-hundred first, one-hundred fifth, and one-hundred thirty-fifth aspects, authentication output methods according to fifty-sixth, sixty-third, one-hundred eleventh, and one-hundred seventeenth aspects, and an output method according to a one-hundred forty-first aspect.
[0171] Moreover, according to a forty-fourth aspect of the invention, there is provided an output control program that performs an output process on the basis of output data. The output control program includes a program that allows a computer to execute a process composed of an output data receiving step of receiving the output data; an output data storing step of storing the output data received in the output data receiving step in an output data storage unit; an output data utilization managing step of managing the use of the output data; and an output control step of performing output control on the basis of the output data stored in the output data storage unit. In the output data utilization managing step, when authentication succeeds in an authenticating step, the output data stored in the output data storage unit is supplied to another network device, and the supply and use of the output data are prohibited until a print completion notice is received. Alternatively, the output of the output data is requested in the output control step, the supply of the output data is prohibited until the output data is completely output, job tickets stored in a job ticket storage unit that stores the job tickets specifying contents related to whether to permit or restrict the use of the output data are updated when the print completion notice is received or when the output data is completely output, and the supply and use of the output data are prohibited when it is determined that the contents of the job tickets satisfy predetermined conditions. In the output control step, the output process is performed on the basis of the output data, according to the output request.
[0172] According to this configuration, when the computer reads out the program to perform the process according to the read program, the same operations and effects as those in the network device according to the twenty-sixth aspect are obtained.
[0173] Furthermore, according to the forty-fifth aspect of the invention, in the output control program of the forty-fourth aspect, in the output data utilization managing step, the supply and use of the output data are prohibited until the print completion notice or a print interruption notice is received. Alternatively, the supply of the output data is prohibited until the output of the output data is interrupted or completed.
[0174] According to this configuration, when the computer reads out the program to perform the process according to the read program, the same operations and effects as those in the network device according to the twenty-seventh aspect are obtained.
[0175] Moreover, according to the forty-sixth aspect of the invention, there is provided an output control program that performs an output process on the basis of output data. The output control program includes a program that allows a computer to execute a process composed of an output data receiving step of receiving the output data; an output data storing step of storing the output data received in the output data receiving step in an output data storage unit; an output data utilization managing step of managing the use of the output data; and an output control step of performing output control on the basis of the output data stored in the output data storage unit. In the output data utilization managing step, when authentication succeeds in an authenticating step, the output data stored in the output data storage unit is supplied to another network device, job tickets stored in a job ticket storage unit that stores the job tickets specifying contents related to whether to permit or restrict the use of the output data are updated, and the supply and use of the output data are prohibited until a print completion notice is received. Alternatively, the output of the output data is requested in the output control step, the job tickets stored in the job ticket storage unit are updated, the supply of the output data is prohibited until the output of the output data is completely, and the supply and use of the output data are prohibited when it is determined that the contents of the job tickets satisfy predetermined conditions. In the output control step, the output process is performed on the basis of the output data, according to the output request.
[0176] According to this configuration, when the computer reads out the program to perform the process according to the read program, the same operations and effects as those in the network device according to the twenty-eighth aspect are obtained.
[0177] Further, according to the forty-seventh aspect of the invention, in the output control program of the forty-sixth aspect, in the output data utilization managing step, the supply and use of the output data are prohibited until the print completion notice or a print interruption notice is received. Alternatively, the supply of the output data is prohibited until the output of the output data is interrupted or completed, and the contents of the job tickets are restored to the original states before the update when the print interruption notice is received or when the output of the output data is interrupted.
[0178] According to this configuration, when the computer reads out the program to perform the process according to the read program, the same operations and effects as those in the network device according to the twenty-ninth aspect are obtained.
[0179] Furthermore, according to a forty-eighth aspect of the invention, the output control program of the forty-fifth aspect or the forty-seventh aspect further includes a program that allows a computer to execute a process composed of an authentication information receiving step of receiving authentication information used for the authentication; an authentication information acquiring step of acquiring the authentication information; and the authenticating step. In the authenticating step, the use of the output data is authenticated on the basis of the authentication information received in the authentication information receiving step and the authentication information received in the authentication information acquiring step. In the output data utilization managing step, when it is determined that the use of the output data is authenticated in the authenticating step, on the basis of the authentication information received in the authentication information receiving step, the output data is supplied to another network device. When it is determined that the use of the output data is authenticated in the authenticating unit on the basis of the authentication information acquired in the authentication information acquiring step, the output request is performed in the output control step.
[0180] According to this configuration, when the computer reads out the program to perform the process according to the read program, the same operations and effects as those in the network device according to the thirtieth aspect are obtained.
[0181] Moreover, according to a forty-ninth aspect of the invention, in the output control program of the forty-eighth aspect, in the output data utilization managing step, when it is determined that the use of the output data is authenticated in the authenticating step on the basis of the authentication information received in the authentication information receiving step and that the job tickets can be updated, the output data is supplied, and the update of the job tickets is prohibited until the print interruption notice or the print completion notice is received. When it is determined that the use of the output data is authenticated in the authenticating step, on the basis of the authentication information acquired in the authentication information acquiring step, and that the job tickets can be updated, the output request is performed, and the update of the job tickets is prohibited until the output of the output data is interrupted or completed.
[0182] According to this configuration, when the computer reads out the program to perform the process according to the read program, the same operations and effects as those in the network device according to the thirty-first aspect are obtained.
[0183] Further, according to a fiftieth aspect of the invention, the output control program according to any one of the forty-fifth, forty-seventh to forty-ninth aspects further includes a program that allows a computer to execute a process composed of a utilization history information generating step of generating utilization history information indicating a utilization history of the output data, on the basis of a utilization result and a supply result of the output data utilization managing unit.
[0184] According to this configuration, when the computer reads out the program to perform the process according to the read program, the same operations and effects as those in the network device according to the thirty-second aspect are obtained.
[0185] Furthermore, according to a fifty-first aspect of the invention, in the output control program according to any one of the forty-second, forty-third, forty-fifth, forty-seventh to fiftieth aspects, in the output data utilization managing step, when it is determined that the contents of the job tickets satisfy the predetermined conditions, the output data and the job tickets are removed.
[0186] According to this configuration, when the computer reads out the program to perform the process according to the read program, the same operations and effects as those in the network device according to the thirty-third aspect are obtained.
[0187] Moreover, according to the fifty-second aspect of the invention, there is provided an authentication output method that performs an output process through authentication in a plurality of network devices each of which performs the output process on the basis of output data, the network devices being connected to a device using apparatus that uses the network devices so as to communicate therewith. The method includes, for the device using apparatus, an output data utilization managing step of supplying, when the authentication succeeds in an authenticating step, the output data stored in an output data storage unit that stores the output data to any one of the plurality of network devices, of prohibiting the supply of the output data until a print completion notice is received, of updating, when the print completion notice is received, job tickets stored in a job ticket storage unit that stores the job tickets specifying contents related to whether to permit or restrict the use of the output data, and of prohibiting the supply of the output data when it is determined that the contents of the job tickets satisfy predetermined conditions. The method includes, for the network devices, an output data receiving step of receiving the output data, and an output control step of transmitting the print completion notice to the device using apparatus when the output of the output data from the network devices is completed.
[0188] According to this structure, the same effects as those in the authentication output system according to the first aspect are obtained.
[0189] Further, according to the fifty-third aspect of the invention, in the authentication output method of the fifty-second aspect, in the output control step, when the output of the output data from the network device is interrupted, the use of the output data received in the output data receiving step, and the print interruption notice is transmitted to the device using apparatus.
[0190] According to this structure, the same effects as those in the authentication output system according to the second aspect are obtained.
[0191] Furthermore, according to the fifty-fourth aspect of the invention, there is provided an authentication output method that performs an output process through authentication in a plurality of network devices each of which performs the output process on the basis of output data, the network devices being connected to a device using apparatus that uses the network devices so as to communicate therewith. The method includes, for the device using apparatus, an output data utilization managing step of supplying, when the authentication succeeds in an authenticating step, the output data stored in an output data storage unit that stores the output data to any one of the plurality of network devices, of updating job tickets stored in a job ticket storage unit that stores the job tickets specifying contents related to whether to permit or restrict the use of the output data, of prohibiting the supply of the output data until a print completion notice is received, and of prohibiting the supply of the output data when it is determined that the contents of the job tickets satisfy predetermined conditions. In addition, the method includes, for the network devices, an output data receiving step of receiving the output data; and an output control step of transmitting the print completion notice to the device using apparatus when the output of the output data from the network devices is completed.
[0192] According to this structure, the same effects as those in the authentication output system according to the third aspect are obtained.
[0193] Moreover, according to the fifty-fifth aspect of the invention, in the authentication output method of the fifty-fourth aspect, in the output data utilization managing step, the supply of the output data is prohibited until the print completion notice or a print interruption notice is received. When the print interruption notice is received, the contents of the job tickets are restored to the original states before the update. In the output control step, when the output of the output data from the network device is interrupted, the use of the output data received in the output data receiving step is prohibited, and the print interruption notice is transmitted to the device using apparatus.
[0194] According to this structure, the same effects as those in the authentication output system according to the fourth aspect are obtained.
[0195] Further, according to a fifty-sixth aspect of the invention, the authentication output method of the fifty-third aspect or the fifth-fifth aspect further includes, for the network device, an authentication information acquiring step of acquiring authentication information used for the authentication; and an authentication information transmitting step of transmitting the authentication information acquired in the authentication information acquiring step to the device using apparatus. In addition, the method further includes, for the device using apparatus, an authentication information receiving unit that receives the authentication information; and the authenticating step. In the authenticating step, the use of the output data is authenticated on the basis of the authentication information received in the authentication information receiving step. In the output data utilization managing step, when it is determined that the use of the output data is authenticated in the authenticating step, the output data is supplied to one of the plurality of network device, which is a source of the authentication information.
[0196] According to this structure, the same effects as those in the authentication output system according to the fifth aspect are obtained.
[0197] Furthermore, according to a fifty-seventh aspect of the invention, in the authentication output method of the fifty-sixth aspect, in the output data utilization managing step, when it is determined that the use of the output data is authenticated in the authenticating step and that the job tickets can be updated, the output data is supplied, and the update of the job tickets is prohibited until the print interruption notice or the print completion notice is received.
[0198] According to this structure, the same effects as those in the authentication output system according to the sixth aspect are obtained.
[0199] Moreover, according to a fifty-eighth aspect of the invention, the authentication output method according to the fifty-third, fifty-fifth to fifty-seventh aspects further includes, for the device using apparatus, a utilization history information generating step of generating utilization history information indicating a utilization history of the output data, on the basis of the result supplied in the output data utilization managing step.
[0200] According to this structure, the same effects as those in the authentication output system according to the seventh aspect are obtained.
[0201] Further, according to the fifty-ninth aspect of the invention, there is provided an authentication output method that performs an output process through authentication in first and second network devices each of which performs the output process on the basis of output data, the first and second network devices being connected to a device using apparatus that uses the network devices so as to communicate therewith. The method includes, for the device using apparatus, an output data transmitting step of transmitting the output data to the first network device. In addition, the method includes, for the first network device, a first output data receiving step of receiving the output data; an output data storing step of storing the output data received in the first output data receiving step in an output data storage unit; an output data utilization managing step of managing the use of the output data; and a first output control step of performing output control on the basis of the output data stored in the output data storage unit. In the output data utilization managing step, when the authentication succeeds in an authenticating step, the output data stored in the output data storage unit is supplied to the second network device, and the supply and use of the output data are prohibited until a print completion notice is received. Alternatively, the output of the output data is requested in the first output control step, the supply of the output data is prohibited until the output of the output data from the first network device is completed, job tickets stored in a job ticket storage unit that stores the job tickets specifying contents related to whether to permit or restrict the use of the output data are updated when the print completion notice is received or when the output of the output data from the first network device is completed, and the supply and use of the output data are prohibited when it is determined that the contents of the job tickets satisfy predetermined conditions. The output process is performed in the first output control step on the basis of the output data, according to the output request. The method includes, for the second network device, a second output data receiving step of receiving the output data; and a second output control step of transmitting the print completion notice to the first network device when the output of the output data from the second network device is completed.
[0202] According to this structure, the same effects as those in the authentication output system according to the eighth aspect are obtained.
[0203] Furthermore, according to the sixtieth aspect of the invention, in the authentication output method of the fifty-ninth aspect, in the output data utilization managing step, the supply and use of the output data are prohibited until the print completion notice or a print interruption notice is received. Alternatively, the supply of the output data is prohibited until the output of the output data from the first network device is interrupted or completed. In the second output control step, when the output of the output data from the second network device is interrupted, the use of the output data received in the second output data receiving step is prohibited, and the print interruption notice is transmitted to the first network device.
[0204] According to this structure, the same effects as those in the authentication output system according to the ninth aspect are obtained.
[0205] Moreover, according to the sixty-first aspect of the invention, there is provided an authentication output method that performs an output process through authentication in first and second network devices each of which performs the output process on the basis of output data, the first and second network devices being connected to a device using apparatus that uses the network devices so as to communicate therewith. The method includes, for the device using apparatus, an output data transmitting step of transmitting the output data to the first network device. In addition, the method includes, for the first network device, a first output data receiving step of receiving the output data; an output data storing step of storing the output data received in the first output data receiving step in an output data storage unit; an output data utilization managing step of managing the use of the output data; and a first output control step of performing output control on the basis of the output data stored in the output data storage unit. In the output data utilization managing step, when the authentication succeeds in an authenticating step, the output data stored in the output data storage unit is supplied to the second network device, job tickets stored in a job ticket storage unit that stores the job tickets specifying contents related to whether to permit or restrict the use of the output data are updated, and the supply and use of the output data are prohibited until a print completion notice is received. Alternatively, the output of the output data is requested in the first output control step, the job tickets stored in the job ticket storage unit are updated, the supply of the output data is prohibited until the output of the output data from the first network device is completed, and the supply and use of the output data are prohibited when it is determined that the contents of the job tickets satisfy predetermined conditions. The output process is performed in the first output control step on the basis of the output data, according to the output request. In addition, the method includes, for the second network device, a second output data receiving step of receiving the output data; and a second output control step of transmitting the print completion notice to the first network device when the output of the output data from the second network device is completed.
[0206] According to this structure, the same effects as those in the authentication output system according to the tenth aspect are obtained.
[0207] Further, according to the sixty-second aspect of the invention, in the authentication output method of the sixty-first aspect, in the output data utilization managing step, the supply and use of the output data are prohibited until the print completion notice or a print interruption notice is received. Alternatively, the supply of the output data is prohibited until the output of the output data from the first network device is interrupted or completed, and the contents of the job tickets are restored to the original states before the update when the print interruption notice is received or when the output of the output data from the first network device is interrupted. In the second output control step, when the output of the output data from the second network device is interrupted, the use of the output data received in the second output data receiving step is prohibited, and the print interruption notice is transmitted to the first network device.
[0208] According to this structure, the same effects as those in the authentication output system according to the eleventh aspect are obtained.
[0209] Furthermore, according to a sixty-third aspect of the invention, the authentication output method of the sixtieth aspect or the sixty-second aspect further includes, for the second network device, a second authentication information acquiring step of acquiring authentication information used for the authentication; and an authentication information transmitting step of transmitting the authentication information acquired in the second authentication information acquiring step to the first network device. In addition, the method further includes, for the first network device, an authentication information receiving step of receiving the authentication information; a first authentication information acquiring step of acquiring the authentication information; and the authenticating unit. In the authenticating step, the use of the output data is authenticated on the basis of the authentication information received in the authentication information receiving step and the authentication information received in the first authentication information acquiring step. In the output data utilization managing unit, when it is determined that the use of the output data is authenticated in the authenticating step, on the basis of the authentication information received in the authentication information receiving step, the output data is supplied to the second network device. In addition, when it is determined that the use of the output data is authenticated in the authenticating step on the basis of the authentication information acquired in the first authentication information acquiring step, the output request is performed in the first output control step.
[0210] According to this structure, the same effects as those in the authentication output system according to the twelfth aspect are obtained.
[0211] Moreover, according to a sixty-fourth aspect of the invention, in the authentication output method of the sixty-third aspect, in the output data utilization managing step, when it is determined that the use of the output data is authenticated in the authenticating step on the basis of the authentication information received in the authentication information receiving step and that the job tickets can be updated, the output data is supplied, and the update of the job tickets is prohibited until the print interruption notice or the print completion notice is received. In the output data utilization managing step, when it is determined that the use of the output data is authenticated in the authenticating step, on the basis of the authentication information acquired in the first authentication information acquiring step, and that the job tickets can be updated, the output request is performed, and the update of the job tickets is prohibited until the output of the output data from the first network device is interrupted or completed.
[0212] According to this structure, the same effects as those in the authentication output system according to the thirteenth aspect are obtained.
[0213] Further, according to a sixty-fifth aspect of the invention, the authentication output method according to any one of the sixtieth, sixty-second to sixty-fourth aspects further includes a utilization history information generating step of generating utilization history information indicating a utilization history of the output data, on the basis of a utilization result and a supply result of the output data utilization managing step.
[0214] According to this structure, the same effects as those in the authentication output system according to the fourteenth aspect are obtained.
[0215] Furthermore, according to a sixty-sixth aspect of the invention, in the authentication output method according to the fifty-third, fifty-fifth to fifty-eighth, sixtieth, sixty-second to sixty fifth aspects, in the output data utilization managing step, when it is determined that the contents of the job tickets satisfy the predetermined conditions, the output data and the job tickets are removed.
[0216] According to this structure, the same effects as those in the authentication output system according to the fifteenth aspect are obtained.
[0217] Moreover, according to the sixty-seventh aspect of the invention, an authentication output system includes a plurality of network devices each of which performs an output process on the basis of output data; and a device using apparatus that uses the network devices, the device using apparatus being connected to the network devices so as to communicate therewith. When authentication succeeds, the network devices perform the output process. The device using apparatus includes: an output data transmitting unit that transmits the output data to the plurality of network devices; a job ticket storage unit that stores job tickets specifying contents related to whether to permit or restrict the use of the output data; and an output data utilization managing unit that manages the use of the output data. When the authentication succeeds, the output data utilization managing unit transmits an output permission notice to any one of the plurality of network devices, and prohibits the transmission of the output permission notice until a print interruption notice or a print completion notice is received. When the print completion notice is received, the output data utilization managing unit updates the job tickets stored in the job ticket storage unit. When it is determined that the contents of the job tickets satisfy predetermined conditions, the output data utilization managing unit transmits a utilization prohibition notice to the plurality of network devices. Each of the network devices includes: an output data storage unit; an output data receiving unit that receives the output data; an output data holding unit that stores the output data received by the output data receiving unit in the output data storage unit; and an output control unit that performs output control on the basis of the output data stored in the output data storage unit. When the output permission notice is received, the output control unit performs the output process on the basis of the output data. When the output of the output data from the network devices is interrupted, the output control unit prohibits the use of the output data and transmits the print interruption notice to the device using apparatus. When the output of the output data from the network devices is completed, the output control unit transmits the print completion notice to the device using apparatus. In addition, when the utilization prohibition notice is received, the output control unit prohibits the use of the output data.
[0218] According to this structure, in the device using apparatus, the output data transmitting unit transmits the output data to the respective network devices.
[0219] In the network device, when the output data receiving unit receives the output data, the output data holding unit stores the received output data in the output data storage unit.
[0220] In the device using apparatus, when the authentication succeeds, the output data utilization managing unit transmits the output permission notice to any one of the plurality of network devices, and prohibits the transmission of the output permission notice until the print interruption notice or the print completion notice is received.
[0221] In the network device, when the output permission notice is received, the output control unit performs the output process on the basis of the output data stored in the output data storage unit. When the output of the output data is completed, the print completion notice is transmitted to the device using apparatus. On the other hand, when the output of the output data is interrupted, the output control unit prohibits the use of the output data and transmits the print interruption notice to the device using apparatus.
[0222] In the device using apparatus, when the print completion notice is received, the output data utilization managing unit updates the job tickets.
[0223] In addition, in the device using apparatus, When it is determined that the contents of the job tickets satisfy predetermined conditions, the output data utilization managing unit transmits the utilization prohibition notice to the respective network devices.
[0224] In the network device, when the utilization prohibition notice is received, the output control unit prohibits the use of the output data.
[0225] In this way, since the job tickets are updated when the output of the output data is completed, it is possible to obtain output contents from another network device even when the output of the output data from a network device is interrupted due to a trouble. Thus, only an authorized user can obtain an output matter.
[0226] Furthermore, since the output permission notice is transmitted to any one of the network devices, it is possible to prevent the same output content from being simultaneously output from the plurality of network devices. In addition, even when the network device is restored from a disable state to a normal state, it is possible to prevent the output content from being output from the network device since the use of the output data is prohibited. Further, it is possible to prevent the output process from being performed beyond an output permission range, and thus to more reliably protect the secrecy of the output content.
[0227] In addition, the output data is stored in the respective network devices. Therefore, even when the output of the output data from a network device is interrupted due to a trouble, the output can be started by another network device at relatively high speed.
[0228] Here, prohibiting the use of the output data includes, for example, removing the output data, rejecting a request for the supply or use of the output data, rewriting the attribute of the output data into ‘unavailable’, and encoding the output data such that the output data cannot be read. This is similarly applied to an authentication output system according to a sixty-eighth aspect, a network device according to an eighty-fifth aspect, an output control program according to the hundredth aspect, and authentication output methods according to one-hundred ninth and one-hundred tenth aspects.
[0229] In addition, updating the job tickets includes, for example, prescribing the number of utilizations of the output data, decrementing the number of available times of the output data whenever the output permission notice is transmitted, and decrementing the number of utilizations of the output data whenever the output permission notice is transmitted. This is similarly applied to authentication output systems according to sixty-eighth, seventy-third, and seventy-fourth aspects, device using apparatuses according to seventy-ninth and eightieth aspects, network devices according to eighty-eighth and eighty-ninth aspects, output data managing programs according to ninety-fourth and ninety-fifth aspects, output control program according to one-hundred third and one-hundred fourth aspects, and authentication output methods according to one-hundred ninth, one-hundred tenth, one-hundred fifteenth, and one-hundred sixteenth aspects.
[0230] Further, according to the sixty-eighth aspect of the invention, an authentication output system includes a plurality of network devices each of which performs an output process on the basis of output data; and a device using apparatus that uses the network devices, the device using apparatus being connected to the network devices so as to communicate therewith. When authentication succeeds, the network devices perform the output process. The device using apparatus includes an output data transmitting unit that transmits the output data to the plurality of network devices; a job ticket storage unit that stores job tickets specifying contents related to whether to permit or restrict the use of the output data; and an output data utilization managing unit that manages the use of the output data. When the authentication succeeds, the output data utilization managing unit transmits an output permission notice to any one of the plurality of network devices, updates the job tickets stored in the job ticket storage unit, and prohibits the transmission of the output permission notice until a print interruption notice or a print completion notice is received. When the print interruption notice is received, the output data utilization managing unit restores the contents of the job tickets to the original states before the update. When it is determined that the contents of the job tickets satisfy predetermined conditions, the output data utilization managing unit transmits a utilization prohibition notice to the plurality of network devices. Each of the network devices includes an output data storage unit; an output data receiving unit that receives the output data; an output data holding unit that stores the output data received by the output data receiving unit in the output data storage unit; and an output control unit that performs output control on the basis of the output data stored in the output data storage unit. When the output permission notice is received, the output control unit performs the output process on the basis of the output data. When the output of the output data from the network devices is interrupted, the output control unit prohibits the use of the output data and transmits the print interruption notice to the device using apparatus. When the output of the output data from the network devices is completed, the output control unit transmits the print completion notice to the device using apparatus. When the utilization prohibition notice is received, the output control unit prohibits the use of the output data.
[0231] According to this structure, in the device using apparatus, the output data transmitting unit transmits the output data to the respective network devices.
[0232] In the network device, when the output data receiving unit receives the output data, the output data holding unit stores the received output data in the output data storage unit.
[0233] In the device using apparatus, when the authentication succeeds, the output data utilization managing unit transmits the output permission notice to any one of the plurality of network devices and updates the job tickets. In addition, the output data utilization managing unit prohibits the transmission of the output permission notice until the print interruption notice or the print completion notice is received.
[0234] In the network device, when the output permission notice is received, the output control unit performs the output process on the basis of the output data stored in the output data storage unit. When the output of the output data is completed, the output control unit transmits the print completion notice to the device using apparatus. On the other hand, when the output of the output data is interrupted, the output control unit prohibits the use of the output data and transmits the print interruption notice to the device using apparatus.
[0235] In the device using apparatus, when the utilization prohibition notice is received, the output data utilization managing unit restores the contents of the job tickets to the original states before the update.
[0236] In addition, in the device using apparatus, when it is determined that the contents of the job tickets satisfy predetermined conditions, the output data utilization managing unit transmits the utilization prohibition notice to the respective network devices.
[0237] In the network device, when the utilization prohibition notice is received, the output control unit prohibits the use of the output data.
[0238] In this way, when the output of the output data is completed, the job tickets are updated. Therefore, even when the output of the output data from a network device is interrupted due to a trouble, output contents can be obtained from another network device. In addition, only an authorized user can obtain an output matter.
[0239] Furthermore, since the output permission notice is transmitted to any one of the network devices, it is possible to prevent the same output content from being simultaneously output from the plurality of network devices. In addition, even when the network device is restored from a disable state to a normal state, it is possible to prevent the output content from being output from the network device since the use of the output data is prohibited. Further, it is possible to prevent the output process from being performed beyond an output permission range, and thus to more reliably protect the secrecy of the output content.
[0240] In addition, the output data is stored in the respective network devices. Therefore, even when the output of the output data from a network device is interrupted due to a trouble, the output can be started by another network device at relatively high speed.
[0241] Furthermore, according to the sixty-ninth aspect of the invention, in the authentication output system of the sixty-seventh aspect or the sixty-eighth aspect, the device using apparatus further includes an authentication information receiving unit that receives authentication information used for the authentication; and an authenticating unit. Each of the network devices further includes an authentication information acquiring unit that acquires the authentication information; and an authentication information transmitting unit that transmits the authentication information acquired by the authentication information acquiring unit to the device using apparatus. The authenticating unit authenticates the use of the output data on the basis of the authentication information received by the authentication information receiving unit. When it is determined that the use of the output data is authenticated by the authenticating unit, the output data utilization managing unit transmits the output data to one of the plurality of network device, which is a source of the authentication information.
[0242] According to this structure, in the network device, when the authentication information acquiring unit acquires the authentication information, the authentication information transmitting unit transmits the acquired authentication information to the device using apparatus.
[0243] In the device using apparatus, when the authentication information receiving unit receives authentication information, the authenticating unit authenticates the use of the output data on the basis of the received authentication information. As a result, when it is determined that the use of the output data is permitted, the output data utilization managing unit transmits the output data to one of the plurality of network device, which is a source of the authentication information.
[0244] In this way, when a user inputs proper authentication information to a desired network device, the user can obtain output contents from the network device.
[0245] Moreover, according to a seventieth aspect of the invention, in the authentication output system of the sixty-ninth aspect, when it is determined that the use of the output data is authenticated by the authenticating unit and that the job tickets can be updated, the output data utilization managing unit transmits the output permission notice, and prohibits the update of the job tickets until the print interruption notice or the print completion notice is received.
[0246] According to this structure, in the device using apparatus, when it is determined that the use of the output data is authenticated by the authenticating unit and that the job tickets can be updated, the output data utilization managing unit transmits the output permission notice, and then prohibits the update of the job tickets until the print interruption notice or the print completion notice is received. Therefore, even when the authentication information is received, the output permission notice is not transmitted until the print interruption notice or the print completion notice is received.
[0247] Further, according to a seventy-first aspect of the invention, the authentication output system according to any one of the sixty-seventh to seventieth aspects further includes a utilization history information generating unit that creates utilization history information indicating a utilization history of the output data, on the basis of the result supplied by the output data utilization managing unit.
[0248] According to this structure, in the device using apparatus, the utilization history information generating unit creates the utilization history information indicating the utilization history of the output data, on the basis of the result supplied by the output data utilization managing unit.
[0249] In this way, it is possible to see how the output data has been used by referring to the utilization history information.
[0250] Furthermore, according to a seventy-second aspect of the invention, in the authentication output system according to the sixty-seventh to seventy-first aspects, when it is determined that the contents of the job tickets satisfy the predetermined conditions, the output data utilization managing unit transmits the utilization prohibition notice and removes the job tickets. The output control unit removes the output data when the utilization prohibition notice is received.
[0251] According to this structure, in the device using apparatus, when it is determined that the contents of the job tickets satisfy the predetermined conditions, the output data utilization managing unit transmits the utilization prohibition notice and removes the job tickets.
[0252] In the network device, the output control unit removes the output data when the utilization prohibition notice is received.
[0253] In this way, it is possible to prevent the output data and the job tickets from being illegally used, and thus to reliably protect the secrecy of the output contents.
[0254] Moreover, according to the seventy-third aspect of the invention, an authentication output system includes first and second network devices each of which performs an output process on the basis of output data; and a device using apparatus that uses the network devices, the device using apparatus being connected to the network devices so as to communicate therewith. When authentication succeeds, the network devices perform the output process. The device using apparatus includes an output data transmitting unit that transmits the output data to the first and second network devices. The first network device includes a first output data storage unit; a first output data receiving unit that receives the output data; a first output data holding unit that stores the output data received by the first output data receiving unit in the first output data storage unit; a job ticket storage unit that stores job tickets specifying contents related to whether to permit or restrict the use of the output data; an output data utilization managing unit that manages the use of the output data; and a first output control unit that performs output control on the basis of the output data stored in the first output data storage unit. When the authentication succeeds, the output data utilization managing unit transmits an output permission notice to the second network device, and prohibits the transmission of the output permission notice and the use of the output data until a print interruption notice or a print completion notice is received. Alternatively, the output data utilization managing unit requires the first output control unit to output the output data, prohibits the transmission of the output permission notice until the output of the output data from the first network device is interrupted or completed, updates the job tickets stored in the job ticket storage unit when the print completion notice is received or when the output of the output data from the first network device is completed, and transmits a utilization prohibition notice to the second network device and prohibits the use of the output data when it is determined that the contents of the job tickets satisfy predetermined conditions. The first output control unit performs the output process on the basis of the output data, according to the output request. The second network device includes a second output data storage unit; a second output data receiving unit that receives the output data; a second output data holding unit that stores the output data received by the second output data receiving unit in the second output data storage unit; and a second output control unit that performs output control on the basis of the output data stored in the second output data storage unit. When the output permission notice is received, the second output control unit performs the output process on the basis of the output data. When the output of the output data from the second network device is interrupted, the second output control unit prohibits the use of the output data and transmits the print interruption notice to the first network device. When the output of the output data from the second network device is completed, the second output control unit transmits the print completion notice to the first network device. When the utilization prohibition notice is received, the second output control unit prohibits the use of the output data.
[0255] According to this structure, in the device using apparatus, the output data transmitting unit transmits the output data to the first and second network devices.
[0256] In the first network device, when the first output data receiving unit receives the output data, the first output data holding unit stores the received output data in the first output data storage unit. Similarly, in the second network device, when the second output data receiving unit receives the output data, the second output data holding unit stores the received output data in the second output data storage unit.
[0257] In the first network device, when the authentication succeeds, the output data utilization managing unit transmits the output permission notice to the second network device, or requests the first output control unit to output the output data. In the former case, the transmission of the output permission notice and the use of the output data are prohibited until the print interruption notice or the print completion notice is received.
[0258] In the second network unit, when the output permission notice is received, the second output control unit performs the output process on the basis of the output data stored in the second storage unit. When the output of the output data is completed, the second output control unit transmits the print completion notice to the first network device. On the other hand, when the output of the output data is interrupted, the second output control unit prohibits the use of the output data and transmits the print interruption notice to the first network device.
[0259] In the first network device, the output data utilization managing unit updates the job tickets when the print completion notice is received.
[0260] Meanwhile, in the first network device, when the output request is preformed on the first output control unit, the first output control unit performs the output process on the basis of the output data stored in the first output data storage unit. The output data utilization managing unit prohibits the transmission of the output permission notice until the output of the output data is interrupted or completed. When the output is completed, the job tickets are updated.
[0261] In addition, in the first network device, when it is determined that the contents of the job tickets satisfy predetermined conditions, the output data utilization managing unit transmits the utilization prohibition notice to the second network device and prohibits the use of the output data.
[0262] In the second network device, when the utilization prohibition notice is received, the second output control unit prohibits the use of the output data.
[0263] In this way, when the output of the output data is completed, the job tickets are updated. Therefore, even when the output of the output data from one of the first and second network devices is interrupted due to a trouble, output contents can be obtained from the other network device. In addition, only an authorized user can obtain an output matter.
[0264] Furthermore, since the output permission notice is transmitted to the second network device or the output data is used in the first network device, it is possible to prevent the same output content from being simultaneously output from the first and second network devices. In addition, even when the network device is restored from a disable state to a normal state, it is possible to prevent the output content from being output from the network device since the use of the output data is prohibited. Further, it is possible to prevent the output process from being performed beyond an output permission range, and thus to more reliably protect the secrecy of the output content.
[0265] In addition, the output data is respectively stored in the first and second network devices. Therefore, even when the output of the output data from one of the first and second network devices is interrupted due to a trouble, the output can be started by the network device at relatively high speed.
[0266] In this structure, when it is determined that the contents of the job tickets satisfy the predetermined conditions, the use of the output data is prohibited. When the output of the output data is interrupted, the use of the output data is prohibited. When the utilization prohibition notice is received, the use of the output data is prohibited. In these cases, prohibiting the use of the output data includes, for example, removing the output data, rejecting a request for the supply or use of the output data, rewriting the attribute of the output data into ‘unavailable’, and encoding the output data such that the output data cannot be read. This is similarly applied to the authentication output system according to the seventy-fourth aspect, the network devices according to the eighty-eighth and eighty-ninth aspects, the output control programs according to the one-hundred third and one-hundred fourth aspects, and the authentication output methods according to the one-hundred fifteenth and one-hundred sixteenth aspects.
[0267] In addition, in the case in which the use of the output data is prohibited until the print interruption notice or the print completion notice is received, prohibiting the use of the output data includes, for example, rejecting a request for the supply or use of the output data, rewriting the attribute of the output data into ‘unavailable’, and encoding the output data such that the output data cannot be read. This is similarly applied to the authentication output system according to the seventy-fourth aspect, the network devices according to the eighty-eighth and eighty-ninth aspects, the output control programs according to the one-hundred third and one-hundred fourth aspects, and the authentication output methods according to the one-hundred fifteenth and one-hundred sixteenth aspects.
[0268] According to the seventy-fourth aspect of the invention, an authentication output system includes first and second network devices each of which performs an output process on the basis of output data; and a device using apparatus that uses the network devices, the device using apparatus being connected to the network devices so as to communicate therewith. When authentication succeeds, the network devices perform the output process. The device using apparatus includes an output data transmitting unit that transmits the output data to the first and second network devices. The first network device includes a first output data storage unit; a first output data receiving unit that receives the output data; a first output data holding unit that stores the output data received by the first output data receiving unit in the first output data storage unit; a job ticket storage unit that stores job tickets specifying contents related to whether to permit or restrict the use of the output data; an output data utilization managing unit that manages the use of the output data; and a first output control unit that performs output control on the basis of the output data stored in the first output data storage unit. When the authentication succeeds, the output data utilization managing unit transmits an output permission notice to the second network device, updates the job tickets stored in the job ticket storage unit, and prohibits the transmission of the output permission notice and the use of the output data until a print interruption notice or a print completion notice is received. Alternatively, the output data utilization managing unit requires the first output control unit to output the output data, updates the job tickets stored in the job ticket storage unit, prohibits the transmission of the output permission notice until the output of the output data from the first network device is interrupted or completed, restores the contents of the job tickets to the original states before the update when the print interruption notice is received or when the output of the output data from the first network device is interrupted, and transmits a utilization prohibition notice to the second network device and prohibits the use of the output data when it is determined that the contents of the job tickets satisfy predetermined conditions. The first output control unit performs the output process on the basis of the output data, according to the output request. The second network device includes a second output data storage unit; a second output data receiving unit that receives the output data; a second output data holding unit that stores the output data received by the second output data receiving unit in the second output data storage unit; and a second output control unit that performs output control on the basis of the output data stored in the second output data storage unit. When the output permission notice is received, the second output control unit performs the output process on the basis of the output data. When the output of the output data from the second network device is interrupted, the second output control unit prohibits the use of the output data and transmits the print interruption notice to the first network device. When the output of the output data from the second network device is completed, the second output control unit transmits the print completion notice to the first network device. When the utilization prohibition notice is received, the second output control unit prohibits the use of the output data.
[0269] According to this structure, in the device using apparatus, the output data transmitting unit transmits the output data to the first and second network devices.
[0270] In the first network device, when the first output data receiving unit receives the output data, the first output data holding unit stores the received output data in the first output data storage unit. Similarly, in the second network device, when the second output data receiving unit receives the output data, the second output data holding unit stores the received output data in the second output data storage unit.
[0271] In the first network device, when the authentication succeeds, the output data utilization managing unit transmits the output permission notice to the second network device, or requests the first output control unit to output the output data. In the former case, the job tickets are updated, and the transmission of the output permission notice and the use of the output data are prohibited until the print interruption notice or the print completion notice is received.
[0272] In the second network unit, when the output permission notice is received, the second output control unit performs the output process on the basis of the output data stored in the second output data storage unit. When the output of the output data is completed, the second output control unit transmits the print completion notice to the first network device. On the other hand, when the output of the output data is interrupted, the second output control unit prohibits the use of the output data and transmits the print interruption notice to the first network device.
[0273] In the first network device, the output data utilization managing unit restores the contents of the job tickets to the original states before update when the print interruption notice is received.
[0274] Meanwhile, in the first network device, when the output request is preformed on the first output control unit, the output data utilization managing unit updates the job tickets, and the first output control unit performs the output process on the basis of the output data stored in the first output data storage unit. Then, the output data utilization managing unit prohibits the transmission of the output permission notice until the output of the output data is interrupted or completed. When the output of the output data is interrupted, the contents of the job tickets are restored to the original states before the update.
[0275] In addition, in the first network device, when it is determined that the contents of the job tickets satisfy predetermined conditions, the output data utilization managing unit transmits the utilization prohibition notice to the second network device and prohibits the use of the output data.
[0276] In the second network device, when the utilization prohibition notice is received, the second output control unit prohibits the use of the output data.
[0277] In this way, when the output of the output data is completed, the job tickets are updated. Therefore, even when the output of the output data from one of the first and second network devices is interrupted due to a trouble, output contents can be obtained from the other network device. In addition, only an authorized user can obtain an output matter.
[0278] Furthermore, since the output permission notice is transmitted to the second network device or the output data is used in the first network device, it is possible to prevent the same output content from being simultaneously output from the first and second network devices. In addition, even when the network device is restored from a disable state to a normal state, it is possible to prevent the output content from being output from the network device since the use of the output data is prohibited. Further, it is possible to prevent the output process from being performed beyond an output permission range, and thus to more reliably protect the secrecy of the output content.
[0279] In addition, the output data is respectively stored in the first and second network devices. Therefore, even when the output of the output data from one of the first and second network devices is interrupted due to a trouble, the output can be started by the network device at relatively high speed.
[0280] Further, according to the seventy-fifth aspect of the invention, in the authentication output system of the seventy-third aspect or the seventy-fourth aspect, the first network device further includes an authentication information receiving unit that receives authentication information used for the authentication; a first authentication information acquiring unit that acquires the authentication information; and an authenticating unit. The second network device further includes: a second authentication information acquiring unit that acquires the authentication information; and an authentication information transmitting unit that transmits the authentication information acquired by the second authentication information acquiring unit to the first network device. The authenticating unit authenticates the use of the output data on the basis of the authentication information received by the authentication information receiving unit and the authentication information received by the first authentication information acquiring unit. When it is determined that the use of the output data is authenticated by the authenticating unit, on the basis of the authentication information received by the authentication information receiving unit, the output data utilization managing unit transmits the output data to the second network device. When it is determined that the use of the output data is authenticated by the authenticating unit on the basis of the authentication information acquired by the first authentication information acquiring unit, the output data utilization managing unit requires the first output control unit to output the output data.
[0281] According to this structure, in the second network device, when the second authentication information acquiring unit acquires the authentication information, the authentication information transmitting unit transmits the acquired authentication information to the first network device.
[0282] In the first network device, when the authentication information receiving unit receives the authentication information, the authenticating unit authenticates the use of the output data on the basis of the received authentication information. As a result, when it is determined that the use of the output data is permitted, the output data utilization managing unit transmits the output permission notice to the second network device.
[0283] In addition, in the first network device, when the authentication information is acquired by the first authentication information acquiring unit, the use of the output data is authenticated by the authenticating unit on the basis of the acquired authentication information. As a result, when it is determined that the use of the output data is permitted, the output data utilization managing unit performs an output request on the first network device.
[0284] In this way, the same effects as those in the authentication output system according to the sixty-ninth aspect are obtained.
[0285] Furthermore, according to a seventy-sixth aspect of the invention, in the authentication output system of the seventy-fifth aspect, when it is determined that the use of the output data is authenticated by the authenticating unit on the basis of the authentication information received by the authentication information receiving unit and that the job tickets can be updated, the output data utilization managing unit transmits the output permission notice, and prohibits the update of the job tickets until the print interruption notice or the print completion notice is received. In addition, when it is determined that the use of the output data is authenticated by the authenticating unit, on the basis of the authentication information acquired by the first authentication information acquiring unit, and that the job tickets can be updated, the output data utilization managing unit performs the output request and prohibits the update of the job tickets until the output of the output data from the first network device is interrupted or completed.
[0286] According to this structure, in the first network device, when it is determined that the use of the output data is authenticated by the authenticating unit on the basis of the received authentication information and that the job tickets can be updated, the output data utilization managing unit transmits the output permission notice to the second network device, and prohibits the update of the job tickets until the print interruption notice or the print completion notice is received.
[0287] In addition, in the first network device, when it is determined that the use of the output data is authenticated on the basis of the acquired authentication information and that the job tickets can be updated, the output data utilization managing unit requests the first network device to output the output data, and prohibits the update of the job tickets until the output of the output data is interrupted or completed.
[0288] Therefore, until the print interruption notice or the print completion notice is received or until the output of the output data is interrupted or completed, the output permission notice is not transmitted even though the authentication information is received, and the output of the output data is not performed even though the authentication information is acquired.
[0289] Moreover, according to a seventy-seventh aspect of the invention, in the authentication output system according to any one of the seventy-third to seventy-sixth aspects, the first network device further includes a utilization history information generating unit that creates utilization history information indicating a utilization history of the output data, on the basis of a utilization result and a supply result of the output data utilization managing unit.
[0290] According to this structure, in the first network device, the utilization history information generating unit creates the utilization history information indicating the utilization history of the output data, on the basis of the utilization result and the supply result of the output data utilization managing unit.
[0291] In this way, the same effects as those in the seventy-first aspect are obtained.
[0292] Moreover, according to a seventy-eighth aspect of the invention, in the authentication output system according to any one of the seventy-third to seventy-seventh aspects, when it is determined that the contents of the job tickets satisfy the predetermined conditions, the output data utilization managing unit transmits the utilization prohibition notice and removes the output data and the job tickets. The second output control unit removes the output data when receiving the utilization prohibition notice.
[0293] According to this structure, in the first network device, when it is determined that the contents of the job tickets satisfy the predetermined conditions, the output data utilization managing unit transmits the utilization prohibition notice and removes the output data and the job tickets.
[0294] In the network device, the second output control unit removes the output data when receiving the utilization prohibition notice.
[0295] In this way, it is possible to prevent the output data and the job tickets from being illegally used, and thus to reliably protect the secrecy of the output contents.
[0296] Further, according to the seventy-ninth aspect of the invention, there is provided a device using apparatus that uses a plurality of network devices. The device using apparatus includes an output data transmitting unit that transmits the output data to the plurality of network devices; a job ticket storage unit that stores job tickets specifying contents related to whether to permit or restrict the use of the output data; and an output data utilization managing unit that manages the use of the output data. When authentication succeeds, the output data utilization managing unit transmits an output permission notice to any one of the plurality of network devices, and prohibits the transmission of the output permission notice until a print interruption notice or a print completion notice is received. When the print completion notice is received, the output data utilization managing unit updates the job tickets stored in the job ticket storage unit. When it is determined that the contents of the job tickets satisfy predetermined conditions, the output data utilization managing unit transmits a utilization prohibition notice to the plurality of network devices.
[0297] According to this structure, the same operations as those in the device using apparatus of the authentication output system according to the sixty-seventh aspect are obtained. Thus, the same effects as those in the authentication output system according to the sixty-seventh aspect are obtained.
[0298] Furthermore, according to the eightieth aspect of the invention, there is provided a device using apparatus that uses a plurality of network devices. The device using apparatus includes an output data transmitting unit that transmits the output data to the plurality of network devices; a job ticket storage unit that stores job tickets specifying contents related to whether to permit or restrict the use of the output data; and an output data utilization managing unit that manages the use of the output data. When authentication succeeds, the output data utilization managing unit transmits an output permission notice to any one of the plurality of network devices, updates the job tickets stored in the job ticket storage unit, and prohibits the transmission of the output permission notice until a print interruption notice or a print completion notice is received. When the print interruption notice is received, the output data utilization managing unit updates the job tickets stored in the job ticket storage unit. When it is determined that the contents of the job tickets satisfy predetermined conditions, the output data utilization managing unit transmits a utilization prohibition notice to the plurality of network devices.
[0299] According to this structure, the same operations as those in the device using apparatus of the authentication output system according to the sixty-eighth aspect are obtained. Thus, the same effects as those in the authentication output system according to the sixty-eighth aspect are obtained.
[0300] Moreover, according to an eighty-first aspect of the invention, the device using apparatus of the seventy-ninth aspect or the eightieth aspect further includes an authentication information receiving unit that receives authentication information used for the authentication; and an authenticating unit. The authenticating unit authenticates the use of the output data on the basis of the authentication information received by the authentication information receiving unit. When it is determined that the use of the output data is authenticated by the authenticating unit, the output data utilization managing unit transmits the output permission notice to one of the plurality of network device, which is a source of the authentication information.
[0301] According to this structure, the same operations as those in the device using apparatus of the authentication output system according to the sixty-ninth aspect are obtained. Thus, the same effects as those in the authentication output system according to the sixty-ninth aspect are obtained.
[0302] Further, according to an eighty-second aspect of the invention, in the device using apparatus of the eighty-first aspect, when it is determined that the use of the output data is authenticated by the authenticating unit and that the job tickets can be updated, the output data utilization managing unit transmits the output permission notice, and prohibits the update of the job tickets until the print interruption notice or the print completion notice is received.
[0303] According to this structure, the same operations as those in the device using apparatus of the authentication output system according to the seventieth aspect are obtained. Thus, the same effects as those in the authentication output system according to the seventieth aspect are obtained.
[0304] Furthermore, according to an eighty-third aspect of the invention, the device using apparatus according to any one of the seventy-ninth to eighty-second aspects further includes a utilization history information generating unit that creates utilization history information indicating a utilization history of the output data, on the basis of the result supplied by the output data utilization managing unit.
[0305] According to this structure, the same operations as those in the device using apparatus of the authentication output system according to the seventy-first aspect are obtained. Thus, the same effects as those in the authentication output system according to the seventy-first aspect are obtained.
[0306] Moreover, according to an eighty-fourth aspect of the invention, in the device using apparatus according to any one of the seventy-ninth to eighty-third aspects, when it is determined that the contents of the job tickets satisfy the predetermined conditions, the output data utilization managing unit transmits the utilization prohibition notice and removes the job tickets. The output control unit removes the output data when the utilization prohibition notice is received.
[0307] According to this structure, the same operations as those in the device using apparatus of the authentication output system according to the seventy-second aspect are obtained. Thus, the same effects as those in the authentication output system according to the seventy-second aspect are obtained.
[0308] Further, according to the eighty-fifth aspect of the invention, there is provided a network device that performs an output process on the basis of output data. The network device includes an output data storage unit; an output data receiving unit that receives the output data; an output data holding unit that stores the output data received by the output data receiving unit in the output data storage unit; and an output control unit that performs output control on the basis of the output data stored in the output data storage unit. When an output permission notice is received, the output control unit performs the output process on the basis of the output data. When the output of the output data from the network device is interrupted, the output control unit prohibits the use of the output data and transmits a print interruption notice to a device using apparatus. When the output of the output data from the network device is completed, the output control unit transmits a print completion notice to the device using apparatus. When a utilization prohibition notice is received, the output control unit prohibits the use of the output data.
[0309] According to this structure, the same operations as those in the network device of the authentication output system according to the sixty-seventh aspect are obtained. Thus, the same effects as those in the authentication output system according to the sixty-seventh aspect are obtained.
[0310] Furthermore, according to an eighty-sixth aspect of the invention, the network device of the eighty-fifth aspect further includes an authentication information acquiring unit that acquires the authentication information used for the authentication; and an authentication information transmitting unit that transmits the authentication information acquired by the authentication information acquiring unit to the device using apparatus.
[0311] According to this structure, the same operations as those in the network device of the authentication output system according to the sixty-ninth aspect are obtained. Thus, the same effects as those in the authentication output system according to the sixty-ninth aspect are obtained.
[0312] Moreover, according to an eighty-seventh aspect of the invention, in the network device of the eighty-fifth aspect or the eighty-sixth aspect, the output control unit removes the output data when the utilization prohibition notice is received.
[0313] According to this structure, the same operations as those in the network device of the authentication output system according to the seventy-second aspect are obtained. Thus, the same effects as those in the authentication output system according to the seventy-second aspect are obtained.
[0314] Further, according to the eighty-eighth aspect of the invention, there is provided a network device that performs an output process on the basis of output data. The network device includes an output data storage unit; an output data receiving unit that receives the output data; an output data holding unit that stores the output data received by the output data receiving unit in the output data storage unit; a job ticket storage unit that stores job tickets specifying contents related to whether to permit or restrict the use of the output data; an output data utilization managing unit that manages the use of the output data; and an output control unit that performs output control on the basis of the output data stored in the output data storage unit. When authentication succeeds, the output data utilization managing unit transmits an output permission notice to another network device, and prohibits the transmission of the output permission notice and the use of the output data until a print interruption notice or a print completion notice is received. Alternatively, the output data utilization managing unit requires the output control unit to output the output data, prohibits the transmission of the output permission notice until the output of the output data from the network device is interrupted or completed, updates the job tickets stored in the job ticket storage unit when the print completion notice is received or when the output of the output data from the network device is completed, and transmits a utilization prohibition notice to another network device and prohibits the use of the output data when it is determined that the contents of the job tickets satisfy predetermined conditions. The output control unit performs the output process on the basis of the output data, according to the output request.
[0315] According to this structure, the same operations as those in the first network device of the authentication output system according to the seventy-third aspect are obtained. Thus, the same effects as those in the authentication output system according to the seventy-third aspect are obtained.
[0316] Furthermore, according to the eighty-ninth aspect of the invention, there is provided a network device that performs an output process on the basis of output data. The network device includes an output data storage unit; an output data receiving unit that receives the output data; an output data holding unit that stores the output data received by the output data receiving unit in the output data storage unit; a job ticket storage unit that stores job tickets specifying contents related to whether to permit or restrict the use of the output data; an output data utilization managing unit that manages the use of the output data; and an output control unit that performs output control on the basis of the output data stored in the output data storage unit. When authentication succeeds, the output data utilization managing unit transmits an output permission notice to another network device, updates the job tickets stored in the job ticket storage unit, and prohibits the transmission of the output permission notice and the use of the output data until a print interruption notice or a print completion notice is received. Alternatively, the output data utilization managing unit requires the output control unit to output the output data, updates the job tickets stored in the job ticket storage unit, prohibits the transmission of the output permission notice until the output of the output data from the network device is interrupted or completed, restores the contents of the job tickets to the original states before the update when the print interruption notice is received or when the output of the output data from the first network device is interrupted, and transmits a utilization prohibition notice to another network device and prohibits the use of the output data when it is determined that the contents of the job tickets satisfy predetermined conditions. The output control unit performs the output process on the basis of the output data, according to the output request.
[0317] According to this structure, the same operations as those in the first network device of the authentication output system according to the seventy-fourth aspect are obtained. Thus, the same effects as those in the authentication output system according to the seventy-fourth aspect are obtained.
[0318] Moreover, according to a ninetieth aspect of the invention, the network device of the eighty-eighth aspect or the eighty-ninth aspect further includes an authentication information receiving unit that receives authentication information used for the authentication; an authentication information acquiring unit that acquires the authentication information; and an authenticating unit. The authenticating unit authenticates the use of the output data on the basis of the authentication information received by the authentication information receiving unit and the authentication information acquired by the authentication information acquiring unit. When it is determined that the use of the output data is authenticated by the authenticating unit, on the basis of the authentication information received by the authentication information receiving unit, the output data utilization managing unit transmits the output permission notice to another network device. When it is determined that the use of the output data is authenticated by the authenticating unit on the basis of the authentication information acquired by the authentication information acquiring unit, the output data utilization managing unit requires the output control unit to output the output data.
[0319] According to this structure, the same operations as those in the first network device of the authentication output system according to the seventy-fifth aspect are obtained. Thus, the same effects as those in the authentication output system according to the seventy-fifth aspect are obtained.
[0320] Further, according to a ninety-first aspect of the invention, in the network device of the ninetieth aspect, when it is determined that the use of the output data is authenticated by the authenticating unit on the basis of the authentication information received by the authentication information receiving unit and that the job tickets can be updated, the output data utilization managing unit transmits the output permission notice, and prohibits the update of the job tickets until the print interruption notice or the print completion notice is received. In addition, when it is determined that the use of the output data is authenticated by the authenticating unit, on the basis of the authentication information acquired by the authentication information acquiring unit, and that the job tickets can be updated, the output data utilization managing unit performs the output request and prohibits the update of the job tickets until the output of the output data from the network device is interrupted or completed.
[0321] According to this structure, the same operations as those in the first network device of the authentication output system according to the seventy-sixth aspect are obtained. Thus, the same effects as those in the authentication output system according to the seventy-sixth aspect are obtained.
[0322] Furthermore, according to a ninety-second aspect of the invention, the network device according to any one of the eighty-eighth to ninety-first aspects further includes a utilization history information generating unit that creates utilization history information indicating a utilization history of the output data, on the basis of a utilization result and a transmission result of the output data utilization managing unit.
[0323] According to this structure, the same operations as those in the first network device of the authentication output system according to the seventy-seventh aspect are obtained. Thus, the same effects as those in the authentication output system according to the seventy-seventh aspect are obtained.
[0324] Moreover, according to a ninety-third aspect of the invention, in the network device according to any one of the eighty-eighth to ninety-second aspects, when it is determined that the contents of the job tickets satisfy the predetermined conditions, the output data utilization managing unit transmits the utilization prohibition notice and removes the output data and the job tickets.
[0325] According to this structure, the same operations as those in the first network device of the authentication output system according to the seventy-eighth aspect are obtained. Thus, the same effects as those in the authentication output system according to the seventy-eighth aspect are obtained.
[0326] Further, according to a ninety-fourth aspect of the invention, there is provided an output data managing program that manages output data used for a plurality of network devices. The output data managing program includes a program that allows a computer to execute a process including an output data transmitting step of transmitting the output data to the plurality of network devices and an output data utilization managing step of managing the use of the output data. In the output data utilization managing step, when authentication succeeds in an authenticating step, an output permission notice is transmitted to any one of the plurality of network devices, and the transmission of the output permission notice is prohibited until a print interruption notice or a print completion notice is received. When the print completion notice is received, job tickets stored in a job ticket storage unit that stores the job tickets specifying contents related to whether to permit or restrict the use of the output data are updated. When it is determined that the contents of the job tickets satisfy predetermined conditions, the output prohibition notice is transmitted to the plurality of network devices.
[0327] According to this configuration, when the computer reads out the program to perform the process according to the read program, the same operations and effects as those in the device using apparatus according to the seventy-ninth aspect are obtained.
[0328] Furthermore, according to a ninety-fifth aspect of the invention, there is provided an output data managing program that manages output data used for a plurality of network devices. The output data managing program includes a program that allows a computer to execute a process including an output data transmitting step of transmitting the output data to the plurality of network devices and an output data utilization managing step of managing the use of the output data. In the output data utilization managing step, when authentication succeeds in an authenticating step, an output permission notice is transmitted to any one of the plurality of network devices, and job tickets stored in a job ticket storage unit that stores job tickets specifying contents related to whether to permit or restrict the use of the output data are updated. In addition, the transmission of the output permission notice is prohibited until a print interruption notice or a print completion notice is received. When the print interruption notice is received, the contents of the job tickets are restored to the original states before the update. When it is determined that the contents of the job tickets satisfy predetermined conditions, a utilization prohibition notice is transmitted to the plurality of network devices.
[0329] According to this configuration, when the computer reads out the program to perform the process according to the read program, the same operations and effects as those in the device using apparatus according to the eightieth aspect are obtained.
[0330] Moreover, according to a ninety-sixth aspect of the invention, the output data managing program of the ninety-fourth aspect or the ninety-fifth aspect further includes a program that allows a computer to execute a process composed of an authentication information receiving step of receiving authentication information used for the authentication; and the authenticating step. In the authenticating step, the use of the output data is authenticated on the basis of the authentication information received in the authentication information receiving step. In the output data utilization managing step, when it is determined that the use of the output data is authenticated in the authenticating step, the output permission notice is transmitted to one of the plurality of network device, which is a source of the authentication information.
[0331] According to this configuration, when the computer reads out the program to perform the process according to the read program, the same operations and effects as those in the device using apparatus according to the eighty-first aspect are obtained.
[0332] Further, according to a ninety-seventh aspect of the invention, in the output data managing program of the ninety-sixth aspect, in the output data utilization managing step, when it is determined that the use of the output data is authenticated in the authenticating step and that the job tickets can be updated, the output permission notice is transmitted, and the update of the job tickets is prohibited until the print interruption notice or the print completion notice is received.
[0333] According to this configuration, when the computer reads out the program to perform the process according to the read program, the same operations and effects as those in the device using apparatus according to the eighty-second aspect are obtained.
[0334] Furthermore, according to a ninety-eighty aspect of the invention, the output data managing program according to any one of the ninety-fourth to ninety-seventh aspects further includes a program that allows a computer to execute a process composed of a utilization history information generating step of generating utilization history information indicating a utilization history of the output data, on the basis of the result supplied in the output data utilization managing step.
[0335] According to this configuration, when the computer reads out the program to perform the process according to the read program, the same operations and effects as those in the device using apparatus according to the eighty-third aspect are obtained.
[0336] Moreover, according to a ninety-ninth aspect of the invention, in the output data managing program according to any one of the ninety-fourth to ninety-eighth aspects, in the output data utilization managing step, when it is determined that the contents of the job tickets satisfy the predetermined conditions, the utilization prohibition notice is transmitted, and the job tickets are removed.
[0337] According to this configuration, when the computer reads out the program to perform the process according to the read program, the same operations and effects as those in the device using apparatus according to the eighty-fourth aspect are obtained.
[0338] Further, according to the hundredth aspect of the invention, there is provided an output control program that performs an output process on the basis of output data. The output control program includes a program that allows a computer to execute a process including an output data receiving step of receiving the output data; an output data storing step of storing the output data received in the output data receiving step in an output data storage unit; and an output control step of performing output control on the basis of the output data stored in the output data storage unit. In the output control step, when an output permission notice is received, the output process is performed on the basis of the output data. When the output of the output data is interrupted, the use of the output data is prohibited, and a print interruption notice is transmitted to a device using apparatus. When the output of the output data is completed, a print completion notice is transmitted to the device using apparatus. When a utilization prohibition notice is received, the use of the output data is prohibited.
[0339] According to this configuration, when the computer reads out the program to perform the process according to the read program, the same operations and effects as those in the network device according to the eighty-fifth aspect are obtained.
[0340] Furthermore, according to a one-hundred first aspect of the invention, the output control program of the hundredth aspect further includes a program that allows a computer to execute a process including an authentication information acquiring step of acquiring authentication information used for the authentication; and an authentication information transmitting step of transmitting the authentication information acquired in the authentication information acquiring step to the device using apparatus.
[0341] According to this configuration, when the computer reads out the program to perform the process according to the read program, the same operations and effects as those in the network device according to the eighty-sixth aspect are obtained.
[0342] Moreover, according to a one-hundred second aspect of the invention, in the output control program of the hundredth aspect or the one-hundred first aspect, in the output control step, when the utilization prohibition notice is received, the output data is removed.
[0343] According to this configuration, when the computer reads out the program to perform the process according to the read program, the same operations and effects as those in the network device according to the eighty-seventh aspect are obtained.
[0344] Further, according to the one-hundred third aspect of the invention, there is provided an output control program that performs an output process on the basis of output data. The output control program includes a program that allows a computer to execute a process including an output data receiving step of receiving the output data; an output data storing step of storing the output data received in the output data receiving step in an output data storage unit; an output data utilization managing step of managing the use of the output data; and an output control step of performing output control on the basis of the output data stored in the output data storage unit. When authentication succeeds in an authenticating step, in the output data utilization managing step, an output permission notice is transmitted to another network device, and the transmission of the output permission notice and the use of the output data are prohibited until a print interruption notice or a print completion notice is received. Alternatively, an output request is performed in the output control step, the transmission of the output permission notice is prohibited until the output of the output data from the network device is interrupted or completed, and job tickets stored in a job ticket storage unit that stores job tickets specifying contents related to whether to permit or restrict the use of the output data are updated when the print completion notice is received or when the output of the output data is completed. In addition, when it is determined that the contents of the job tickets satisfy predetermined conditions, a utilization prohibition notice is transmitted to another network device, and the use of the output data is prohibited. In the output control step, the output process is performed on the basis of the output data, according to the output request.
[0345] According to this configuration, when the computer reads out the program to perform the process according to the read program, the same operations and effects as those in the network device according to the eighty-eighth aspect are obtained.
[0346] Furthermore, according to a one-hundred fourth aspect of the invention, there is provided an output control program that performs an output process on the basis of output data. The output control program includes a program that allows a computer to execute a process including an output data receiving step of receiving the output data; an output data storing step of storing the output data received in the output data receiving step in an output data storage unit; an output data utilization managing step of managing the use of the output data; and an output control step of performing output control on the basis of the output data stored in the output data storage unit. In the output data utilization managing step, when authentication succeeds in an authenticating step, an output permission notice is transmitted to another network device, job tickets stored in a job ticket storage unit that stores job tickets specifying contents related to whether to permit or restrict the use of the output data are updated, and the transmission of the output permission notice and the use of the output data are prohibited until a print interruption notice or a print completion notice is received. Alternatively, an output request is performed in the output control step, the job tickets stored in the job ticket storage unit are updated, the transmission of the output permission notice is prohibited until the output of the output data is interrupted or completed, the contents of the job tickets are restored to the original states before the update when the print interruption notice is received or when the output of the output data is interrupted, and a utilization prohibition notice is transmitted to another network device and the use of the output data is prohibited when it is determined that the contents of the job tickets satisfy predetermined conditions. In the output control step, the output process is performed on the basis of the output data, according to the output request.
[0347] According to this configuration, when the computer reads out the program to perform the process according to the read program, the same operations and effects as those in the network device according to the eighty-ninth aspect are obtained.
[0348] Moreover, according to a one-hundred fifth aspect of the invention, the output control program of the one-hundred third aspect or the one-hundred fourth aspect further includes a program that allows a computer to execute a process including an authentication information receiving step of receiving authentication information used for the authentication; an authentication information acquiring step of acquiring the authentication information; and the authenticating step. In the authenticating step, the use of the output data is authenticated on the basis of the authentication information received in the authentication information receiving step and the authentication information received in the authentication information acquiring step. In the output data utilization managing step, when it is determined that the use of the output data is authenticated in the authenticating step, on the basis of the authentication information received in the authentication information receiving step, the output permission notice is transmitted to another network device. When it is determined that the use of the output data is authenticated in the authenticating step on the basis of the authentication information acquired in the authentication information acquiring step, the output request is performed in the output control step.
[0349] According to this configuration, when the computer reads out the program to perform the process according to the read program, the same operations and effects as those in the network device according to the ninetieth aspect are obtained.
[0350] Further, according to a one-hundred sixth aspect of the invention, in the output control program of the one-hundred fifth aspect, in the output data utilization managing step, when it is determined that the use of the output data is authenticated in the authenticating step on the basis of the authentication information received in the authentication information receiving step and that the job tickets can be updated, the output permission notice is transmitted, and the update of the job tickets is prohibited until the print interruption notice or the print completion notice is received. In addition, when it is determined that the use of the output data is authenticated in the authenticating step, on the basis of the authentication information acquired in the authentication information acquiring step, and that the job tickets can be updated, the output request is performed, and the update of the job tickets is prohibited until the output of the output data is interrupted or completed.
[0351] According to this configuration, when the computer reads out the program to perform the process according to the read program, the same operations and effects as those in the network device according to the ninety-first aspect are obtained.
[0352] Furthermore, according to a one-hundred seventh aspect of the invention, the output control program according to any one of the one-hundred third to one-hundred sixth aspects further includes a program that allows a computer to execute a process including a utilization history information generating step of generating utilization history information indicating a utilization history of the output data, on the basis of the transmission result and the utilization result of the output data utilization managing step.
[0353] According to this configuration, when the computer reads out the program to perform the process according to the read program, the same operations and effects as those in the device using apparatus according to the ninety-second aspect are obtained.
[0354] Moreover, according to a one-hundred eighth aspect of the invention, in the output control program according to any one of the one-hundred third to one-hundred seventh aspects, in the output data utilization managing step, when it is determined that the contents of the job tickets satisfy the predetermined conditions, the utilization prohibition notice is transmitted, and the output data and the job tickets are removed.
[0355] According to this configuration, when the computer reads out the program to perform the process according to the read program, the same operations and effects as those in the device using apparatus according to the ninety-third aspect are obtained.
[0356] Further, according to the one-hundred ninth aspect of the invention, there is provided an authentication output method that performs an output process through authentication in a plurality of network devices each of which performs the output process on the basis of output data, the network devices being connected to a device using apparatus that uses the network devices so as to communicate therewith. The method includes, for the device using apparatus, an output data transmitting step of transmitting the output data to the plurality of network devices; and an output data utilization managing step of, when authentication succeeds in an authenticating step, transmitting an output permission notice to any one of the plurality of network devices, of prohibits the transmission of the output permission notice until a print interruption notice or a print completion notice is received, of updating job tickets stored in a job ticket storage unit that stores the job tickets specifying contents related to whether to permit or restrict the use of the output data when the print completion notice is received, and of transmitting a utilization prohibition notice to the plurality of network devices when it is determined that the contents of the job tickets satisfy predetermined conditions. The method includes, for the network devices, an output data receiving step of receiving the output data; an output data storing step of storing the output data received in the output data receiving step in an output data storage unit; and an output control step of performing the output process on the basis of the output data stored in the output data storage unit when the output permission notice is received, of prohibiting the use of the output data and transmitting the print interruption notice to the device using apparatus when the output of the output data from the network devices is interrupted, of transmitting the print completion notice to the device using apparatus when the output of the output data from the network devices is completed, and of prohibiting the use of the output data when the utilization prohibition notice is received.
[0357] According to this structure, the same effects as those in the authentication output system according to the sixty-seventh aspect are obtained.
[0358] Furthermore, according to a one-hundred tenth aspect of the invention, there is provided an authentication output method that performs an output process through authentication in a plurality of network devices each of which performs the output process on the basis of output data, the network devices being connected to a device using apparatus that uses the network devices so as to communicate therewith. The method includes, for the device using apparatus, an output data transmitting step of transmitting the output data to the plurality of network devices; and an output data utilization managing step of, when authentication succeeds in an authenticating step, transmitting an output permission notice to any one of the plurality of network devices, of updating job tickets stored in a job ticket storage unit that stores the job tickets specifying contents related to whether to permit or restrict the use of the output data, of prohibits the transmission of the output permission notice until a print interruption notice or a print completion notice is received, of restoring the contents of the job tickets to the original states before the update when the print interruption notice is received, and of transmitting a utilization prohibition notice to the plurality of network devices when it is determined that the contents of the job tickets satisfy predetermined conditions. In addition, the method includes, for the network devices, an output data receiving step of receiving the output data; an output data storing step of storing the output data received in the output data receiving step in an output data storage unit; and an output control step of performing the output process on the basis of the output data stored in the output data storage unit when the output permission notice is received, of prohibiting the use of the output data and transmitting the print interruption notice to the device using apparatus when the output of the output data from the network devices is interrupted, of transmitting the print completion notice to the device using apparatus when the output of the output data from the network devices is completed, and of prohibiting the use of the output data when the utilization prohibition notice is received.
[0359] According to this structure, the same effects as those in the authentication output system according to the sixty-eighth aspect are obtained.
[0360] Moreover, according to a one-hundred eleventh aspect of the invention, the authentication output method of the one-hundred ninth aspect or the one-hundred tenth aspect further includes, for the network device, an authentication information acquiring step of acquiring the authentication information; and an authentication information transmitting step of transmitting authentication information acquired in the authentication information acquiring step to the device using apparatus. In addition, the authentication output method further includes, for the device using apparatus, an authentication information receiving step of receiving the authentication information; and an authenticating step. In the authenticating step, the use of the output data is authenticated on the basis of the authentication information received in the authentication information receiving step. In the output data utilization managing step, when it is determined that the use of the output data is authenticated in the authenticating step, the output permission notice is transmitted to one of the plurality of network device, which is a source of the authentication information.
[0361] According to this structure, the same effects as those in the authentication output system according to the sixty-ninth aspect are obtained.
[0362] Further, according to a one-hundred twelfth aspect of the invention, in the authentication output method of the one-hundred eleventh aspect, in the output data utilization managing step, when it is determined that the use of the output data is authenticated in the authenticating step and that the job tickets can be updated, the output permission notice is transmitted, and the update of the job tickets is prohibited until the print interruption notice or the print completion notice is received.
[0363] According to this structure, the same effects as those in the authentication output system according to the seventieth aspect are obtained.
[0364] Furthermore, according to a one-hundred thirteenth aspect of the invention, the authentication output method according to any one of the one-hundred ninth to one-hundred twelfth aspects further includes, for the device using apparatus, a utilization history information generating step of generating utilization history information indicating a utilization history of the output data, on the basis of the transmission result of the output data utilization managing step.
[0365] According to this structure, the same effects as those in the authentication output system according to the seventy-first aspect are obtained.
[0366] Moreover, according to a one-hundred fourteenth aspect of the invention, in the authentication output method according to any one of the one-hundred ninth to one-hundred thirteenth aspects, in the output data utilization managing step, when it is determined that the contents of the job tickets satisfy the predetermined conditions, the utilization prohibition notice is transmitted, and the job tickets are removed. In the output control step, when the utilization prohibition notice is received, the output data is removed.
[0367] According to this structure, the same effects as those in the authentication output system according to the seventy-second aspect are obtained.
[0368] Further, according to the one-hundred fifteenth aspect of the invention, there is provided an authentication output method that performs an output process through authentication in first and second network devices each of which performs the output process on the basis of output data, the first and second network devices being connected to a device using apparatus that uses the network devices so as to communicate therewith. The method includes, for the device using apparatus, an output data transmitting step of transmitting the output data to the first and second network devices. The method includes, for the first network device, a first output data receiving step of receiving the output data; a first output data storing step of storing the output data received in the first output data receiving step in a first output data storage unit; an output data utilization managing step of managing the use of the output data; and a first output control step of performing output control on the basis of the output data stored in the first output data storage unit. In the output data utilization managing step, when the authentication succeeds in an authenticating step, an output permission notice is transmitted to the second network device, and the transmission of the output permission notice and the use of the output data are prohibited until a print interruption notice or a print completion notice is received. Alternatively, in the output data utilization managing step, the output of the output data is requested in the first output control step, the transmission of the output permission notice is prohibited until the output of the output data from the first network device is interrupted or completed, job tickets stored in a job ticket storage unit that stores the job tickets specifying contents related to whether to permit or restrict the use of the output data are updated when the print completion notice is received or when the output of the output data from the first network device is completed, and a utilization prohibition notice is transmitted to the second network device and the use of the output data is prohibited when it is determined that the contents of the job tickets satisfy predetermined conditions. In the first output control step, the output process is performed on the basis of the output data, according to the output request. The method includes, for the second network device, a second output data receiving step of receiving the output data; a second output data storing step of storing the output data received in the second output data receiving step in a second output data storage unit; and a second output control step of, when the output permission notice is received, performing the output process on the basis of the output data stored in the second output data storage unit, of prohibiting the use of the output data and transmitting the print interruption notice to the first network device when the output of the output data from the second network device is interrupted, of transmitting the print completion notice to the first network device when the output of the output data from the second network device is completed, and of prohibiting the use of the output data when the utilization prohibition notice is received.
[0369] According to this structure, the same effects as those in the authentication output system according to the seventy-third aspect are obtained.
[0370] Furthermore, according to the one-hundred sixteenth aspect of the invention, there is provided an authentication output method that performs an output process through authentication in first and second network devices each of which performs the output process on the basis of output data, the first and second network devices being connected to a device using apparatus that uses the network devices so as to communicate therewith. The method includes, for the device using apparatus, an output data transmitting step of transmitting the output data to the first and second network devices. The method includes, for the first network device, a first output data receiving step of receiving the output data; a first output data storing step of storing the output data received in the first output data receiving step in a first output data storage unit; an output data utilization managing step of managing the use of the output data; and a first output control step of performing output control on the basis of the output data stored in the first output data storage unit. In the output data utilization managing step, when the authentication succeeds in an authenticating step, an output permission notice is transmitted to the second network device, job tickets stored in a job ticket storage unit that stores the job tickets specifying contents related to whether to permit or restrict the use of the output data are updated, and the transmission of the output permission notice and the use of the output data are prohibited until a print interruption notice or a print completion notice is received. Alternatively, in the output data utilization managing step, the output of the output data is requested in the first output control step, the job tickets stored in the job ticket storage unit are updated, the transmission of the output permission notice is prohibited until the output of the output data from the first network device is interrupted or completed, the contents of the job tickets are restored to the original states before the update when the print interruption notice is received or when the output of the output data from the first network device is interrupted, and a utilization prohibition notice is transmitted to the second network device and the use of the output data is prohibited when it is determined that the contents of the job tickets satisfy predetermined conditions. In the first output control step, the output process is performed on the basis of the output data, according to the output request. In addition, the method includes, for the second network device, a second output data receiving step of receiving the output data; a second output data storing step of storing the output data received in the second output data receiving step in a second output data storage unit; and a second output control step of, when the output permission notice is received, performing the output process on the basis of the output data stored in the second output data storage unit, of prohibiting the use of the output data and transmitting the print interruption notice to the first network device when the output of the output data from the second network device is interrupted, of transmitting the print completion notice to the first network device when the output of the output data from the second network device is completed, and of prohibiting the use of the output data when the utilization prohibition notice is received.
[0371] According to this structure, the same effects as those in the authentication output system according to the seventy-fourth aspect are obtained.
[0372] Moreover, according to a one-hundred seventeenth aspect of the invention, the authentication output method of the one-hundred fifteenth aspect or the one-hundred sixteenth aspect further includes, for the second network device, a second authentication information acquiring step of acquiring authentication information; and an authentication information transmitting step of transmitting the authentication information acquired by the second authentication information acquiring unit to the first network device. In addition, the authentication output method further includes, for the first network device, an authentication information receiving step of receiving the authentication information; a first authentication information acquiring step of acquiring the authentication information; and the authenticating unit. In the authenticating step, the use of the output data is authenticated on the basis of the authentication information received in the authentication information receiving step and the authentication information acquired in the first authentication information acquiring step. In the output data utilization managing step, when it is determined that the use of the output data is authenticated in the authenticating step, on the basis of the authentication information received in the authentication information receiving step, the output permission notice is transmitted to the second network device. When it is determined that the use of the output data is authenticated in the authenticating unit on the basis of the authentication information acquired in the first authentication information acquiring step, the output request is performed in the first output control step.
[0373] According to this structure, the same effects as those in the authentication output system according to the seventy-fifth aspect are obtained.
[0374] Further, according to a one-hundred eighteenth aspect of the invention, in the authentication output method of the one-hundred seventeenth aspect, in the output data utilization managing step, when it is determined that the use of the output data is authenticated in the authenticating step on the basis of the authentication information received in the authentication information receiving step and that the job tickets can be updated, the output permission notice is transmitted, and the update of the job tickets is prohibited until the print interruption notice or the print completion notice is received. In addition, when it is determined that the use of the output data is authenticated in the authenticating step, on the basis of the authentication information acquired in the first authentication information acquiring step, and that the job tickets can be updated, the output request is performed, and the update of the job tickets is prohibited until the output of the output data from the first network device is interrupted or completed.
[0375] According to this structure, the same effects as those in the authentication output system according to the seventy-sixth aspect are obtained.
[0376] Furthermore, according to a one-hundred nineteenth aspect of the invention, the authentication output method according to any one of the one-hundred fifteenth to one-hundred eighteenth aspects further includes, for the first network device, a utilization history information generating step of generating utilization history information indicating a utilization history of the output data, on the basis of a transmission result and a utilization result of the output data utilization managing step.
[0377] According to this structure, the same effects as those in the authentication output system according to the seventy-seventh aspect are obtained.
[0378] Moreover, according to a one-hundred twentieth aspect of the invention, in the authentication output method according to any one of the one-hundred fifteenth to one-hundred nineteenth aspects, in the output data utilization managing step, when it is determined that the contents of the job tickets satisfy the predetermined conditions, the utilization prohibition notice is transmitted, and the output data and the job tickets are removed. In the second output control step, the output data is removed when the utilization prohibition notice is received.
[0379] According to this structure, the same effects as those in the authentication output system according to the seventy-eighth aspect are obtained.
[0380] Further, according to the one-hundred twentieth aspect of the invention, an output system includes first and second network devices each of which performs an output process on the basis of output data; and a data managing apparatus that manages the output data, the data managing apparatus being connected to the network devices so as to communicate therewith. The data managing apparatus includes: an output data storage unit that stores the output data; and an output data supplying unit that supplies the output data stored in the output data storage unit to the first network device in response to an acquiring request of the first network device. The first network device includes a job ticket storage unit that stores job tickets specifying contents related to whether to permit or restrict the use of the output data; an output data utilization managing unit that manages the use of the output data; and a first output control unit that performs output control on the basis of the output data. The output data utilization managing unit acquires the output data from the data managing apparatus, supplies the acquired output data to the second network device, and prohibits the supply and use of the output data until a print interruption notice or a print completion notice is received. Alternatively, the output data utilization managing unit outputs the acquired output data to the first output control unit, prohibits the supply of the output data until the output of the output data from the first network device is interrupted or completed, updates the job tickets stored in the job ticket storage unit when the print completion notice is received or when the output of the output data from the first network device is completed, and prohibits the supply and use of the output data when it is determined that the contents of the job tickets satisfy predetermined conditions. The first output control unit performs the output process on the basis of the output data from the output data utilization managing unit. The second network device includes an output data receiving unit that receives the output data; and a second output control unit that performs output control on the basis of the output data received by the output data receiving unit. When the output of the output data from the second network device is interrupted, the second output control unit prohibits the use of the output data and transmits the print interruption notice to the first network device. When the output of the output data from the second network device is completed, the second output control unit transmits the print completion notice to the first network device.
[0381] According to this structure, in the first network device, the output data utilization managing unit acquires the output data from the data managing apparatus.
[0382] In the data managing unit, the output data supplying unit supplies the output data to the first network device in response to the acquiring request of the first network device.
[0383] In the first network device, when the output data is acquired, the output data utilization managing unit supplies the acquired output data to the second network device, or outputs the acquired output data to the first output control unit. In the former case, the supply and use of the output data are prohibited until the print interruption notice or the print completion notice is received.
[0384] In the second network device, when the output data receiving unit receives the output data, the second output control unit performs the output control on the basis of the received output data. When the output of the output data is completed, the print completion notice is transmitted to the first network device. On the other hand, when the output of the output data is interrupted, the use of the output data is prohibited, and the print interruption notice is transmitted to the first network device.
[0385] In the first network device, when the print completion notice is received, the output data utilization managing unit updates the job tickets.
[0386] Further, in the first network device, when the output data is output to the first output control unit, the first output control unit performs the output process on the basis of the output data. Then, the output data utilization managing unit prohibits the supply of the output data until the output of the output data is interrupted or completed. When the output is completed, the job tickets are updated.
[0387] In addition, in the first network device, when it is determined that the contents of the job tickets satisfy predetermined conditions, the output data utilization managing unit prohibits the supply and use of the output data.
[0388] In this way, when the output of the output data is completed, the job tickets are updated. Therefore, even when the output of the output data from one of the first and second network devices is interrupted due to a trouble, output contents can be obtained from the other network device. In addition, only an authorized user can obtain an output matter.
[0389] Furthermore, since the output data is supplied to the second network device or the output data is used in the first network device, it is possible to prevent the same output content from being simultaneously output from the first and second network devices. In addition, even when the network device is restored from a disable state to a normal state, it is possible to prevent the output content from being output from the network device since the use of the output data is prohibited. Further, it is possible to prevent the output process from being performed beyond an output permission range, and thus to more reliably protect the secrecy of the output content.
[0390] In this structure, when it is determined that the contents of the job tickets satisfy the predetermined conditions, the supply and use of the output data are prohibited. When the output of the output data is interrupted, the use of the output data is prohibited. In these cases, prohibiting the use of the output data includes, for example, removing the output data, rejecting a request for the supply or use of the output data, transmitting the utilization prohibition notice to the data managing apparatus, rewriting the attribute of the output data into ‘unavailable’, and encoding the output data such that the output data cannot be read. This is similarly applied to an output system according to a one-hundred twenty-second aspect, network devices according to one-hundred twenty-seventh and one-hundred twenty-eighth aspects, output control programs according to one-hundred thirty-third and one-hundred thirty-fourth aspects, and output methods according to one-hundred ninth and one-hundred fortieth aspects.
[0391] Further, according to the one-hundred twenty-second aspect of the invention, an output system includes first and second network devices each of which performs an output process on the basis of output data; and a data managing apparatus that manages the output data, the data managing apparatus being connected to the network devices so as to communicate therewith. The data managing apparatus includes an output data storage unit that stores the output data; and an output data supplying unit that supplies the output data stored in the output data storage unit to the first network device in response to an acquiring request of the first network device. The first network device includes a job ticket storage unit that stores job tickets specifying contents related to whether to permit or restrict the use of the output data; an output data utilization managing unit that manages the use of the output data; and a first output control unit that performs output control on the basis of the output data. The output data utilization managing unit acquires the output data from the data managing apparatus, supplies the acquired output data to the second network device, updates the job tickets stored in the job ticket storage unit, and prohibits the supply and use of the output data until a print interruption notice or a print completion notice is received. Alternatively, the output data utilization managing unit outputs the acquired output data to the first output control unit, updates the job tickets stored in the job ticket storage unit, prohibits the supply of the output data until the output of the output data from the first network device is interrupted or completed, restores the contents of the job tickets to the original states before the update when the print interruption notice is received or when the output of the output data from the first network device is interrupted, and prohibits the supply and use of the output data when it is determined that the contents of the job tickets satisfy predetermined conditions. The first output control unit performs the output process on the basis of the output data from the output data utilization managing unit. The second network device includes an output data receiving unit that receives the output data; and a second output control unit that performs output control on the basis of the output data received by the output data receiving unit. When the output of the output data from the second network device is interrupted, the second output control unit prohibits the use of the output data and transmits the print interruption notice to the first network device. When the output of the output data from the second network device is completed, the second output control unit transmits the print completion notice to the first network device.
[0392] According to this structure, in the first network device, the output data utilization managing unit acquires the output data from the data managing apparatus.
[0393] In the data managing unit, the output data supplying unit supplies the output data to the first network device in response to the acquiring request of the first network device.
[0394] In the first network device, when the output data is acquired, the output data utilization managing unit supplies the acquired output data to the second network device, or outputs the acquired output data to the first output control unit. In the former case, the job tickets are updated, and the supply and use of the output data are prohibited until the print interruption notice or the print completion notice is received.
[0395] In the second network device, when the output data receiving unit receives the output data, the second output control unit performs the output control on the basis of the received output data. When the output of the output data is completed, the print completion notice is transmitted to the first network device. On the other hand, when the output of the output data is interrupted, the use of the output data is prohibited, and the print interruption notice is transmitted to the first network device.
[0396] In the first network device, when the print completion notice is received, the output data utilization managing unit restores the contents of the job tickets to the original states before the update.
[0397] Further, in the first network device, when the output data is output to the first output control unit, the output data utilization managing unit updates the job tickets, and the first output control unit performs the output process on the basis of the output data. Then, the output data utilization managing unit prohibits the supply of the output data until the output of the output data is interrupted or completed. When the output is interrupted, the contents of the job tickets are restored to the original states before the update.
[0398] In addition, in the first network device, when it is determined that the contents of the job tickets satisfy predetermined conditions, the output data utilization managing unit prohibits the supply and use of the output data.
[0399] In this way, when the output of the output data is completed, the job tickets are updated. Therefore, even when the output of the output data from one of the first and second network devices is interrupted due to a trouble, output contents can be obtained from the other network device. In addition, only an authorized user can obtain an output matter.
[0400] Furthermore, since the output data is supplied to the second network device or the output data is used in the first network device, it is possible to prevent the same output content from being simultaneously output from the first and second network devices. In addition, even when the network device is restored from a disable state to a normal state, it is possible to prevent the output content from being output from the network device since the use of the output data is prohibited. Further, it is possible to prevent the output process from being performed beyond an output permission range, and thus to more reliably protect the secrecy of the output content.
[0401] Further, according to a one-hundred twenty-third aspect of the invention, in the output system of the one-hundred twenty-first aspect or the one-hundred twenty-second aspect, the first network device includes an authentication information receiving unit that receives authentication information used for the authentication; a first authentication information acquiring unit that acquires the authentication information; and an authenticating unit that authenticates the use of the output data on the basis of the authentication information received by the authentication information receiving unit and the authentication information acquired by the first authentication information acquiring unit. The second network device includes a second authentication information acquiring unit that acquires the authentication information; and an authentication information transmitting unit that transmits the authentication information acquired by the second authentication information acquiring unit to the first network device. When it is determined that the use of the output data is authenticated by the authenticating unit, on the basis of the authentication information received by the authentication information receiving unit, the output data utilization managing unit supplies the output data to the second network device. When it is determined that the use of the output data is authenticated by the authenticating unit on the basis of the authentication information acquired by the first authentication information acquiring unit, the output data utilization managing unit requires the first output control unit to output the output data.
[0402] According to this structure, in the second network device, when the authentication information is acquired by the second authentication information acquiring unit, the authentication information transmitting unit transmits the acquired authentication information to the first network device.
[0403] In the first network device, when the authentication information is received by the authentication information receiving unit, the authenticating unit authenticates the use of the output data on the basis of the received authentication information. As a result, when it is determined that the use of the output data is permitted, the output data utilization managing unit supplies the output data to the second network device.
[0404] Further, in the first network device, when the first authentication information acquiring unit acquires the authentication information, the authenticating unit authenticates the use of the output data on the basis of the acquired authentication information. As a result, when the use of the output data is permitted, the output data utilization managing unit requests the first network device to output the output data.
[0405] In this way, when a user inputs proper authentication information to a desired network device, the user can obtain output contents from the network device.
[0406] Furthermore, according to a one-hundred twenty-fourth aspect of the invention, in the output system of the one-hundred twenty-third aspect, when it is determined that the use of the output data is authenticated by the authenticating unit on the basis of the authentication information received by the authentication information receiving unit and that the job tickets can be updated, the output data utilization managing unit supplies the output data to the second network device, and prohibits the update of the job tickets until the print interruption notice or the print completion notice is received. In addition, when it is determined that the use of the output data is authenticated by the authenticating unit, on the basis of the authentication information acquired by the first authentication information acquiring unit and that the job tickets can be updated, the output data utilization managing unit outputs the output data to the first output control unit and prohibits the update of the job tickets until the output of the output data from the first network device is interrupted or completed.
[0407] According to this structure, in the first network device, when it is determined that the use of the output data is authenticated by the authenticating unit on the basis of the received authentication information and that the job tickets can be updated, the output data utilization managing unit supplies the output data to the second network device, and prohibits the update of the job tickets until the print interruption notice or the print completion notice is received.
[0408] In addition, in the first network device, when it is determined that the use of the output data is authenticated on the basis of the acquired authentication information and that the job tickets can be updated, the output data utilization managing unit outputs the output data to the first network device, and prohibits the update of the job tickets until the output of the output data is interrupted or completed.
[0409] Therefore, until the print interruption notice or the print completion notice is received or until the output of the output data is interrupted or completed, the output data is not supplied even though the authentication information is received, and the output of the output data is not performed even though the authentication information is acquired.
[0410] Moreover, according to a one-hundred twenty-fifth aspect of the invention, in the output system according to any one of the one-hundred twenty-first to one-hundred twenty-fourth aspects, the first network device further includes a utilization history information generating unit that creates utilization history information indicating a utilization history of the output data, on the basis of a utilization result and a supply result of the output data utilization managing unit.
[0411] According to this structure, in the first network device, the utilization history information generating unit creates the utilization history information indicating the utilization history of the output data, on the basis of the utilization result and the supply result of the output data utilization managing unit.
[0412] In this way, it is possible to see how the output data has been used by referring to the utilization history information.
[0413] Further, according to a one-hundred twenty-sixth aspect of the invention, in the output system according to the one-hundred twenty-first to one-hundred twenty-fifth aspects, when it is determined that the contents of the job tickets satisfy the predetermined conditions, the output data utilization managing unit removes the job tickets and transmits the utilization prohibition notice to the data managing apparatus. The data managing apparatus includes an output data removing unit that removes the output data when the utilization prohibition notice is received.
[0414] According to this structure, in the first network device, when it is determined that the contents of the job tickets satisfy the predetermined conditions, the output data utilization managing unit removes the job tickets and transmits the utilization prohibition notice to the data managing apparatus.
[0415] In the data managing apparatus, the output data removing unit removes the output data when the utilization prohibition notice is received.
[0416] In this way, it is possible to prevent the output data and the job tickets from being illegally used, and thus to reliably protect the secrecy of the output contents.
[0417] Furthermore, according to the one-hundred twenty-seventh aspect, there is provided a network device that performs an output process on the basis of output data. The network device includes a job ticket storage unit that stores job tickets specifying contents related to whether to permit or restrict the use of the output data; an output data utilization managing unit that manages the use of the output data; and an output control unit that performs output control on the basis of the output data. The output data utilization managing unit acquires the output data from a data managing apparatus, supplies the acquired output data to another network device, and prohibits the supply and use of the output data until a print interruption notice or a print completion notice is received. Alternatively, the output data utilization managing unit outputs the acquired output data to the output control unit, prohibits the supply of the output data until the output of the output data from the first network device is interrupted or completed, updates the job tickets stored in the job ticket storage unit when the print completion notice is received or when the output of the output data from the network device is completed, and prohibits the supply and use of the output data when it is determined that the contents of the job tickets satisfy predetermined conditions. The output control unit performs the output process on the basis of the output data from the output data utilization managing unit.
[0418] According to this structure, the same operations as those in the first network device of the authentication output system according to the one-hundred twenty-first aspect are obtained. Thus, the same effects as those in the authentication output system according to the one-hundred twenty-first aspect are obtained.
[0419] Moreover, according to the one-hundred twenty-eighth aspect of the invention, there is provided a network device that performs an output process on the basis of output data. The network device includes a job ticket storage unit that stores job tickets specifying contents related to whether to permit or restrict the use of the output data; an output data utilization managing unit that manages the use of the output data; and an output control unit that performs output control on the basis of the output data. The output data utilization managing unit acquires the output data from a data managing apparatus, supplies the acquired output data to another network device, updates the job tickets stored in the job ticket storage unit, and prohibits the supply and use of the output data until a print interruption notice or a print completion notice is received. Alternatively, the output data utilization managing unit outputs the acquired output data to the output control unit, updates the job tickets stored in the job ticket storage unit, prohibits the supply of the output data until the output of the output data from the network device is interrupted or completed, restores the contents of the job tickets to the original states before the update when the print interruption notice is received or when the output of the output data from the network device is interrupted, and prohibits the supply and use of the output data when it is determined that the contents of the job tickets satisfy predetermined conditions. The output control unit performs the output process on the basis of the output data from the output data utilization managing unit.
[0420] According to this structure, the same operations as those in the first network device of the authentication output system according to the one-hundred twenty-second aspect are obtained. Thus, the same effects as those in the authentication output system according to the one-hundred twenty-second aspect are obtained.
[0421] Further, according to a one-hundred twenty-ninth aspect of the invention, the network device of the one-hundred twenty-seventh aspect or the one-hundred twenty-eighth aspect further includes an authentication information receiving unit that receives authentication information used for the authentication; an authentication information acquiring unit that acquires the authentication information; and an authenticating unit that authenticates the use of the output data on the basis of the authentication information received by the authentication information receiving unit and the authentication information acquired by the authentication information acquiring unit. When it is determined that the use of the output data is authenticated by the authenticating unit, on the basis of the authentication information received by the authentication information receiving unit, the output data utilization managing unit supplies the output data to another network device. When it is determined that the use of the output data is authenticated by the authenticating unit on the basis of the authentication information acquired by the authentication information acquiring unit, the output data utilization managing unit outputs the output data to the output control unit.
[0422] According to this structure, the same operations as those in the first network device of the authentication output system according to the one-hundred twenty-third aspect are obtained. Thus, the same effects as those in the authentication output system according to the one-hundred twenty-third aspect are obtained.
[0423] Furthermore, according to a one-hundred thirtieth aspect of the invention, in the network device of the one-hundred twenty-ninth aspect, when it is determined that the use of the output data is authenticated by the authenticating unit on the basis of the authentication information received by the authentication information receiving unit and that the job tickets can be updated, the output data utilization managing unit supplies the output data to another network device, and prohibits the update of the job tickets until the print interruption notice or the print completion notice is received. In addition, when it is determined that the use of the output data is authenticated by the authenticating unit, on the basis of the authentication information acquired by the authentication information acquiring unit and that the job tickets can be updated, the output data utilization managing unit outputs the output data to the output control unit and prohibits the update of the job tickets until the output of the output data from the network device is interrupted or completed.
[0424] According to this structure, the same operations as those in the first network device of the authentication output system according to the one-hundred twenty-fourth aspect are obtained. Thus, the same effects as those in the authentication output system according to the one-hundred twenty-fourth aspect are obtained.
[0425] Moreover, according to a one-hundred thirty-first aspect of the invention, the network device according to the one-hundred twenty-seventh to one-hundred thirtieth aspects further includes a utilization history information generating unit that creates utilization history information indicating a utilization history of the output data, on the basis of a utilization result and a supply result of the output data utilization managing unit.
[0426] According to this structure, the same operations as those in the first network device of the authentication output system according to the one-hundred twenty-fifth aspect are obtained. Thus, the same effects as those in the authentication output system according to the one-hundred twenty-fifth aspect are obtained.
[0427] Further, according to a one-hundred thirty-second aspect of the invention, in the network device according to the one-hundred twenty-seventh to one-hundred thirty-first aspects, when it is determined that the contents of the job tickets satisfy the predetermined conditions, the output data utilization managing unit removes the job tickets and transmits the utilization prohibition notice to the data managing apparatus.
[0428] According to this structure, the same operations as those in the first network device of the authentication output system according to the one-hundred twenty-sixth aspect are obtained. Thus, the same effects as those in the authentication output system according to the one-hundred twenty-sixth aspect are obtained.
[0429] Furthermore, according to the one-hundred thirty-third aspect of the invention, there is provided an output control program that performs an output process on the basis of output data. The output control program includes a program that allows a computer to execute a process including an output data utilization managing step of managing the use of the output data; and an output control step of performing output control on the basis of the output data. In the output data utilization managing step, the output data is acquired from a data managing apparatus, the acquired output data is supplied to another network device, and the supply and use of the output data are prohibited until a print interruption notice or a print completion notice is received. Alternatively, in the output data utilization managing step, the acquired output data is output to the output control unit, the supply of the output data is prohibited until the output of the output data is interrupted or completed, job tickets stored in a job ticket storage unit that stores job tickets specifying contents related to whether to permit or restrict the use of the output data are updated when the print completion notice is received or when the output of the output data from the network device is completed, and the supply and use of the output data is prohibited when it is determined that the contents of the job tickets satisfy predetermined conditions. In the output control step, the output process is performed on the basis of the output data from the output data utilization managing step.
[0430] According to this configuration, when the computer reads out the program to perform the process according to the read program, the same operations and effects as those in the device using apparatus according to the one-hundred twenty-seventh aspect are obtained.
[0431] Moreover, according to the one-hundred thirty-fourth aspect of the invention, there is provided an output control program that performs an output process on the basis of output data. The output control program includes a program that allows a computer to execute a process including an output data utilization managing step of managing the use of the output data; and an output control step of performing output control on the basis of the output data. In the output data utilization managing step, the output data is acquired from a data managing apparatus, the acquired output data is supplied to another network device, job tickets stored in a job ticket storage unit that stores job tickets specifying contents related to whether to permit or restrict the use of the output data are updated, and the supply and use of the output data are prohibited until a print interruption notice or a print completion notice is received. Alternatively, in the output data utilization managing step, the acquired output data is output to the output control step, the job tickets stored in the job ticket storage unit are updated, the supply of the output data is prohibited until the output of the output data from the network device is interrupted or completed, the contents of the job tickets are restored to the original states before the update when the print interruption notice is received or when the output of the output data from the network device is interrupted, and the supply and use of the output data are prohibited when it is determined that the contents of the job tickets satisfy predetermined conditions. In the output control step, the output process is performed on the basis of the output data from the output data utilization managing step.
[0432] According to this configuration, when the computer reads out the program to perform the process according to the read program, the same operations and effects as those in the device using apparatus according to the one-hundred twenty-eighth aspect are obtained.
[0433] Further, according to a one-hundred thirty-fifth aspect of the invention, the output control program of the one-hundred thirty-third aspect or the one-hundred thirty-fourth aspect further includes a program that allows a computer to execute a process including an authentication information receiving step of receiving authentication information used for the authentication; an authentication information acquiring step of acquiring the authentication information; and an authenticating step of authenticating the use of the output data on the basis of the authentication information received in the authentication information receiving step and the authentication information acquired in the authentication information acquiring step. In the output data utilization managing step, when it is determined that the use of the output data is authenticated in the authenticating step, on the basis of the authentication information received in the authentication information receiving step, the output data is supplied to another network device. When it is determined that the use of the output data is authenticated in the authenticating unit on the basis of the authentication information acquired in the authentication information acquiring step, the output data is output to the output control step.
[0434] According to this configuration, when the computer reads out the program to perform the process according to the read program, the same operations and effects as those in the device using apparatus according to the one-hundred twenty-ninth aspect are obtained.
[0435] Furthermore, according to a one-hundred thirty-sixth aspect of the invention, in the output control program of the one-hundred thirty-fifth aspect, in the output data utilization managing step, when it is determined that the use of the output data is authenticated in the authenticating step on the basis of the authentication information received in the authentication information receiving step and that the job tickets can be updated, the output data is supplied to another network device, and the update of the job tickets is prohibited until the print interruption notice or the print completion notice is received. In addition, in the output data utilization managing step, when it is determined that the use of the output data is authenticated in the authenticating step, on the basis of the authentication information acquired in the authentication information acquiring step, and that the job tickets can be updated, the output data is output to the output control step, and the update of the job tickets is prohibited until the output of the output data from the network device is interrupted or completed.
[0436] According to this configuration, when the computer reads out the program to perform the process according to the read program, the same operations and effects as those in the device using apparatus according to the one-hundred thirtieth aspect are obtained.
[0437] Moreover, according to a one-hundred thirty-seventh aspect of the invention, the output control program according to any one of the one-hundred thirty-third to one-hundred thirty-sixth aspects further includes a program that allows a computer to execute a process including a utilization history information generating step of generating utilization history information indicating a utilization history of the output data, on the basis of a utilization result and a supply result of the output data utilization managing step.
[0438] According to this configuration, when the computer reads out the program to perform the process according to the read program, the same operations and effects as those in the device using apparatus according to the one-hundred thirty-first aspect are obtained.
[0439] Further, according to a one-hundred thirty-eighth aspect of the invention, in the output control program according to any one of the one-hundred thirty-third to one-hundred thirty-seventh aspects, in the output data utilization managing step, when it is determined that the contents of the job tickets satisfy the predetermined conditions, the job tickets are removed, and the utilization prohibition notice is transmitted to the data managing apparatus.
[0440] According to this configuration, when the computer reads out the program to perform the process according to the read program, the same operations and effects as those in the device using apparatus according to the one-hundred thirty-second aspect are obtained.
[0441] Furthermore, according to the one-hundred thirty-ninth aspect of the invention, there is provided an output method used for an output system including first and second network devices each of which performs an output process on the basis of output data and a data managing apparatus that manages the output data, the data managing apparatus being connected to the network devices so as to communicate therewith. The output method includes, for the first network device, an output data utilization managing step of managing the use of the output data; and a first output control step of performing output control on the basis of the output data. In the output data utilization managing step, the output data is acquired from the data managing apparatus, the acquired output data is supplied to the second network device, and the supply and use of the output data are prohibited until a print interruption notice or a print completion notice is received. Alternatively, in the output data utilization managing step, the acquired output data is output to the first output control unit, the supply of the output data is prohibited until the output of the output data from the first network device is interrupted or completed, job tickets stored in a job ticket storage unit that stores job tickets specifying contents related to whether to permit or restrict the use of the output data are updated when the print completion notice is received or when the output of the output data from the first network device is completed, and the supply and use of the output data are prohibited when it is determined that the contents of the job tickets satisfy predetermined conditions. In the first output control step, the output process is performed on the basis of the output data from the output data utilization managing step. In addition, the output method includes, for the data managing apparatus, an output data supplying step of supplying the output data stored in an output data storage unit to the first network device in response to an acquiring request of the first network device. The output method includes, for the second network device, an output data receiving step of receiving the output data; and a second output control step of, when the output of the output data from the second network device is interrupted, prohibiting the use of the output data received in the output data receiving step and transmitting the print interruption notice to the first network device, and of transmitting the print completion notice to the first network device when the output of the output data from the second network device is completed.
[0442] According to this structure, the same effects as those in the authentication output system according to the one-hundred twenty-first aspect are obtained.
[0443] Moreover, according to the one-hundred fortieth aspect of the invention, there is provided an output method used for an output system including first and second network devices each of which performs an output process on the basis of output data, and a data managing apparatus that manages the output data, the data managing apparatus being connected to the network devices so as to communicate therewith. The output method includes, for the first network device, an output data utilization managing step of managing the use of the output data; and a first output control step of performing output control on the basis of the output data. In the output data utilization managing step, the output data is acquired from the data managing apparatus, the acquired output data is supplied to the second network device, job tickets stored in a job ticket storage unit that stores the job tickets specifying contents related to whether to permit or restrict the use of the output data are updated, and the supply and use of the output data are prohibited until a print interruption notice or a print completion notice is received. Alternatively, in the output data utilization managing step, the acquired output data is output to the first output control unit, the job tickets stored in the job ticket storage unit are updated, the supply of the output data is prohibited until the output of the output data from the first network device is interrupted or completed, the contents of the job tickets are restored to the original states before the update when the print interruption notice is received or when the output of the output data from the first network device is interrupted, and the supply and use of the output data are prohibited when it is determined that the contents of the job tickets satisfy predetermined conditions. In the first output control step, the output process is performed on the basis of the output data from the output data utilization managing step. The output method includes, for the data managing apparatus, an output data supplying step of supplying the output data stored in an output data storage unit to the first network device in response to an acquiring request of the first network device. In addition, the method includes, for the data managing apparatus, an output data receiving step of receiving the output data; and a second output control step of, when the output of the output data from the second network device is interrupted, prohibiting the use of the output data received in the output data receiving step and transmitting the print interruption notice to the first network device, and of transmitting the print completion notice to the first network device when the output of the output data from the second network device is completed.
[0444] According to this structure, the same effects as those in the authentication output system according to the one-hundred twenty-second aspect are obtained.
[0445] Further, according to a one-hundred forty-first aspect of the invention, in the output method of the one-hundred thirty-ninth aspect or the one-hundred fortieth aspect, the output method further includes, for the second network device, a second authentication information acquiring step of acquiring authentication information; and an authentication information transmitting step of transmitting the authentication information acquired in the second authentication information acquiring step to the first network device. In addition, the output method further includes, for the first network device, an authentication information receiving step of receiving the authentication information; a first authentication information acquiring step of acquiring the authentication information; and an authenticating step of authenticating the use of the output data on the basis of the authentication information received in the authentication information receiving step and the authentication information acquired in the first authentication information acquiring step. In the output data utilization managing step, when it is determined that the use of the output data is authenticated in the authenticating step, on the basis of the authentication information received in the authentication information receiving step, the output data is supplied to the second network device. When it is determined that the use of the output data is authenticated in the authenticating step on the basis of the authentication information acquired in the first authentication information acquiring step, the output data is output to the first output control step.
[0446] According to this structure, the same effects as those in the authentication output system according to the one-hundred twenty-third aspect are obtained.
[0447] Furthermore, according to a one-hundred forty-second aspect of the invention, in the output method of the one-hundred forty-first aspect, in the output data utilization managing step, when it is determined that the use of the output data is authenticated in the authenticating step, on the basis of the authentication information received in the authentication information receiving step, and that the job tickets can be updated, the output data is supplied to the second network device, and the update of the job tickets are prohibited until the print interruption notice or the print completion notice is received. In addition, in the output data utilization managing step, when it is determined that the use of the output data is authenticated in the authenticating unit, on the basis of the authentication information acquired in the first authentication information acquiring step, and that the job tickets can be updated, the output data is output to the first output control step, and the update of the job tickets is prohibited until the output of the output data from the first network device is interrupted or completed.
[0448] According to this structure, the same effects as those in the authentication output system according to the one-hundred twenty-fourth aspect are obtained.
[0449] Moreover, according to a one-hundred forty-third aspect of the invention, the output method according to any one of the one-hundred thirty-ninth to one-hundred forty-second aspects further includes, the first network device, a utilization history information generating step of generating utilization history information indicating a utilization history of the output data, on the basis of a utilization result and a supply result of the output data utilization managing step.
[0450] According to this structure, the same effects as those in the authentication output system according to the one-hundred twenty-fifth aspect are obtained.
[0451] Further, according to a one-hundred forty-fourth aspect of the invention, in the output method according to any one of the one-hundred thirty-ninth to one-hundred forty-third aspects, in the output data utilization managing step, when it is determined that the contents of the job tickets satisfy the predetermined conditions, the job tickets are removed, and the utilization prohibition notice is transmitted to the data managing apparatus. In addition, the output method further includes, for the data managing apparatus, includes an output data removing step of removing the output data when the utilization prohibition notice is received.
[0452] According to this structure, the same effects as those in the authentication output system according to the one-hundred twenty-sixth aspect are obtained.
BRIEF DESCRIPTION OF THE DRAWINGS
[0453] The invention will be described with reference to the accompanying drawings, wherein like numbers reference like elements.
[0454] FIG. 1 is a functional block diagram illustrating a functional outline of a network device.
[0455] FIG. 2 is a block diagram illustrating the hardware configuration of a host terminal.
[0456] FIG. 3 is a flowchart illustrating a print data generating process.
[0457] FIG. 4 is a view illustrating the data structure of a job ticket.
[0458] FIG. 5 is a flowchart illustrating a print request receiving process.
[0459] FIG. 6 is a flowchart illustrating a print result receiving process.
[0460] FIG. 7 is a block diagram illustrating the hardware configuration of a network printer.
[0461] FIG. 8 is a flowchart illustrating a print control process.
[0462] FIG. 9 is a flowchart illustrating the print state monitoring process.
[0463] FIG. 10 is a functional block diagram illustrating a functional outline of the network system.
[0464] FIG. 11 is a flowchart illustrating a print data generating process.
[0465] FIG. 12 is a block diagram illustrating the hardware configuration of a network printer.
[0466] FIG. 13 is a flowchart illustrating a print data storing process.
[0467] FIG. 14 is a flowchart illustrating a print control process.
[0468] FIG. 15 is a flowchart illustrating a print state monitoring process.
[0469] FIG. 16 is a view illustrating the data structure of the job ticket.
[0470] FIG. 17 is a view illustrating the data structure of the job ticket.
[0471] FIG. 18 is a flowchart illustrating the job ticket updating process.
[0472] FIG. 19 is a functional block diagram illustrating a functional outline of a network device.
[0473] FIG. 20 is a block diagram illustrating the hardware configuration of a host terminal.
[0474] FIG. 21 is a flowchart illustrating a print data generating process.
[0475] FIG. 22 is a view illustrating the data structure of a job ticket.
[0476] FIG. 23 is a flowchart illustrating a print request receiving process.
[0477] FIG. 24 is a flowchart illustrating a print result receiving process.
[0478] FIG. 25 is a block diagram illustrating the hardware configuration of a network printer.
[0479] FIG. 26 is a flowchart illustrating a print data storing process.
[0480] FIG. 27 is a flowchart illustrating a print control process.
[0481] FIG. 28 is a flowchart illustrating a print state monitoring process.
[0482] FIG. 29 is a flowchart illustrating a print data deleting process.
[0483] FIG. 30 is a functional block diagram illustrating a functional outline of a network device.
[0484] FIG. 31 is a flowchart illustrating a print data generating process.
[0485] FIG. 32 is a block diagram illustrating the hardware configuration of a network printer.
[0486] FIG. 33 is a flowchart illustrating a print data storing process.
[0487] FIG. 34 is a flowchart illustrating a print control process.
[0488] FIG. 35 is a flowchart illustrating a print state monitoring process.
[0489] FIG. 36 is a view illustrating the data structure of a job ticket.
[0490] FIG. 37 is a view illustrating the data structure of a job ticket.
[0491] FIG. 38 is a flowchart illustrating the job ticket updating process.
[0492] FIG. 39 is a functional block diagram illustrating a functional outline of a network device.
[0493] FIG. 40 is a block diagram illustrating the hardware configuration of a host terminal.
[0494] FIG. 41 is a flowchart illustrating a print data generating process.
[0495] FIG. 42 is a view illustrating the data structure of a job ticket.
[0496] FIG. 43 is a flowchart illustrating a print data supplying process.
[0497] FIG. 44 is a flowchart illustrating a print data deleting process.
[0498] FIG. 45 is a block diagram illustrating the hardware configuration of a network printer.
[0499] FIG. 46 is a view illustrating a job ticket storing process.
[0500] FIG. 47 is a flowchart illustrating a print control process.
[0501] FIG. 48 is a flowchart illustrating a print state monitoring process.
[0502] FIG. 49 is a flowchart illustrating a print request receiving process.
[0503] FIG. 50 is a flowchart illustrating a print result receiving process.
[0504] FIG. 51 is a block diagram illustrating the hardware configuration of a network printer.
[0505] FIG. 52 is a flowchart illustrating a print control process.
[0506] FIG. 53 is a flowchart illustrating a print state monitoring process.
[0507] FIG. 54 is a view illustrating the data structure of a job ticket.
[0508] FIG. 55 is a view illustrating the data structure of a job ticket.
[0509] FIG. 56 is a flowchart illustrating the job ticket updating process.
DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0510] Hereinafter, a first embodiment of the invention will be described with reference to the drawings. FIGS. 1 to 9 are diagrams showing the first embodiment of an authentication output system, a device utilizing apparatus, a network device, an output data management program, an output control program, and an authentication output method according to the invention.
[0511] In the present embodiment, as shown in FIG. 1 , the authentication output system, the device utilizing apparatus, the network device, the output data management program, the output control program, and the authentication output method according to the invention are applied to a case in which printing is performed by a network printer 200 by using an authentication card.
[0512] First, the functional outline of a network system, to which the invention is applied, will be described with reference to FIG. 1 .
[0513] FIG. 1 is a functional block diagram illustrating the functional outline of the network system.
[0514] As shown in FIG. 1 , a host terminal 100 and a plurality of network printers 200 are connected to a network 199 .
[0515] The host terminal 100 has a print data generating unit 10 that generates print data, a print data storage unit 11 that stores print data generated by the print data generating unit 10 , a job ticket storage unit that stores a job ticket specifying the number of printable copies, an authentication information receiving unit 13 that receives authentication information, a user authenticating unit 14 that performs user authentication on the basis of the authentication information received by the authentication information receiving unit 13 , and a print data utilization managing unit 15 that manages the utilization of print data.
[0516] When the user authentication is accomplished by the user authenticating unit 14 and when it is determined that the job ticket of the job ticket storage unit 12 is updatable, the print data utilization managing unit 15 provides print data of the print data storage unit 11 to one of the network printers 200 , the one (of the network printers 200 ) being a source having transmitted the authentication information, and prohibits the update of the job ticket until a print interruption notice or a print completion notice is received. When the print completion notice is received, the number of printable copies of the job ticket is decremented. Then, when it is determined that the number of printable copies is ‘0’, print data and the job ticket are deleted. Hereinafter, prohibiting the update of the job ticket is referred to as ‘freezing the job ticket’.
[0517] In addition, the host terminal 100 also has a utilization history information generating unit 16 that generates utilization history information on the basis of the provision result of the print data utilization managing unit 15 , the utilization history information indicating the utilization history of print data.
[0518] The network printer 200 has a card reader 20 that reads the authentication information from an insert authentication card, an authentication information transmitting unit 21 that transmits the authentication information read by the card reader 20 to the host terminal 100 , a print data receiving unit 22 that receives print data, a printer engine 23 that has a print head, a head driving unit, and other mechanisms required for printing, and a print control unit 24 that performs a print control of the printer engine 23 on the basis of print data received by the print data receiving unit 22 .
[0519] When the printer engine 23 stops printing, the print control unit 24 removes print data being printed and transmits the print interruption notice to the host terminal 100 . Further, when printing is completed by the printer engine 23 , the print control unit 24 transmits the print completion notice to the host terminal 100 .
[0520] Next, the configuration of the host terminal 100 will be described.
[0521] FIG. 2 is a block diagram illustrating the hardware configuration of the host terminal 100 .
[0522] As shown in FIG. 2 , the host terminal 100 has a CPU 50 that performs operations and controls the overall system on the basis of a control program, a ROM 52 that stores the control program of the CPU 50 or the like in a predetermined area in advance, a RAM 54 that stores data read from the ROM 52 or the like and operation results required for the operation process of the CPU 50 , and an I/F 58 that intermediates an input/output of data to/from peripheral devices. Those are communicably connected to one another by a bus 59 , which serves as a signal line for transmitting data.
[0523] To the I/F 58 , an input device 60 , serving as a human interface, such as a keyboard, a mouse, or the like, through which data can be inputted, a storage device 62 that stores data or tables in files, a display device 64 that displays an image on the basis of an image signal, a card writer 66 that writes the authentication information into an inserted authentication card, all of which are peripheral devices, and signal lines for connection with the network 199 are connected.
[0524] The CPU 50 has a micro processing unit or the like, starts the control program stored in the predetermined area of the ROM 52 , and executes a print data generating process, a print request receiving process, and a print result receiving process shown in flowcharts of FIGS. 3 , 5 and 6 according to the control program in a time-division manner.
[0525] First, the print data generating process will be described in detail with reference to FIG. 3 .
[0526] FIG. 3 is the flowchart showing the print data generating process.
[0527] As shown in FIG. 3 , if the print data generating process is executed by the CPU 50 , first, the process proceeds to step S 100 .
[0528] In step S 100 , it is determined whether or not printing is requested from a documentation application or the like. If it is determined that printing is requested (Yes), the process proceeds to step S 102 . On the other hand, if it is determined that printing is not requested (No), the process is on standby at step S 100 until printing is requested.
[0529] In step S 102 , a job ID for uniquely identifying print data is issued, and print data including the issued job ID is generated on the basis of document data edited by the documentation application or the like. Then, the process proceeds to step S 104 .
[0530] In step S 104 , user information of a user who uses the host terminal 100 at present is acquired, and the process proceeds to step S 106 . Then, in step S 106 , a job ticket is generated on the basis of the issued job ID and the acquired user information.
[0531] FIG. 4 is a view illustrating the data structure of the job ticket 400 .
[0532] As shown in FIG. 4 , the job ticket 400 includes a field 402 that stores the job ID, a field 404 that stores an exclusive flag indicating whether or not the job ticket 400 is frozen, a field 406 that stores the number of printable copies, and a field 408 that stores the user information. In addition, the job ticket 400 also has a field 410 that stores the utilization history information whenever print data is used.
[0533] In the example of FIG. 4 , ‘001’, ‘0’, ‘3’, and ‘UserA’ are stored as the job ID, the exclusive flag, the number of printable copies, and the user information, respectively. This indicates that print data of the job ID of ‘001’ can be printed by a user having the user information of ‘UserA’, and the number of printable copies is three. Further, the exclusive flag is reset, which indicates that the job ticket is not frozen at present. Here, the number of printable copies may be optionally specified by the user or may be set to a predetermined value.
[0534] Further, five records are stored as the utilization history information. This indicates that print data of the job ID of ‘001’ has been already printed by five copies. In this case, as the utilization history, the printed date and time is shown.
[0535] Next, the process proceeds to step S 108 , and generated print data is stored in the storage device 62 . Subsequently, the process proceeds to step S 110 , the generated job ticket is stored in the storage device 62 . After the series of steps are completed, the process returns to the initial step.
[0536] Next, the print request receiving process will be described in detail with reference to FIG. 5 .
[0537] FIG. 5 is the flowchart showing the print request receiving process.
[0538] The print request receiving process is a process of receiving the print request from the network printer 200 . As shown in FIG. 5 , if the print request receiving process is executed by the CPU 50 , first, the process proceeds to step S 150 .
[0539] In step S 150 , it is determined whether or not the print request is received. If it is determined that the print request is received (Yes), the process proceeds to step S 152 . On the other hand, if it is determined that the print request is not received (No), the process is on standby at step S 150 until the print request is received.
[0540] In step S 152 , the authentication information including the job ID and the user information is received, and the process proceeds to step S 154 . In step S 154 , a user authentication process for performing the user authentication on the basis of the received authentication information is executed. In the user authentication process, the job ticket corresponding to the job ID included in the received authentication information is retrieved from the storage device 62 . As a result, when the corresponding job ticket is retrieved, it is determined whether or not the user information of the retrieved job ticket corresponds with the user information included in the received authentication information. Then, if it is determined that the user information of the job ticket corresponds with the user information included in the received authentication information, it is determined that the user is eligible to use the print data. On the other hand, when the corresponding job ticket is not retrieved or when the user information of the job ticket does not correspond with the user information included in the authentication information, it is determined that the user is not eligible to use the print data.
[0541] Next, the process proceeds to step S 156 , and the result of the user authentication process is determined. If it is determined that the user is eligible to use the print data (Yes), the process proceeds to step S 158 . In step S 158 , it is determined whether or not the exclusive flag of the retrieved job ticket is set. If it is determined that the exclusive flag is not set (No), it is determined that the job ticket is not frozen, and then the process proceeds to step S 160 .
[0542] In step S 160 , the exclusive flag of the retrieved job ticket is set, and the process proceeds to step S 162 . In step S 162 , print data corresponding to the job ID of the retrieved job ticket is read out from the storage device 62 and the process proceeds to step S 164 . In step S 164 , print data read from the storage device 62 is transmitted to the network printer 200 , which is a source of the print request. After the series of steps are completed, the process returns to the initial step.
[0543] In step S 158 , when it is determined that the exclusive flag of the retrieved job ticket is set (Yes), it is determined that the job ticket is frozen. Next, the process proceeds to step S 166 , and a print prohibition notice is transmitted to the network printer 200 , which is a source of the print request. After the series of steps are completed, the process returns to the initial step.
[0544] In step S 156 , when it is determined that the user is not eligible to use the print data (No), the process proceeds to step S 166 .
[0545] Next, the print result receiving process will be described in detail with reference to FIG. 6 .
[0546] FIG. 6 is the flowchart showing the print result receiving process.
[0547] The print result receiving process is a process of receiving the print result from the network printer 200 . As shown in FIG. 6 , if the print result receiving process is executed by the CPU 50 , first, the process proceeds to step S 200 .
[0548] In step S 200 , it is determined whether or not the print completion notice including the job ID is received, and when it is determined that the print completion notice is received (Yes), the process proceeds to step S 202 . In step S 202 , the job ticket corresponding to the job ID included in the received print completion notice is retrieved from the storage device 62 , and the exclusive flag of the retrieved job ticket is reset. Next, the process proceeds to step S 204 , and the number of printable copies of the retrieved job ticket is decremented by ‘1’. Then, the process proceeds to step S 206 .
[0549] In step S 206 , it is determined whether or not the number of printable copies is ‘0’, and when it is determined that the number of printable copies is not ‘0’ (No), the process proceeds to step S 208 . In step S 208 , the utilization history information including the printed date and time is generated, and the process proceeds to step S 210 .
[0550] In step S 210 , the generated utilization history information is stored in the storage device 62 while being added to the retrieved job ticket, and the process proceeds to step S 212 .
[0551] In step S 212 , it is determined whether or not the print interruption notice including the job ID is received, and when it is determined that the print interruption notice is received (Yes), the process proceeds to step S 214 . In step S 214 , the job ticket corresponding to the job ID included in the received print completion notice is retrieved from the storage device 62 and the exclusive flag of the retrieved job ticket is reset. After the series of steps are completed, the process returns to the initial step.
[0552] In step S 212 , when it is determined that the print interruption notice is not received (No), the series of steps are completed, and then the process returns to the initial step.
[0553] In step S 206 , when it is determined that the number of printable copies is ‘0’ (Yes), the process proceeds to step S 216 . In step S 216 , print data corresponding to the job ID included in the received print completion notice is deleted from the storage device 62 and the process proceeds to step S 218 . In step S 218 , the job ticket corresponding to the job ID included in the received print completion notice is deleted from the storage device 62 , and the process proceeds to step S 212 .
[0554] In step S 200 , when it is determined that the print completion notice is not received (No), the process proceeds to step S 212 .
[0555] Next, the configuration of the network printer 200 will be described.
[0556] FIG. 7 is a block diagram illustrating the hardware configuration of the network printer 200 .
[0557] As shown in FIG. 7 , the network printer 200 has a CPU 70 that performs operations and controls the overall system on the basis of a control program, a ROM 72 that stores the control program of the CPU 70 or the like in a predetermined area in advance, a RAM 74 that stores data read from the ROM 72 or the like and operation results required for the operation process of the CPU 70 , and an I/F 78 that intermediates an input/output of data to/from peripheral devices. Those are communicably connected to one another by a bus 79 , which serves as a signal line for transmitting data.
[0558] To the I/F 78 , an operation panel 80 , serving as a human interface, such as a touch panel through which data can be inputted and displayed, a storage device 82 for storing data or tables in files, the card reader 20 , the printer engine 23 , all of which are peripheral devices, and signal lines for connection with the network 199 are connected.
[0559] The CPU 70 has a micro processing unit or the like, runs a predetermined program stored in a predetermined area of the ROM 72 , and executes a print control process and a print state monitoring process shown in flowcharts of FIGS. 8 and 9 according to the program in a time-division manner.
[0560] First, the print control process will be described in detail with reference to FIG. 8 .
[0561] FIG. 8 is the flowchart showing the print control process.
[0562] The print control process is a process of performing the print control of the printer engine 23 . As shown in FIG. 8 , if the print control process is executed by the CPU 70 , first, the process proceeds to step S 300 .
[0563] In step S 300 , it is determined whether or not the authentication card is inserted into the card reader 20 , and when it is determined that the authentication card is inserted (Yes), the process proceeds to step S 302 . If it is determined that the authentication card is not inserted (No), the process is on standby at step S 300 until the authentication card is inserted.
[0564] In step S 302 , the authentication information is read from the authentication card by the card reader 20 , and the process proceeds to step S 304 . In step S 304 , the print request is transmitted to the host terminal 100 , and the process proceeds to step S 306 . In step S 306 , the authentication information read from the authentication card is transmitted to the host terminal 100 , and the process proceeds to step S 308 .
[0565] In step S 308 , it is determined whether or not print data is received, and when it is determined that print data is received (Yes), the process proceeds to step S 310 . In step S 310 , a print process for performing the print control of the printer engine 23 is executed on the basis of received print data. After the series of steps are completed, the process returns to the initial step.
[0566] In step S 308 , when it is determined that print data is not received (No), the process proceeds to step S 312 . In step S 312 , it is determined whether or not the print prohibition notice is received, and when it is determined that the print prohibition notice is received (Yes), the process proceeds to step S 314 . In step S 314 , an error message is displayed on the operation panel 80 . After the series of steps are completed, the process returns to the initial step.
[0567] In step S 312 , when it is determined that the print prohibition notice is not received (No), the process proceeds to step S 308 .
[0568] Next, the print state monitoring process will be described in detail with reference to FIG. 9 .
[0569] FIG. 9 is the flowchart showing the print state monitoring process.
[0570] The print state monitoring process is a process of monitoring a printing state of the printer engine 23 . As shown in FIG. 9 , if the print state monitoring process is executed by the CPU 70 , first, the process proceeds to step S 350 .
[0571] In step S 350 , it is determined whether or not printing is completed by the printer engine 23 , and when it is determined that printing is completed (Yes), the process proceeds to step S 352 . In step S 352 , the print completion notice including the job ID of the print-completed print data is transmitted to the host terminal 100 and the process proceeds to step S 354 .
[0572] In step S 354 , it is determined whether or not the printer engine 23 has stopped printing, and when it is determined that the printer engine 23 has stopped printing (Yes), the process proceeds to step S 356 . In step S 356 , the print interruption notice including the job ID of the print-interrupted print data is transmitted to the host terminal 100 and the process proceeds to step S 358 . In step S 358 , print data being printed is removed and the process proceeds to step S 360 . In step S 360 , an error message is displayed on the operation panel 80 . After the series of steps are completed, the process returns to the initial step.
[0573] In step S 354 , when it is determined that the printer engine 23 has not stopped printing (No), the series of steps are completed, and then the process returns to the initial step.
[0574] In step S 350 , when it is determined that printing is not completed by the printer engine 23 (No), the process proceeds to step S 354 .
[0575] Next, the operation of the present embodiment will be described.
[0576] In the host terminal 100 , the user edits document data by using the documentation application or the like and requests to print it.
[0577] In the host terminal 100 , if printing is requested, print data and the job ticket are generated and print data and the job ticket generated are stored in the storage device 62 through steps to S 102 S 110 .
[0578] Next, in the host terminal 100 , the user inserts the authentication card into the card writer 66 so as to allow the job ID and the user information of his own to be written into the authentication card by the card writer 66 . Then, the user goes to one of the network printers 200 and inserts the authentication card into the card reader 20 .
[0579] In the network printer 200 , if the authentication card is inserted, the authentication information is read from the authentication card by the card reader 20 , and the read authentication information and the print request are transmitted to the host terminal 100 through steps S 302 to 5306 .
[0580] In the host terminal 100 , if the authentication information and the print request are received, the user authentication is performed on the basis of the received authentication information in step S 154 . As a result, if the user authentication is accomplished, through steps S 160 to 5164 , the job ticket is frozen, print data is read out from the storage device 62 , and print data read from the storage device 62 is transmitted to the network printer 200 , which is a source of the print request.
[0581] In the network printer 200 , if print data is received, through step S 310 , the print control is performed on the basis of received print data. Then, if printing is completed, through step S 352 , the print completion notice is transmitted to the host terminal 100 .
[0582] In the host terminal 100 , if the print completion notice is received, through steps S 202 and S 204 , the job ticket is not frozen (e.g., released) and the number of printable copies of the job ticket is decremented. As a result, if the number of printable copies becomes ‘0’, through steps S 208 and S 210 , the utilization history information is generated and the generated utilization history information is stored in the storage device 62 while being added to the job ticket.
[0583] Next, a case in which printing is interrupted will be described.
[0584] In the network printer 200 , if printing is interrupted due to a trouble, such as a paper jam or the like, through steps S 356 to S 360 , the print interruption notice is transmitted to the host terminal 100 , print data being printed is removed, and the error message is displayed.
[0585] In the host terminal 100 , if the print interruption notice is received, through step S 214 , the job ticket is not frozen.
[0586] Next, the user removes the authentication card from the card reader 20 in the network printer 200 , in which printing is interrupted. Then, the user goes to another network printer 200 and inserts the authentication card into the card reader 20 . Hereinafter, in another network printer 200 and the host terminal 100 , the same operation as described above is performed, and printing is performed by another network printer 200 . The number of printable copies is not decremented even when printing is interrupted. When printing is completed by another network printer 200 , the number of printable copies is decremented.
[0587] Next, a case will be described in which the authentication card is removed for the purpose of insertion into the card reader 20 of another network printer 200 while one of the network printers 200 is in a printing operation.
[0588] In the network printer 200 , if the authentication card is inserted, the authentication information is read from the authentication card by the card reader 20 , and the read authentication information and the print request are transmitted to the host terminal 100 .
[0589] In the host terminal 100 , if the authentication information and the print request are received, the user authentication is performed on the basis of the received authentication information. As a result, even when the user authentication is accomplished, since the job ticket is frozen during the print process, through step S 166 , the print prohibition notice is transmitted to the network printer 200 , which is a source of the print request.
[0590] In the network printer 200 , if the print prohibition notice is received, through step S 314 , the error message is displayed. That is, printing is not performed.
[0591] Moreover, when an authentication card in which incorrect authentication information is stored is used, in the host terminal 100 , the user authentication is not accomplished, and thus the print prohibition notice is transmitted to the network printer 200 , which is a source of the print request.
[0592] Further, when the number of printable copies becomes ‘0’, in the host terminal 100 , through steps S 216 and S 218 , print data and the job ticket are deleted.
[0593] In the present embodiment, in such a manner, when the user authentication is accomplished and it is determined that the job ticket is not frozen, the host terminal 100 provides print data to one of the plurality of network printers 200 , and freezes the job ticket until the print interruption notice or the print completion notice is received. When receiving the print completion notice, the host terminal 100 decrements the number of printable copies of the job ticket. Then, when it is determined that the number of printable copies is ‘0’, the host terminal 100 deletes print data and the job ticket. Further, the network printer 200 receives print data and performs the print control on the basis of received print data. When printing is interrupted, the network printer 200 removes print data being printed, and at the same time, transmits the print interruption notice to the host terminal 100 . When printing is completed, the network printer 200 transmits the print completion notice to the host terminal 100 .
[0594] In such a manner, when printing is completed, the number of printable copies is decremented, and thus, even when the network printer 200 stops printing due to a trouble, such as a paper jam or the like, the printed contents can be obtained from another network printer 200 . Therefore, only an authorized user can acquire the printed matter.
[0595] Further, since print data is provided to one of the network printers 200 , the possibility that the same printed contents are printed with the plurality of network printers 200 at one time can be reduced. In addition, even when the network printer 200 , in which printing is interrupted, is recovered, since print data being printed is removed, the possibility that the printed contents are printed with the recovered network printer 200 can be reduced. Therefore, the possibility that printing is performed in excess of the number of printable copies can be reduced, and thus secrecy of the printed contents can be protected, as compared with the related art.
[0596] In addition, since print data and the job ticket are unitarily managed by the host terminal 100 , the management of print data and the job ticket can be strictly performed, as compared with the case in which print data and the job ticket are managed by different apparatuses or the like.
[0597] In addition, in the present embodiment, when the user authentication is accomplished on the basis of the received authentication information and it is determined that the job ticket is not frozen, the host terminal 100 provides print data to one of the plurality of network printers 200 , the one being a source having transmitted the authentication information.
[0598] In such a manner, when the authentication card with correct authentication information is given to the network printer 200 in which printing is to be performed, the user can obtain the printed contents with the network printer 200 .
[0599] In addition, in the present embodiment, the host terminal 100 generates the utilization history information whenever print data is used.
[0600] In such a manner, it is possible to see how the print data has been used by referring to the utilization history information.
[0601] In addition, in the present embodiment, when it is determined that the number of printable copies is ‘0’, the host terminal 100 deletes print data and the job ticket.
[0602] In such a manner, the possibility that print data and the job ticket are incorrectly used can be reduced, and thus secrecy of the printed contents can be reliably protected.
[0603] In the first embodiment described above, the host terminal 100 corresponds to the device utilization apparatuses according to the first, second, fifth, seventh, sixteenth, seventeenth, twentieth to twenty-fifth, forty-first to forty-third, fifty-second, fifty-third, fifty-sixth, and fifty-eighth aspects, and the print data storage unit 11 and the storage device 62 correspond to the output data storage units according to the first, sixteenth, thirty-fourth, and fifty-second aspects. Further, the job ticket storage unit 12 and the storage device 62 correspond to the job ticket storage units according to the first, sixteenth, thirty-fourth, and fifty-second aspects, and the authentication information receiving unit 13 , the I/F 58 , and step S 152 correspond to the authentication information receiving unit of the fifth or twentieth aspect. In addition, step S 152 corresponds to the authentication information receiving step of the thirty-eighth or fifty-sixth aspect.
[0604] Further, in the first embodiment described above, the user authenticating unit 14 and step S 154 correspond to the authenticating units according to the fifth, sixth, twentieth, and twenty-first aspects, step S 154 corresponds to the authenticating steps according to the thirty-fourth, thirty-eighth, thirty-ninth, forty-second, forty-sixth, and forty-seventh aspects, and the print data utilization managing unit 15 , the I/F 58 , and steps S 156 to S 164 , S 200 to S 206 , and S 212 to S 218 correspond to the output data utilization managing units according to the first, second, fifth to seventh, fifteenth to seventeenth, twentieth to twenty-second, and thirty-third aspects. Further, steps S 156 to S 164 , S 200 to S 206 , and S 212 to S 218 correspond to the output data utilization managing steps according to the thirty-fourth, thirty-fifth, thirty-eighth to fortieth, fifty-first to fifty-third, fifty-sixth to fifty-eighth, and sixty-sixth aspects, and the utilization history information generating unit 16 and step S 208 correspond to the utilization history information generating unit of the seventh or twenty-second aspect.
[0605] Further, in the first embodiment described above, step S 208 corresponds to the utilization history information generating step of the fortieth or fifty-eighth aspect, and the network printer 200 corresponds to the network devices according to the first, second, fifth, sixteenth, twentieth, twenty-third to twenty-fifth, thirty-third, thirty-fourth, thirty-eighth, fifty-second, fifty-third, and fifty-sixth aspects. Further, the card reader 20 and step S 302 correspond to the authentication information acquiring unit of the fifth or twenty-fifth aspect, and step S 302 corresponds to the authentication information acquiring step of the forty-third or fifty-sixth aspect. In addition, the authentication information transmitting unit 21 , the I/F 78 , and step S 306 correspond to the authentication information transmitting unit of the fifth or twenty-fifth aspect.
[0606] Further, in the first embodiment described above, step S 306 corresponds to the authentication information transmitting step of the forty-third or fifty-sixth aspect, and the print data receiving unit 22 , the I/F 78 , and step S 308 correspond to the first or twenty-third aspect. Further, step S 308 corresponds to the output data receiving steps according to the forty-first, fifty-second, and fifty-third aspects. In addition, the print control unit 24 , the I/F 78 , and step S 310 correspond to the output control units according to the first, second, twenty-third, and twenty-fourth aspects, step S 310 corresponds to the output control steps according to the forty-first, forty-second, fifty-second, and fifty-third aspects, and print data corresponds to output data according to the first, second, fifth to seventh, fifteenth to seventeenth, twentieth to twenty-fourth, thirty-third to thirty-fifth, thirty-eighth to forty-second, fifty-first to fifty-third, fifty-sixth to or fifty-eighth, and sixty-sixth aspects.
[0607] Further, in the first embodiment described above, the print interruption notice corresponds to the output interruption notice according to the second, sixth, seventeenth, twenty-first, twenty-fourth, thirty-fifth, thirty-ninth, forty-second, fifty-third, and fifty-seventh aspects, and the print completion notice corresponds to the output completion notice according to the first, second, sixth, sixteenth, seventeenth, twenty-first, twenty-third, thirty-fourth, thirty-fifth, thirty-ninth, forty-first, fifty-second, fifty-third, and fifty-seventh aspects.
[0608] Hereinafter, a second embodiment of the invention will be described with reference to the drawings. FIGS. 10 to 15 are diagrams showing the second embodiment of an authentication output system, a device utilizing apparatus, a network device, an output data management program, an output control program, and an authentication output method according to the invention.
[0609] In the present embodiment, as shown in FIG. 10 , the authentication output system, the device utilizing apparatus, the network device, the output data management program, the output control program, and the authentication output method according to the invention are applied to a case in which printing is performed by a network printer 200 or 300 by using an authentication card. The present embodiment is different from the first embodiment in that print data and a job ticket are managed by the network printer 300 , not the host terminal 100 . Moreover, hereinafter, only different parts from the first embodiment will be described. The same parts as those in the first embodiment are represented by the same reference numerals and the descriptions thereof will be omitted.
[0610] First, the functional outline of a network system, to which the invention is applied, will be described with reference to FIG. 10 .
[0611] FIG. 10 is a functional block diagram illustrating the functional outline of the network system.
[0612] As shown in FIG. 10 , a host terminal 100 , a plurality of network printers 200 , and a network printer 300 that manages print data and the job ticket are connected to a network 199 .
[0613] The host terminal 100 has a print data generating unit 10 , and a print data transmitting unit 17 that transmits print data generated by the print data generating unit 10 to the network printer 300 .
[0614] The network printer 300 has a print data storage unit 30 , a print data receiving unit 31 that receives print data, a print data storage unit 32 that stores print data received by the print data receiving unit 31 in the print data storage unit 30 , an authentication information receiving unit 33 that receives authentication information, a card reader 34 that reads authentication information from an inserted authentication card, and a user authenticating unit 35 that performs user authentication on the basis of the authentication information received by the authentication information receiving unit 33 and the authentication information read by the card reader 34 .
[0615] In addition, the network printer 300 also has a job ticket storage unit 36 that stores the job ticket, a print data utilization managing unit 37 that manages the utilization of print data, a printer engine 38 that has a print head, a head driving unit, and other mechanisms required for printing, and a print control unit 39 that performs a print control of the printer engine 38 on the basis of print data of the print data storage unit 30 .
[0616] When the user authentication is accomplished by the user authenticating unit 35 on the basis of the authentication information received by the authentication information receiving unit 33 and when it is determined that the job ticket of the job ticket storage unit 36 is not frozen, the print data utilization managing unit 37 provides print data of the print data storage unit 30 to one of the plurality of network printers 200 , the one being a source having transmitted the authentication information, and freezes the job ticket until the print interruption notice or the print completion notice is received. Further, when the user authentication is accomplished by the user authenticating unit 35 on the basis of the authentication information read by the card reader 34 and when it is determined that the job ticket of the job ticket storage unit 36 is not frozen, the print data utilization managing unit 37 requests the print control unit 39 for printing and freezes until the printer engine 38 stops or completes the printing. Then, when the print completion notice is received or when printing is completed by the printer engine 38 , the number of printable copies of the job ticket is decremented, and when it is determined that the number of printable copies is ‘0’, the print data and the job ticket are deleted.
[0617] The print control unit 39 performs printing on the basis of print data of the print data storage unit 30 according to the print request from the print data utilization managing unit 37 .
[0618] In addition, the network printer 300 has a utilization history information generating unit 40 that generates utilization history information on the basis of the provision result of the print data utilization managing unit 37 and the utilization result.
[0619] The present embodiment is different from the first embodiment in that the network printer 200 communicates with the network printer 300 , not the host terminal 100 .
[0620] Next, the configuration of the host terminal 100 will be described.
[0621] The CPU 50 runs a predetermined program stored in a predetermined area of the ROM 52 and executes a print data generating process shown in a flowchart of FIG. 11 , instead of the print data generating process, the print request receiving process, and the print result receiving process shown in the flowcharts of FIGS. 3 , 5 and 6 , according to the program.
[0622] FIG. 11 is the flowchart showing the print data generating process.
[0623] As shown in FIG. 11 , if the print data generating process is executed by the CPU 50 , first, the process proceeds to step S 400 .
[0624] In step S 400 , it is determined whether or not printing is requested from a documentation application or the like. If it is determined that printing is requested (Yes), the process proceeds to step S 402 . On the other hand, if it is determined that printing is not requested (No), the process is on standby at step S 400 until printing is requested.
[0625] In step S 402 , a job ID is issued, and print data including the issued job ID is generated on the basis of document data edited by the documentation application or the like. Then, the process proceeds to step S 404 . In step S 404 , user information of a user who uses the host terminal 100 at present is acquired, and the process proceeds to step S 406 . Then, in step S 406 , a job ticket is generated on the basis of the issued job ID and the acquired user information, and the process proceeds to step S 408 .
[0626] In step S 408 , a storage request is transmitted to the network printer 300 , and the process proceeds to step S 410 . In step S 410 , generated print data is transmitted to the network printer 300 , and the process proceeds to step S 412 . In step S 412 , the generated job ticket is transmitted to the network printer 300 . After the series of steps are completed, the process returns to the initial step.
[0627] Next, the configuration of the network printer 300 will be described.
[0628] FIG. 12 is a block diagram illustrating the hardware configuration of the network printer 300 .
[0629] As shown in FIG. 12 , the network printer 300 has a CPU 90 that performs operations and controls the overall system on the basis of a control program, a ROM 92 that stores the control program of the CPU 90 or the like in a predetermined area in advance, a RAM 94 that stores data read from the ROM 92 or the like and operation results required for the operation process of the CPU 90 , and an I/F 98 that intermediates an input/output of data to/from peripheral devices. Those are communicably connected to one another by a bus 99 , which serves as a signal line for transmitting data.
[0630] To the I/F 98 , an operation panel 81 , serving as a human interface, such as a touch panel or the like, through which data can be inputted and displayed, a storage device 83 for storing data or tables in files, the card reader 34 , the printer engine 38 , all of which are peripheral devices, and signal lines for connection with the network 199 are connected.
[0631] The CPU 90 has a micro processing unit or the like, runs a predetermined program stored in a predetermined area of the ROM 92 , and executes a print data storing process, a print control process, and a print state monitoring process shown in flowcharts of FIGS. 13 to 15 according to the program in a time-division manner. Besides, the CPU 90 executes the same processes as the print request receiving process and the print result receiving process shown in the flowcharts of FIGS. 5 and 6 in a time-division manner.
[0632] First, the print data storing process will be described in detail with reference to FIG. 13 .
[0633] FIG. 13 is the flowchart showing the print data storing process.
[0634] The print data storing process is a process of storing print data from the host terminal 100 . As shown in FIG. 13 , if the print data storing process is executed by the CPU 90 , first, the process proceeds to step S 500 .
[0635] In step S 500 , it is determined whether or not a storage request is received, and when it is determined that the storage request is received (Yes), the process proceeds to step S 502 . On the other hand, when it is determined that the storage request is not received (No), the process is on standby at step S 500 until the storage request is received.
[0636] In step S 502 , print data is received, and the process proceeds to step S 504 . In step S 504 , received print data is stored in the storage device 83 , and the process proceeds to step S 506 . In step S 506 , the job ticket is received, and the process proceeds to step S 508 . In step S 508 , the received job ticket is stored in the storage device 83 . After the series of steps are completed, the process returns to the initial step.
[0637] Next, the print control process will be described in detail with reference to FIG. 14 .
[0638] FIG. 14 is the flowchart showing the print control process.
[0639] The print control process is a process of performing the print control of the printer engine 38 . As shown in FIG. 14 , if the print control process is executed by the CPU 90 , first, the process proceeds to step S 550 .
[0640] In step S 550 , it is determined whether or not the authentication card is inserted into the card reader 34 , and when it is determined that the authentication card is inserted (Yes), the process proceeds to step S 552 . On the other hand, when it is determined that the authentication card is not inserted (No), the process is on standby at step S 550 until the authentication card is inserted.
[0641] In step S 552 , the authentication information is read from the authentication card by the card reader 34 , and the process proceeds to step S 554 . In step S 554 , a user authentication process for performing the user authentication is executed on the basis of the read authentication information. In the user authentication process, the job ticket corresponding to the job ID included in the read authentication information is retrieved from the storage device 83 . As a result, when the corresponding job ticket is retrieved, it is determined whether or not the user information of the retrieved job ticket and the user information included in the read authentication information correspond with each other. When it is determined that the user information of the job ticket and the user information included in the authentication information correspond with each other, it is determined that the user is eligible to use the print data. On the other hand, when the corresponding job ticket is not retrieved or when the user information of the job ticket and the user information included in the authentication information correspond with each other, it is determined that the user is not eligible to use the print data.
[0642] Next, the process proceeds to step S 556 , the result of the user authentication process is determined. At this time, when it is determined that the user is eligible to use the print data (Yes), the process proceeds to step S 558 , and it is determined whether or not the exclusive flag of the retrieved job ticket is set. When it is determined that the exclusive flag is not set (No), it is determined that the job ticket is not frozen, and the process proceeds to step S 560 .
[0643] In step S 560 , the exclusive flag of the retrieved job ticket is set, and the process proceeds to step S 562 . In step S 562 , print data corresponding to the job ID of the retrieved job ticket is read out from the storage device 83 , and the process proceeds to step S 564 . In step S 564 , a print process for performing the print control of the printer engine 38 is executed on the basis of print data read out from the storage device 83 . After the series of steps are completed, the process returns to the initial step.
[0644] In step S 558 , when it is determined that the exclusive flag of the retrieved job ticket is set (Yes), it is determined that the job ticket is frozen, and the process proceeds to step S 566 . In step S 566 , an error message is displayed on the operation panel 81 . After the series of steps are completed, the process returns to the initial step.
[0645] In step S 556 , when it is determined that the user is not eligible to use the print data (No), the process proceeds to step S 566 .
[0646] Next, the print state monitoring process will be described in detail with reference to FIG. 15 .
[0647] FIG. 15 is the flowchart showing the print state monitoring process.
[0648] The print state monitoring process is a process of monitoring the print situation of the printer engine 38 . As shown in FIG. 15 , if the print state monitoring process is executed by the CPU 90 , first, the process proceeds to step S 600 .
[0649] In step S 600 , it is determined whether or not printing is completed by the printer engine 38 , and when it is determined that printing is completed (Yes), the process proceeds to step S 602 . In step S 602 , the job ticket corresponding to the job ID of the print-completed print data is retrieved from the storage device 83 , the exclusive flag of the retrieved job ticket is reset, and the process proceeds to step S 604 . In step S 604 , the number of printable copies of the retrieved job ticket is decremented by ‘1’, and the process proceeds to step S 606 .
[0650] In step S 606 , it is determined whether or not the number of printable copies is ‘0’, and when it is determined that the number of printable copies is not ‘0’ (No), the process proceeds to step S 608 . In step S 608 , the utilization history information including the printed date and time is generated, and the process proceeds to step S 610 . In step S 610 , the generated utilization history information is stored in the storage device 83 while being added to the retrieved job ticket, and the process proceeds to step S 612 .
[0651] In step S 612 , it is determined whether or not the printer engine 38 has stopped printing, and when it is determined that the printer engine 38 has stopped printing (Yes), the process proceeds to step S 614 . In step S 614 , the job ticket corresponding to the job ID of the print-interrupted print data is retrieved from the storage device 83 , the exclusive flag of the retrieved job ticket is reset, and the process proceeds to step S 616 . In step S 616 , an error message is displayed on the operation panel 81 . After the series of steps are completed, the process returns to the initial step.
[0652] In step S 612 , when it is determined that the printer engine 38 has not stopped printing (No), the series of steps are completed, and then the process returns to the initial step.
[0653] In step S 606 , when it is determined that the number of printable copies is ‘0’ (Yes), the process proceeds to step S 618 . In step S 618 , print data corresponding to the job ID of the print-completed print data is deleted from the storage device 83 , and the process proceeds to step S 620 . In step S 620 , the job ticket corresponding to the job ID of the print-completed print data is deleted from the storage device 83 , and the process proceeds to step S 612 .
[0654] In step S 600 , when it is determined that printing is not completed by the printer engine 38 (No), the process proceeds to step S 612 .
[0655] Next, the operation of the present embodiment will be described.
[0656] In the host terminal 100 , the user edits document data by using the documentation application or the like and requests to print it.
[0657] In the host terminal 100 , if printing is requested, through steps S 402 to S 412 , print data and the job ticket are generated and print data and the job ticket generated are transmitted to the network printer 300 , together with the storage request.
[0658] In the network printer 300 , when print data and the job ticket and the storage request are received, through steps 5504 and 5506 , print data and the job ticket received are stored in the storage device 83 .
[0659] First, a case in which printing is performed by the network printer 200 will be described.
[0660] The user goes to one of the network printers 200 and inserts the authentication card into the card reader 20 .
[0661] In the network printer 200 , if the authentication card is inserted, through steps S 302 to S 306 , the authentication information is read from the authentication card by the card reader 20 , and the read authentication information and the print request are transmitted to the network printer 300 .
[0662] In the network printer 300 , if the authentication information and the print request are received, through step S 154 , the user authentication is performed on the basis of the received authentication information. As a result, if the user authentication is accomplished, through steps S 160 to S 164 , the job ticket is frozen, print data is read out from the storage device 83 , and print data read from the storage device 83 is transmitted to the network printer 200 , which is a source of the print request.
[0663] In the network printer 200 , if print data is received, through step S 310 , the print control is performed on the basis of received print data. Then, if printing is completed, through step S 352 , the print completion notice is transmitted to the network printer 300 .
[0664] In the network printer 300 , if the print completion notice is received, through steps S 202 and S 204 , the job ticket is not frozen (e.g., released) and the number of printable copies is decremented. As a result, if the number of printable copies becomes ‘0’, through steps S 208 and S 210 , the utilization history information is generated and the generated utilization history information is stored in the storage device 83 while being added to the job ticket.
[0665] Next, a case in which printing is performed by the network printer 300 will be described.
[0666] The user goes to the network printer 300 and inserts the authentication card into the card reader 34 .
[0667] In the network printer 300 , if the authentication card is inserted, through steps S 552 and S 554 , the authentication information is read from the authentication card by the card reader 34 , and the user authentication is performed on the basis of the read authentication information. As a result, if the user authentication is accomplished, through steps S 560 to S 564 , the job ticket is frozen, print data is read out from the storage device 83 , and the print control is performed on the basis of read print data. Then, if printing is completed, through steps S 602 and S 604 , the job ticket is not frozen (e.g., released) and the number of printable copies of the job ticket is decremented. As a result, if the number of printable copies becomes ‘0’, through steps S 608 and S 610 , the utilization history information is generated and the generated utilization history information is stored in the storage device 83 while being added to the job ticket.
[0668] Next, a case in which the network printer 200 stops printing will be described.
[0669] In the network printer 200 , if printing is interrupted due to a trouble, such as a paper jam or the like, through steps S 356 to S 360 , the print interruption notice is transmitted to the network printer 300 , print data being printed is removed, and the error message is displayed.
[0670] In the network printer 300 , if the print interruption notice is received, through step S 214 , the job ticket is not frozen.
[0671] Next, the user removes the authentication card from the card reader 20 in the network printer 200 , in which printing has been interrupted. Then, the user goes to another network printer 200 and inserts the authentication card into the card reader 20 . Hereinafter, in another network printer 200 and the network printer 300 , the same operation as described above is performed, and printing is performed by another network printer 200 . The number of printable copies is not decremented even when printing is interrupted. When printing is completed by another network printer 200 , the number of printable copies is decremented.
[0672] Next, a case in which the network printer 300 stops printing will be described.
[0673] In the network printer 300 , if printing is interrupted due to a trouble, such as a paper jam or the like, through steps S 614 and S 616 , the job ticket is not frozen, and the error message is displayed.
[0674] Next, the user removes the authentication card from the card reader 34 in the network printer 300 . Then, the user goes to another network printer 200 and inserts the authentication card into the card reader 20 . Hereinafter, in another network printer 200 and the network printer 300 , the same operation as described above is performed, and printing is performed by another network printer 200 . The number of printable copies is not decremented even when printing is interrupted. When printing is completed by another network printer 200 , the number of printable copies is decremented.
[0675] Next, a case, in which while one of the network printers 200 or the network printer 300 is in a printing operation, the authentication card is removed to be inserted into the card reader 20 of another network printer 200 , will be described.
[0676] In the network printer 200 , if the authentication card is inserted, the authentication information is read from the authentication card by the card reader 20 , and the read authentication information and the print request are transmitted to the network printer 300 .
[0677] In the network printer 300 , if the authentication information and the print request are received, the user authentication is performed on the basis of the received authentication information. As a result, even when the user authentication is accomplished, since the job ticket is frozen during the print process, through step S 166 , the print prohibition notice is transmitted to the network printer 200 , which is a source of the print request.
[0678] In the network printer 200 , if the print prohibition notice is received, through step S 314 , the error message is displayed. That is, printing is not performed.
[0679] Next, a case, in which while one of the network printers 200 is in a printing operation, the authentication card is removed to be inserted into the card reader 34 of the network printer 300 , will be described.
[0680] In the network printer 300 , if the authentication card is inserted, the authentication information is read from the authentication card by the card reader 34 , and the user authentication is performed on the basis of the read authentication information. As a result, even when the user authentication is accomplished, since the job ticket is frozen during the print process, through step S 566 , the error message is displayed. That is, printing is not performed.
[0681] Moreover, when an authentication card in which incorrect authentication information is stored is used, in the network printer 300 , the user authentication is not accomplished, and thus the print prohibition notice is transmitted to the network printer 200 , which is a source of the print request, or the error message is displayed.
[0682] Further, when the number of printable copies becomes ‘0’, in the network printer 300 , through steps S 216 and S 218 or steps S 618 and S 620 , print data and the job ticket are deleted.
[0683] In the present embodiment, in such a manner, the host terminal 100 generates print data and transmits generated print data to the network printer 300 , and the network printer 300 receives print data and stores received print data in the storage device 83 . When the user authentication is accomplished and it is determined that the job ticket is not frozen, the network printer 300 provides print data to one of the plurality of network printers 200 , and freezes the job ticket until the print interruption notice or the print completion notice is received. Further, the network printer 300 performs the print control on the basis of print data of the storage device 83 , freezes the job ticket until printing is interrupted or completed, and when the print completion notice is received or when printing is completed, decrements the number of printable copies of the job ticket. Then, when it is determined that the number of printable copies is ‘0’, the network printer 200 deletes print data and the job ticket. Further, the network printer 200 receives print data and performs the print control on the basis of received print data. When printing is interrupted, the network printer 200 removes print data being printed, and at the same time, transmits the print interruption notice to the network printer 300 . When printing is completed, the network printer 200 transmits the print completion notice to the network printer 300 .
[0684] In such a manner, when printing is completed, the number of printable copies is decremented, and thus, even when any one of the network printers 200 and 300 stops printing due to the trouble, such as a paper jam or the like, the printed contents can be obtained from one of the other network printers 200 and 300 . Therefore, only an authorized user can obtain the printed matter.
[0685] Further, since print data is provided to the network printer 200 or print data is used by the network printer 300 , the possibility that the same printed contents are printed with the network printers 200 and 300 at one time can be reduced. In addition, even when the network printer 200 or 300 , in which printing is interrupted, is recovered, since print data being printed is removed, the possibility that the printed contents are printed with the recovered network printer 200 or 300 can be reduced. Therefore, the possibility that printing is performed in excess of the number of printable copies can be reduced, and thus secrecy of the printed contents can be protected, as compared with the related art.
[0686] In addition, since print data and the job ticket are unitarily managed by the network printer 300 , the management of print data and the job ticket can be strictly performed, as compared with the case in which print data and the job ticket are managed by different apparatuses or the like.
[0687] In addition, in the present embodiment, when the user authentication is accomplished on the basis of the received authentication information and when it is determined that the job ticket is not frozen, the network printer 300 provides print data to one of the plurality of network printers 200 , the one being a source having transmitted the authentication information. Further, when the user authentication is accomplished on the basis of the read authentication information and it is determined that the job ticket is not frozen, the network printer 300 performs the print control on the basis of print data of the storage device 83 .
[0688] In such a manner, when giving the authentication card with the correct authentication information recorded therein to the network printer 200 or 300 in which printing is to be performed, the user can obtain the printed contents with the network printer 200 or 300 .
[0689] In addition, in the present embodiment, the network printer 300 generates the utilization history information whenever print data is used.
[0690] In such a manner, it is possible to see how the print data has been used by referring to the utilization history information.
[0691] In addition, in the present embodiment, when it is determined that the number of printable copies is ‘0’, the network printer 300 deletes print data and the job ticket.
[0692] In such a manner, the possibility that print data and the job ticket are incorrectly used can be reduced, and thus secrecy of the printed contents can be protected more reliably.
[0693] In the second embodiment described above, the host terminal 100 corresponds to the device utilization apparatus of the eighth or fifty-ninth aspect, and the print data transmitting unit 17 , the I/F 58 , and step S 410 correspond to the output data transmitting unit of the eighth aspect. Further, step S 410 corresponds to the output data transmitting step of the fifty-ninth aspect. In addition, the network printer 300 corresponds to the first network devices according to the eighth, ninth, twelfth to fourteenth, fifty-ninth, sixtieth, and sixty-third to sixty-fifth aspects, and the print data storage unit 30 and the storage device 83 correspond to the output data storage units according to the eighth, twenty-sixth, forty-fourth, and fifty-ninth aspects.
[0694] Further, in the second embodiment described above, the job ticket storage unit 36 and the storage device 83 correspond to the job ticket storage units according to eighth, twenty-sixth, forty-fourth, and fifty-ninth aspects, and the print data receiving unit 31 , the I/F 98 , and step S 502 correspond to the first output data receiving unit of the eighth aspect or the output data receiving unit of the twenty-sixth aspect. Further, step S 502 corresponds to the first output data receiving step of the fifty-ninth aspect or the output data receiving step of the forty-fourth aspect, the print data storage unit 32 and step S 504 correspond to the output data holding unit of the eighth or twenty-sixth aspect, and step S 504 corresponds to the output data storing step of the forty-fourth or fifty-ninth aspect.
[0695] Further, in the second embodiment described above, the authentication information receiving unit 33 , the I/F 98 , and step S 152 correspond to the authentication information receiving units according to the twelfth, thirteenth, thirtieth, and thirty-first aspects, step S 152 corresponds to the authentication information receiving steps according to the forty-eighth, forty-ninth, sixty-third, and the sixty-fourth aspects, and the card reader and step S 552 correspond to the first authentication information acquiring unit of the twelfth or thirteenth aspect, or the authentication information acquiring unit of the thirtieth or thirty-first aspect. Further, step S 552 corresponds to the first authentication information acquiring step of the sixty-third or sixty-fourth aspect or corresponds to the authentication information acquiring step of the forty eighth or forty-ninth aspect, and the user authenticating unit 35 and steps S 154 and S 554 correspond to the authenticating units according to the twelfth, thirteenth, thirtieth, and thirty-first aspects.
[0696] Further, in the second embodiment described above, steps S 154 and S 554 correspond to the authenticating steps according to the forty-fourth, forty-eighth, forty-ninth, fifty-ninth, sixty-third, and sixty-fourth aspects, and the print data utilization managing unit 37 , the I/F 98 , and steps S 156 to S 164 , S 200 to S 206 , S 212 to S 218 , S 556 to S 562 , S 600 to S 606 , and S 612 to S 620 correspond to the output data utilization managing units according to eighth, ninth, twelfth to fifteenth, twenty-sixth, twenty-seventh, and thirtieth to thirty-third aspects. Further, steps S 156 to S 164 , S 200 to S 206 , S 212 to S 218 , S 556 to S 562 , S 600 to S 606 , and S 612 to S 620 correspond to the output data utilization managing steps according to the forty-fourth, forty-fifth, forty-eighth to fifty-first, fifty-ninth, sixtieth, sixty-third to sixty-sixth aspects.
[0697] Further, in the second embodiment described above, the print control unit 39 and step S 564 correspond to the first output control unit of the eighth or twelfth aspect or the output control unit of the twenty-sixth or thirtieth aspect, and step S 564 corresponds to the first output control step of the fifty-ninth or sixty-third aspect or the output control step of the forty-fourth or forty-eighth aspect. Further, the utilization history information generating unit 40 and steps S 208 and S 608 correspond to the utilization history information generating unit of the fourteenth or thirty-second aspect, steps S 208 and S 608 correspond to the utilization history information generating step of the fiftieth or sixty-fifth aspect, and the network printer 200 corresponds to the second network devices according to the eighth, ninth, twelfth, fifty-ninth, sixtieth, and sixty-third aspects.
[0698] Further, in the second embodiment described above, the card reader 20 and step S 302 correspond to the second authentication information acquiring unit of the twelfth aspect, step S 302 corresponds to the second authentication information acquiring step of the sixty-third aspect, and the authentication information transmitting unit 21 , the I/F 78 , and step S 306 correspond to the authentication information transmitting unit of the twelfth aspect. Further, step S 306 corresponds to the authentication information transmitting step of the sixty-third aspect, the print data receiving unit 22 , the I/F 78 , and step S 308 correspond to the second output data receiving unit of the eighth aspect, and step S 308 corresponds to the second output data receiving step of the forty-ninth or sixtieth aspect.
[0699] Further, in the second embodiment described above, the print control unit 24 , the I/F 78 , and step S 310 correspond to the second output control unit of the eighth or ninth aspect, step S 310 corresponds to the second output control step of the fifty-ninth or sixtieth aspect, and print data corresponds to output data according to eighth, ninth, twelfth to fifteenth, twenty-sixth, twenty-seventh, thirtieth to thirty-third, forty-fourth, forty-fifth, forty-eighth to fifty-first, fifty-ninth, sixtieth, sixty-third to sixty-sixth aspects. Further, the print interruption notice corresponds to the output interruption notice according to the ninth, thirteenth, twenty-seventh, thirty-first, forty-fifth, fifty-ninth, sixtieth, and sixty-fourth aspects, and the print completion notice corresponds to the output completion notice according to eighth, ninth, thirteenth, twenty-sixth, twenty-seventh, thirty-first, forty-fourth, forty-fifth, forty-ninth, fifty-ninth, sixtieth, and sixty-fourth aspects.
[0700] Moreover, in the first and second embodiments described above, the number of printable copies of the job ticket is decremented, and when the number of printable copies becomes ‘0’, print data and the job ticket are deleted. However, the invention is not limited thereto. For example, the number of printable copies and the number of printed copies may be specified in the job ticket, the number of printed copies of the job ticket may be incremented, and when the number of printed copies reaches the number of printable copies, print data and the job ticket may be deleted. Specifically, the job ticket is constituted as shown in FIG. 16 .
[0701] FIG. 16 is a view illustrating the data structure of the job ticket 400 .
[0702] As shown in FIG. 16 , the job ticket 400 includes a field 402 that stores a job ID, a field 404 that stores an exclusive flag, a field 406 that stores the number of printable copies, a field 412 that stores the number of printed copies, and a field 408 that stores user information.
[0703] In the example of FIGS. 16 , ‘8’, and ‘5’ are stored as the number of printable copies and the number of printed copies, respectively. This indicates that the number of printable copies is eight and print data of the job ID of ‘001’ has been already printed by five copies.
[0704] Further, in the first and second embodiments described above, the user information is specified in the job ticket and the user authentication is performed on the basis of the authentication information and the job ticket. However, the invention is not limited thereto. For example, any user may print, without the user authentication. In this case, the user information and the printed date and time as the utilization history information are preferably recorded. Specifically, the job ticket is constituted as shown in FIG. 17 .
[0705] FIG. 17 is a view illustrating the data structure of the job ticket 400 .
[0706] As shown in FIG. 17 , the job ticket 400 includes a field 402 that stores a job ID, a field 404 that stores an exclusive flag, a field 406 that stores the number of printable copies, and a field 412 that stores the number of printed copies. In addition, the job ticket 400 also includes a field 414 that stores the utilization history information whenever print data is used.
[0707] In the example of FIG. 17 , five records are stored as the utilization history information. This indicates that print data of the job ID of ‘001’ has been already printed by five copies. In this case, as the utilization history, the user information and the printed date and time are shown. Here, as the user information, for example, a host ID of the host terminal 100 and an IP address may be set, in addition to the user ID.
[0708] Further, in the first and second embodiments described above, after printing is interrupted or completed, the number of printable copies of the job ticket is decremented. However, the invention is not limited thereto. For example, before the job ticket is frozen, the number of printable copies of the job ticket may be decremented. Specifically, a job ticket updating process shown in a flowchart of FIG. 18 is executed.
[0709] FIG. 18 is the flowchart of the job ticket updating process.
[0710] As shown in FIG. 18 , if the job ticket updating process is executed by the CPU 50 or 90 , first, the process proceeds to step S 700 .
[0711] In step S 700 , the number of printable copies of the job ticket is decremented by ‘1’, and the process proceeds to step S 702 . In step S 702 , the job ticket is frozen, and the process proceeds to step S 704 . In step S 704 , it is determined whether or not printing has been interrupted, and when it is determined that the printing has been interrupted (No), the process proceeds to step S 706 .
[0712] In step S 706 , it is determined whether or not printing is completed, and when it is determined that printing is completed (Yes), the process proceeds to step S 708 . In step S 708 , the job ticket is not frozen, and the process proceeds to step S 710 . In step S 710 , it is determined whether or not the number of printable copies is ‘0’, and when it is determined that the number of printable copies is not ‘0’ (No), the series of steps are completed and then the process returns to the initial step.
[0713] In step S 710 , when it is determined that the number of printable copies is ‘0’ (Yes), the process proceeds to step S 712 . In step S 712 , print data is deleted, and the process proceeds to step S 714 . In step S 714 , the job ticket is deleted. After the series of steps are completed, the process returns to the initial step.
[0714] In step S 706 , when it is determined that printing is not completed (No), the process proceeds to step S 704 .
[0715] In step S 704 , when it is determined that printing has been interrupted (Yes), the process proceeds to step S 716 . In step S 716 , the job ticket is not frozen (i.e., released), and the process proceeds to step S 718 . In step S 718 , the number of printable copies of the job ticket is incremented by ‘1’. After the series of steps are completed, the process returns to the initial step.
[0716] In this case, steps S 700 to S 718 correspond to the output data utilization managing units according to third, fourth, tenth, eleventh, eighteenth, nineteenth, twenty-eighth, and twenty-ninth aspects or the output data utilization managing steps according to the thirty-sixth, thirty-seventh, forty-sixth, forty-seventh, fifty-fourth, fifty-fifth, sixty-first, and sixty-second aspects.
[0717] Further, in the first and second embodiments described above, the number of printable copies is specified in the job ticket. However, the invention is not limited thereto. For example, the number of printable pages may be specified in the job ticket and the number of printed pages may be restricted.
[0718] Further, in the first and second embodiments described above, the host terminal 100 is used, but the invention is not limited thereto. For example, instead of the host terminal 100 , a printer server may be used.
[0719] Further, in the first and second embodiments described above, the authentication information is read from the authentication card by the card reader 20 or 34 , but the invention is not limited thereto. For example, the authentication information may be inputted from the operation panel 80 or 81 . In this case, the card reader 20 or 34 does not need to be provided.
[0720] Further, in the first and second embodiments described above, the card reader 20 or 34 is integrally provided in the network printer 200 or 300 , but the invention is not limited thereto. For example, the card reader 20 or 34 may be separately provided from the network printer 200 or 300 . Specifically, a user authenticating device having the card reader 20 or 34 is communicably connected to the network printer 200 or 300 , and the network printer 200 or 300 inputs the authentication information by receiving the authentication information from the user authenticating device.
[0721] Further, in the first and second embodiments described above, in order to execute each of the processes shown in the flowcharts of FIGS. 3 , 5 , 6 , 8 , 9 , 11 , 13 to 15 , and 18 , the control program stored in the ROM 52 , 72 , or 92 in advance is executed, but the invention is not limited thereto. For example, programs indicating these procedures may be stored in a storage medium. Then, each program may be read in the RAM 54 , 74 , or 94 to be executed.
[0722] Here, as the storage medium, a semiconductor storage medium, such as the RAM, the ROM, or the like, a magnetic recordable storage medium, such as the FD, the HD, or the like, an optical readable storage medium, such as the CD, the CDV, the LC, the DVD, or the like, and a magnetic recordable/optical readable storage medium, such as the MO or the like may be used. Specifically, any storage media may be used as long as it is a computer readable storage medium, regardless of reading methods such as electronic, magnetic, or optical.
[0723] Further, in the first and second embodiments described above, the authentication output system, the device utilizing apparatus, the network device, the output data management program, the output control program, and the authentication output method according to the invention are applied to the case in which printing is performed by the network printer 200 or 300 by using the authentication card. However, the invention is not limited thereto, and, for example, the invention can be applied to other cases without departing from the subject matter of the invention. Instead of the network printer 200 or 300 , for example, the invention can be applied to a projector, a home gateway, a personal computer, a PDA (personal digital assistant), a network storage, an audio apparatus, a mobile phone, PHS (Registered Trademark) (personal handyphone system), a watch-type PDA, an STB (set top box), a POS (point of sale) terminal, a facsimile machine, a phone (including an IP phone or the like), and other output devices.
[0724] Next, a third embodiment of the invention will be described with reference to the drawings. FIG. 19 to are diagrams showing the third embodiment of an authentication output system, a device utilizing apparatus, a network device, an output data management program, an output control program, and an authentication output method according to the invention.
[0725] In the present embodiment, as shown in FIG. 19 , the authentication output system, the device utilizing apparatus, the network device, the output data management program, the output control program, and the authentication output method according to the invention are applied to a case in which printing is performed by a network printer 200 a by using an authentication card.
[0726] First, the functional outline of a network system, to which the invention is applied, will be described with reference to FIG. 19 .
[0727] FIG. 19 is a functional block diagram illustrating the functional outline of the network system.
[0728] As shown in FIG. 19 , a host terminal 100 a and a plurality of network printers 200 a are connected to a network 1999 .
[0729] The host terminal 100 a has a print data generating unit 10 a that generates print data, a print data transmitting unit 11 a that transmits print data generated by the print data generating unit 10 a to all the network printers 200 a , a job ticket storage unit 12 a that stores a job ticket specifying the number of printable copies, an authentication information receiving unit 13 a that receives authentication information, a user authenticating unit 14 a that performs user authentication on the basis of the authentication information received by the authentication information receiving unit 13 a , and a print data utilization managing unit 15 a that manages the utilization of print data.
[0730] When the user authentication is accomplished by the user authenticating unit 14 a and when it is determined that the job ticket of the job ticket storage unit 12 a is updatable, the print data utilization managing unit 15 a transmits a print enablement notice to one of the plurality of network printers 200 a , the one being a source having transmitted the authentication information, and prohibits the update of the job ticket until a print interruption notice or a print completion notice is received. When the print completion notice is received, the number of printable copies of the job ticket is decremented. Then, when it is determined that the number of printable copies is ‘0’, the print data utilization managing unit 15 a transmits a to all the network printers 200 a and simultaneously deletes the job ticket.
[0731] In addition, the host terminal 100 a also has a utilization history information generating unit 16 a that generates utilization history information on the basis of the transmission result of the print data utilization managing unit 15 a , the utilization history information indicating the utilization history of print data.
[0732] The network printer 200 a has a print data storage unit 20 a , a print data receiving unit 21 a that receives print data, a print data storage unit 22 a that stores print data received by the print data receiving unit 21 a in the print data storage unit 20 a , a card reader 23 a that reads the authentication information from an inserted authentication card, an authentication information transmitting unit 24 a that transmits the authentication information read by the card reader 23 a to the host terminal 100 a , a printer engine 25 a that has a print head, a head driving unit, and other mechanisms required for printing, and a print control unit 26 a that performs a print control of the printer engine 25 a on the basis of print data of the print data storage unit 20 a.
[0733] When the print enablement notice is received, the print control unit 26 a performs printing on the basis of print data of the print data storage unit 20 a . Further, when the printer engine 25 a stops printing, the print control unit 26 a removes print data being printed and transmits the print interruption notice to the host terminal 100 a . Further, when printing is completed by the printer engine 25 a , the print control unit 26 a transmits the print completion notice to the host terminal 100 a , and when the data deletion notice is received, the print control unit 26 a deletes the print data.
[0734] Next, the configuration of the host terminal 100 a will be described.
[0735] FIG. 20 is a block diagram illustrating the hardware configuration of the host terminal 100 a.
[0736] As shown in FIG. 20 , the host terminal 100 a has a CPU 50 a that performs operations and controls the overall system on the basis of a control program, a ROM 52 a that stores the control program of the CPU 50 a or the like in a predetermined area in advance, a RAM 54 a that stores data read from the ROM 52 a or the like and operation results required for the operation process of the CPU 50 a , and an I/F 58 a that intermediates an input/output of data to/from peripheral devices. Those are communicably connected to one another by a bus 59 a , which serves as a signal line for transmitting data.
[0737] To the I/F 58 a , an input device 60 a , serving as a human interface, such as a keyboard, a mouse, or the like, through which data can be inputted, a storage device 62 a that stores data or tables in files, a display device 64 a that displays an image on the basis of an image signal, a card writer 66 a that writes the authentication information into an inserted authentication card, all of which are peripheral devices, and signal line for connections with the network 199 a are connected.
[0738] The CPU 50 a has a micro processing unit or the like, runs a predetermined program stored in a predetermined area of the ROM 52 a , and executes a print data generating process, a print request receiving process, and a print result receiving process shown in flowcharts of FIGS. 21 , 23 and 24 according to the program in a time-division manner.
[0739] First, the print data generating process will be described in detail with reference to FIG. 21 .
[0740] FIG. 21 is the flowchart showing the print data generating process.
[0741] As shown in FIG. 21 , if the print data generating process is executed by the CPU 50 a , first, the process proceeds to step S 100 a.
[0742] In step S 100 a , it is determined whether or not printing is requested from a documentation application or the like. If it is determined that printing is requested (Yes), the process proceeds to step S 102 a . On the other hand, if it is determined that printing is not requested (No), the process is on standby at step S 100 a until printing is requested.
[0743] In step S 102 a , a job ID for uniquely identifying print data is issued, and print data including the issued job ID is generated on the basis of document data edited by the documentation application or the like. Then, the process proceeds to step S 104 a.
[0744] In step S 104 a , user information of a user who uses the host terminal 100 a at present is acquired, and the process proceeds to step S 106 a . Then, in step S 106 a , a job ticket is generated on the basis of the issued job ID and the acquired user information.
[0745] FIG. 22 is a view illustrating the data structure of the job ticket 400 a.
[0746] As shown in FIG. 22 , the job ticket 400 a includes a field 402 a that stores the job ID, a field 404 a that stores an exclusive flag indicating whether or not the job ticket 400 a is frozen, a field 406 a that stores the number of printable copies, and a field 408 a that stores the user information. In addition, the job ticket 400 a also has a field 410 a that stores the utilization history information whenever print data is used.
[0747] In the example of FIG. 22 , ‘001’, ‘0’, ‘3’, and ‘UserA’ are stored as the job ID, the exclusive flag, the number of printable copies, and the user information, respectively. This indicates that print data of the job ID of ‘001’ can be printed by a user of the user information of ‘UserA’, and the number of printable copies is three. Further, the exclusive flag is reset, which indicates that the job ticket is not frozen at present. Here, the number of printable copies may be optionally specified by the user or may be set to a predetermined value.
[0748] Further, five records are stored as the utilization history information. This indicates that print data of the job ID of ‘001’ has been already printed by five copies. In this case, as the utilization history, the printed date and time is shown.
[0749] Next, the process proceeds to step S 108 a , a storage request is transmitted to all the network printers 200 a , and the process proceeds to step S 110 a . In step S 110 a , generated print data is transmitted to all the network printers 200 a , and the process proceeds to step S 112 a . In step S 112 a , the generated job ticket is stored in the storage device 62 a . After the series of steps are completed, the process returns to the initial step.
[0750] Next, the print request receiving process will be described in detail with reference to FIG. 23 .
[0751] FIG. 23 is the flowchart showing the print request receiving process.
[0752] The print request receiving process is a process of receiving the print request from the network printer 200 a . As shown in FIG. 23 , if the print request receiving process is executed by the CPU 50 a , first, the process proceeds to step S 150 a.
[0753] In step S 150 a , it is determined whether or not the print request is received. If it is determined that the print request is received (Yes), the process proceeds to step S 152 a . On the other hand, if it is determined that the print request is not received (No), the process is on standby at step S 150 a until the print request is received.
[0754] In step S 152 a , the authentication information including the job ID and the user information is received, and the process proceeds to step S 154 a . In step S 154 a , a user authentication process for performing the user authentication on the basis of the received authentication information is executed. In the user authentication process, the job ticket corresponding to the job ID included in the received authentication information is retrieved from the storage device 62 a . As a result, when the corresponding job ticket is retrieved, it is determined whether or not the user information of the retrieved job ticket corresponds with the user information included in the received authentication information. Then, if it is determined that the user information of the job ticket corresponds with the user information included in the received authentication information, it is determined that the user is eligible to use the print data. On the other hand, when the corresponding job ticket is not retrieved or when it is determined that the user information of the job ticket does not correspond with the user information included in the authentication information, it is determined that the user is not eligible to use the print data.
[0755] Next, the process proceeds to step S 156 a , and the result of the user authentication process is determined. If it is determined that the user is eligible to use the print data (Yes), the process proceeds to step S 158 a . In step S 158 a , it is determined whether or not the exclusive flag of the retrieved jot ticket is set. If it is determined that the exclusive flag is not set (No), it is determined that the job ticket is not frozen, and then the process proceeds to step S 160 a.
[0756] In step S 160 a , the exclusive flag of the retrieved job ticket is set, and the process proceeds to step S 162 a . In step S 162 a , the print enablement notice is transmitted to the network printer 200 a which is a source of the print request. After the series of steps are completed, the process returns to the initial step.
[0757] In step S 158 a , when it is determined that the exclusive flag of the retrieved job ticket is set (Yes), it is determined that the job ticket is frozen. Next, the process proceeds to step S 164 a , and the print prohibition notice is transmitted to the network printer 200 a , which is a source of the print request. After the series of steps are completed, the process returns to the initial step.
[0758] In step S 156 a , when it is determined that the user is not eligible to use the print data (No), the process proceeds to step S 164 a.
[0759] Next, the print result receiving process will be described in detail with reference to FIG. 24 .
[0760] FIG. 24 is the flowchart showing the print result receiving process.
[0761] The print result receiving process is a process of receiving the print result from the network printer 200 a . As shown in FIG. 24 , if the print result receiving process is executed by the CPU 50 a , first, the process proceeds to step S 200 a.
[0762] In step S 200 a , it is determined whether or not the print completion notice including the job ID is received, and when it is determined that the print completion notice is received (Yes), the process proceeds to step S 202 a . In step S 202 a , the job ticket corresponding to the job ID included in the received print completion notice is retrieved from the storage device 62 a , and the exclusive flag of the retrieved job ticket is reset. Next, the process proceeds to step S 204 a , and the number of printable copies of the retrieved job ticket is decremented by ‘1’. Then, the process proceeds to step S 206 a.
[0763] In step S 206 a , it is determined whether or not the number of printable copies is ‘0’, and when it is determined that the number of printable copies is not ‘0’ (No), the process proceeds to step S 208 a . In step S 208 a , the utilization history information including the printed date and time is generated, and the process proceeds to step S 210 a . In step S 210 a , the generated utilization history information is stored in the storage device 62 a while being added to the retrieved job ticket, and the process proceeds to step S 212 a.
[0764] In step S 212 a , it is determined whether or not the print interruption notice including the job ID is received, and when it is determined that the print interruption notice is received (Yes), the process proceeds to step S 214 a . In step S 214 a , the job ticket corresponding to the job ID included in the received print completion notice is retrieved from the storage device 62 a and the exclusive flag of the retrieved job ticket is reset. After the series of steps are completed, the process returns to the initial step.
[0765] In step S 212 a , when it is determined that the print interruption notice is not received (No), the series of steps are completed, and then the process returns to the initial step.
[0766] In step S 206 a , when it is determined that the number of printable copies is ‘0’ (Yes), the process proceeds to step S 216 a . In step S 216 a , the data deletion notice including the job ID included in the received print completion notice is transmitted to all the network printers 200 a , and the process proceeds to step S 218 a . In step S 218 a , the job ticket corresponding to the job ID included in the received print completion notice is deleted from the storage device 62 a , and the process proceeds to step S 212 a.
[0767] In step S 200 a , when it is determined that the print completion notice is not received (No), the process proceeds to step S 212 a.
[0768] Next, the configuration of the network printer 200 a will be described.
[0769] FIG. 25 is a block diagram illustrating the hardware configuration of the network printer 200 a.
[0770] As shown in FIG. 25 , the network printer 200 a has a CPU 70 a that performs operations and controls the overall system on the basis of a control program, a ROM 72 a that stores the control program of the CPU 70 a or the like in a predetermined area in advance, a RAM 74 a that stores data read from the ROM 72 a or the like and operation results required for the operation process of the CPU 70 a , and an I/F 78 a that intermediates an input/output of data to/from peripheral devices. Those are communicably connected to one another by a bus 79 a , which serves as a signal line for transmitting data.
[0771] To the I/F 78 a , an operation panel 80 a , serving as a human interface, such as a touch panel or the like, through which data can be inputted and displayed, a storage device 82 a for storing data or tables in files, the card reader 23 a , the printer engine 25 a , all of which are peripheral devices, and signal lines for connection with the network 199 a are connected.
[0772] The CPU 70 a has a micro processing unit or the like, runs a predetermined program stored in a predetermined area of the ROM 72 a , and executes a data storage process, a print control process, a print state monitoring process, and a print data deletion process shown in flowcharts of FIGS. 26 to 29 according to the program in a time-division manner.
[0773] First, the print data storing process will be described in detail with reference to FIG. 26 .
[0774] FIG. 26 is the flowchart showing the print data storing process.
[0775] The print data storing process is a process of storing print data from the host terminal 100 a . As shown in FIG. 26 , if the print data storing process is executed by the CPU 70 a , first, the process proceeds to step S 300 a.
[0776] In step S 300 a , it is determined whether or not the storage request is received, and when it is determined that the storage request is received (Yes), the process proceeds to step S 302 a . On the other hand, when it is determined that the storage request is not received (No), the process is on standby at step S 300 a until the storage request is received.
[0777] In step S 302 a , print data is received, and the process proceeds to step S 304 a . In step S 304 a , received print data is stored in the storage device 82 a . After the series of steps are completed, the process returns to the initial step.
[0778] Next, the print control process will be described in detail with reference to FIG. 27 .
[0779] FIG. 27 is the flowchart showing the print control process.
[0780] The print control process is a process of performing the print control of the printer engine 25 a . As shown in FIG. 27 , if the print control process is executed by the CPU 70 a , first, the process proceeds to step S 350 a.
[0781] In step S 350 a , it is determined whether or not the authentication card is inserted into the card reader 23 a , and when it is determined that the authentication card is inserted (Yes), the process proceeds to step S 352 a . If it is determined that the authentication card is not inserted (No), the process in on standby at step S 350 a until the authentication card is inserted.
[0782] In step S 352 a , the authentication information is read from the authentication card by the card reader 23 a , and the process proceeds to step S 354 a . In step S 354 a , the print request is transmitted to the host terminal 100 a , and the process proceeds to step S 356 a . In step S 356 a , the read authentication information is transmitted to the host terminal 100 a , and the process proceeds to step S 358 a.
[0783] In step S 358 a , it is determined whether or not the print enablement notice is received, and when it is determined that the print enablement notice is received (Yes), the process proceeds to step S 360 a . In step S 360 a , print data corresponding to the job ID included in the read authentication information is read out from the storage device 82 a , and the process proceeds to step S 362 a . In step S 362 a , a print process for performing the print control of the printer engine 25 a is executed on the basis of read print data. After the series of steps are completed, the process returns to the initial step.
[0784] In step S 358 a , when it is determined that the print enablement notice is not received (No), the process proceeds to step S 364 a . In step S 364 a , it is determined whether or not the print prohibition notice is received, and when it is determined that the print prohibition notice is received (Yes), the process proceeds to step S 366 a . In step S 366 a , an error message is displayed on the operation panel 80 a . After the series of steps are completed, the process returns to the initial step.
[0785] In step S 364 a , when it is determined that the print prohibition notice is not received (No), the process proceeds to step S 358 a.
[0786] Next, the print state monitoring process will be described in detail with reference to FIG. 28 .
[0787] FIG. 28 is the flowchart showing the print state monitoring process.
[0788] The print state monitoring process is a process of monitoring the print situation of the printer engine 25 a . As shown in FIG. 28 , if the print state monitoring process is executed by the CPU 70 a , first, the process proceeds to step S 400 a.
[0789] In step S 400 a , it is determined whether or not printing is completed by the printer engine 25 a , and when it is determined that printing is completed (Yes), the process proceeds to step S 402 a . In step S 402 a , the print completion notice including the job ID of the print-completed print data is transmitted to the host terminal 100 a , and the process proceeds to step S 404 a.
[0790] In step S 404 a , it is determined whether or not the printer engine 25 a printing has been interrupted, and when it is determined that the printing has been interrupted (Yes), the process proceeds to step S 406 a . In step S 406 a , the print interruption notice including the job ID of the print-interrupted print data is transmitted to the host terminal 100 a , and the process proceeds to step S 408 a . In step S 408 a , print data being printed is removed and the process proceeds to step S 410 a . In step S 410 a , an error message is displayed on the operation panel 80 a . After the series of steps are completed, the process returns to the initial step.
[0791] In step S 404 a , when it is determined that the printer engine 25 a has not stopped printing (No), the series of steps are completed, and then the process returns to the initial step.
[0792] In step S 400 a , when it is determined that printing is not completed by the printer engine 25 a (No), the process proceeds to step S 404 a.
[0793] Next, the print data deletion process will be described in detail with reference to FIG. 29 .
[0794] FIG. 29 is the flowchart showing the print data deletion process.
[0795] As shown in FIG. 29 , if the print data deletion process is executed by the CPU 70 a , first, the process proceeds to step S 450 a.
[0796] In step S 450 a , it is determined whether or not the data deletion notice is received, and when it is determined that the data deletion notice is received (Yes), the process proceeds to step S 452 a . On the other hand, if it is determined that the data deletion notice is not received (No), the process is on standby at step S 450 a until the data deletion notice is received.
[0797] In step S 452 a , print data corresponding to the job ID included in the received data deletion notice is deleted from the storage device 82 a . After the series of steps are completed, the process returns to the initial step.
[0798] Next, the operation of the present embodiment will be described.
[0799] In the host terminal 100 a , the user edits document data by using the documentation application or the like and requests to print it.
[0800] In the host terminal 100 a , if printing is requested, through steps S 102 a to S 110 a , print data and the job ticket are generated, and generated print data is requested to store and simultaneously is transmitted to all the network printers 200 a . Further, through step S 112 a , the generated job ticket is stored in the storage device 62 a.
[0801] When print data and the storage request are received in the network printer 200 a , through step S 304 a , received print data is stored in the storage device 82 a.
[0802] Next, in the host terminal 100 a , the user inserts the authentication card into the card writer 66 a so as to allow the job ID and the user information of his own to be written into the authentication card by the card writer 66 a . Then, the user goes to one of the network printers 200 a and inserts the authentication card into the card reader 23 a.
[0803] In the network printer 200 a , if the authentication card is inserted, through steps S 352 a to S 356 a , the authentication information is read from the authentication card by the card reader 23 a , and the read authentication information and the print request are transmitted to the host terminal 100 a.
[0804] In the host terminal 100 a , if the authentication information and the print request are received, through step S 154 a , the user authentication is performed on the basis of the received authentication information. As a result, if the user authentication is accomplished, through steps S 160 a to S 162 a , the job ticket is frozen, the print enablement notice is transmitted to the network printer 200 a , which is a source of the print request.
[0805] In the network printer 200 a , if the print enablement notice is received, through steps S 360 a and S 362 a , print data is read out from the storage device 82 a , and the print control is performed on the basis of read print data. Then, if printing is completed, through step S 402 a , the print completion notice is transmitted to the host terminal 100 a.
[0806] In the host terminal 100 a , if the print completion notice is received, through steps S 202 a and S 204 a , the job ticket is not frozen (e.g., released) and the number of printable copies of the job ticket is decremented. As a result, if the number of printable copies becomes ‘0’, through steps S 208 a and S 210 a , the utilization history information is generated and the generated utilization history information is stored in the storage device 62 a while being added to the job ticket.
[0807] Next, a case in which printing is interrupted will be described.
[0808] In the network printer 200 a , if printing is interrupted due to a trouble, such as a paper jam or the like, through steps S 406 a to S 410 a , the print interruption notice is transmitted to the host terminal 100 a , print data being printed is removed, and the error message is displayed.
[0809] In the host terminal 100 a , if the print interruption notice is received, through step S 214 a , the job ticket is not frozen.
[0810] Next, the user removes the authentication card from the card reader 23 a in the network printer 200 a , in which printing has been interrupted. Then, the user goes to another network printer 200 a and inserts the authentication card into the card reader 23 a . Hereinafter, in another network printer 200 a and the host terminal 100 a , the same operation as described above is performed, and printing is performed by another network printer 200 a . The number of printable copies is not decremented even when printing is interrupted. When printing is completed by another network printer 200 a , the number of printable copies is decremented.
[0811] Next, a case, in which while one of the network printers 200 a is in a printing operation, the authentication card is removed to be inserted into the card reader 23 a of another network printer 200 a , will be described.
[0812] In the network printer 200 a , if the authentication card is inserted, the authentication information is read from the authentication card by the card reader 23 a , and the read authentication information and the print request are transmitted to the host terminal 100 a.
[0813] In the host terminal 100 a , if the authentication information and the print request are received, the user authentication is performed on the basis of the received authentication information. In this case, even when the user authentication is accomplished, since the job ticket is frozen during the print process, through step S 164 a , the print prohibition notice is transmitted to the network printer 200 a , which is a source of the print request.
[0814] In the network printer 200 a , if the print prohibition notice is received, through step S 366 a , the error message is displayed. That is, printing is not performed.
[0815] Moreover, when an authentication card in which incorrect authentication information is stored is used, in the host terminal 100 a , the user authentication is not accomplished, and thus the print prohibition notice is transmitted to the network printer 200 a , which is a source of the print request.
[0816] Further, when the number of printable copies becomes ‘0’, in the host terminal 100 a , through steps S 216 a and S 218 a , the data deletion notice is transmitted to all the network printers 200 a , and the job ticket is deleted.
[0817] In the network printer 200 a , if the data deletion notice is received, through step S 452 a , print data is deleted.
[0818] In the present embodiment, in such a manner, when print data is transmitted to all the network printers 200 a , the user authentication is accomplished, and it is determined that the job ticket is not frozen, the host terminal 100 a transmits the print enablement notice to one of the plurality of network printers 200 a , and freezes the job ticket until the print interruption notice or the print completion notice is received. When receiving the print completion notice, the host terminal 100 a decrements the number of printable copies of the job ticket. Then, when it is determined that the number of printable copies is ‘0’, the host terminal 100 a transmits the data deletion notice to all the network printers 200 a and deletes the job ticket. Further, the network printer 200 a receives print data and stores received print data in the storage device 82 a . When receiving the print enablement notice, the network printer 200 a performs printing on the basis of print data of the storage device 82 a . When printing is interrupted, the network printer 200 a removes print data being printed and simultaneously transmits the print interruption notice to the host terminal 100 a . When printing is completed, the network printer 200 a transmits the print completion notice to the host terminal 100 a . Further, when receiving the data deletion notice, the network printer 200 a deletes print data.
[0819] In such a manner, when printing is completed, the number of printable copies is decremented, and thus, even when the network printer 200 a stops printing due to the trouble, such as the paper jam or the like, the printed contents can be obtained from another network printer 200 a . Therefore, only an authorized user can obtain the printed matter.
[0820] Further, since the print enablement notice is transmitted to one of the network printers 200 a , the possibility that the same printed contents are printed with the plurality of network printers 200 a at one time can be reduced. In addition, even when the network printer 200 a , in which printing is interrupted, is recovered, since print data being printed is removed, the possibility that the printed contents are printed with the recovered network printer 200 a can be reduced. Therefore, the possibility that printing is performed in excess of the number of printable copies can be reduced, and thus secrecy of the printed contents can be protected, as compared with the related art.
[0821] In addition, since print data is stored in the respective network printers 200 a , even when the network printer 200 a stops printing due to a trouble, such as a paper jam or the like, printing can start with another network printer 200 a at relatively high speed.
[0822] In addition, in the present embodiment, when the user authentication is accomplished on the basis of the received authentication information and when it is determined that the job ticket is not frozen, the host terminal 100 a transmits the print enablement notice to one of the plurality of network printers 200 a , the one being a source having transmitted the authentication information.
[0823] In such a manner, when giving the authentication card with the correct authentication information recorded therein to the network printer 200 a in which printing is to be performed, the user can obtain the printed contents with that network printer 200 a.
[0824] In addition, in the present embodiment, the host terminal 100 a generates the utilization history information whenever print data is used.
[0825] In such a manner, it is possible to see how the print data has been used by referring to the utilization history information.
[0826] In addition, in the present embodiment, when it is determined that the number of printable copies is ‘0’, the host terminal 100 a transmits the data deletion notice to all the network printers 200 a and simultaneously deletes the job ticket. Further, when receiving the data deletion notice, the network printer 200 a deletes print data.
[0827] In such a manner, the possibility that print data and the job ticket are incorrectly used can be reduced, and thus secrecy of the printed contents can be protected more reliably.
[0828] In the third embodiment described above, the host terminal 100 a corresponds to the device utilization apparatuses according to the sixty-seventh, sixty-ninth, seventy-first, seventy-ninth, eighty-first to eighty-sixth, one-hundredth, one-hundred first, one-hundred ninth, one-hundred eleventh, and one-hundred thirteenth aspects, and the job ticket storage unit 12 a and the storage device 62 a correspond to the job ticket storage units according to sixty-seventh, seventy-ninth, ninety-fourth, and one-hundred ninth aspects. Further, the print data transmitting unit 11 a , the I/F 58 a , and step S 110 a correspond to the output data transmitting unit of the sixty-seventh or seventy-ninth aspect, and step S 110 a corresponds to the output data transmitting step of the ninety-fourth or one-hundred ninth aspect. In addition, the authentication information receiving unit 13 a , the I/F 58 a , and step S 152 a correspond to the authentication information receiving unit of the sixty-ninth or eighty-first aspect.
[0829] Further, in the third embodiment described above, step 152 a corresponds to the authentication information receiving step of the ninety-sixth or one-hundred eleventh aspect, the user authenticating unit 14 a and step S 154 a correspond to the authenticating units according to the sixty-ninth, seventieth, eighty-first, and eighty-second aspects, and step S 154 a corresponds to the authenticating steps according to the ninety-fourth, ninety-sixth, ninety-seventh, one-hundred ninth, one-hundred eleventh, and one-hundred twelfth aspects.
[0830] Further, the print data utilization managing unit 15 a , the I/F 58 a , and steps S 156 a to S 162 a , S 200 a to S 206 a , and S 212 a to S 218 a correspond to the output data utilization managing units according to the sixty-seventh, sixty-ninth to seventy-second, seventy-ninth, eighty-first to eighty-fourth aspects, and steps S 156 a to S 162 a , S 200 a to S 206 a , and S 212 a to S 218 a correspond to the output data utilization managing steps according to the ninety-fourth, ninety-sixth to ninety-ninth, one-hundred ninth, and one-hundred eleventh to one-hundred fourteenth aspects.
[0831] Further, in the third embodiment described above, the utilization history information generating unit 16 a and step S 208 a correspond to the utilization history information generating unit of the seventy-first or eighty-third aspect, step S 208 a corresponds to the utilization history information generating step of the ninety-eighth or one-hundred thirteenth aspect, and the network printer 200 a corresponds to the network devices according to the sixty-seventh, sixty-ninth, seventy-ninth, eighty-first, eighty-fifth to eighty-seventh, ninety-fourth, ninety-sixth, one-hundred ninth and one-hundred eleventh aspects. Further, the print data storage unit 20 a and the storage device 82 a correspond to the output data storage units according to sixty-seventh, eighty-fifth, one-hundredth, and one-hundred ninth aspects, and the print data receiving unit 21 a , the I/F 78 a , and step S 302 a corresponds to the output data receiving step of the sixty-seventh or eighty-fifth aspect.
[0832] Further, in the third embodiment described above, step S 302 a corresponds to the output data receiving step of the one-hundredth or one-hundred ninth aspect, the print data storage unit 22 a and step S 304 a correspond to the output data holding unit of the sixty-seventh or eighty-fifth aspect, and step S 304 a corresponds to the output data storing step of the one-hundredth or one-hundred ninth aspect. Further, the card reader 23 a and step S 352 a correspond to the authentication information acquiring unit of the sixty-ninth or eighty-sixth aspect, step S 352 a corresponds to the authentication information acquiring step of the one-hundred first or one-hundred eleventh aspect, and the authentication information transmitting unit 24 a , the I/F 78 a , and step S 356 a corresponds to the authentication information transmitting unit of the sixty-ninth or eighty-sixth aspect.
[0833] Further, in the third embodiment described above, step S 356 a corresponds to the authentication information transmitting step of the one-hundred first or one-hundred eleventh aspect, the print control unit 26 a , the I/F 78 a , and steps S 360 a and S 362 a correspond to the output control units according to the sixty-seventh, seventy-second, eighty-seventh, and the eighty-fifth aspects, and steps S 360 a and S 362 a correspond to the output control steps according to the one-hundredth, one-hundred second, one-hundred ninth, and one-hundred fourteenth aspects. Further, print data corresponds to output data according to the sixty-seventh, sixty-ninth to seventy-second, seventy-ninth, eighty-first to eighty-third, eighty-fifth, eighty-seventh, ninety-fourth, ninety-sixth to ninety-eighth, one-hundredth, one-hundred second, one-hundred ninth, and one-hundred eleventh to one-hundred fourteenth aspects, and the print interruption notice corresponds to the output interruption notice according to the sixty-seventh, seventieth, seventy-ninth, eighty-second, eighty-fifth, ninety-fourth, ninety-seventh, one-hundredth, one-hundred ninth, and one-hundred twelfth aspects.
[0834] Further, in the third embodiment described above, the print completion notice corresponds to the output completion notice according to the sixty-seventh, seventieth, seventy-ninth, eighty-second, eighty-fifth, ninety-fourth, ninety-seventh, one-hundredth, one-hundred ninth, one-hundred twelfth aspects, and the print enablement notice corresponds to the output enablement notice according to the sixty-seventh, sixty-ninth, seventieth, seventy-ninth, eighty-first, eighty-second, eighty-fifth, ninety-fourth, ninety-sixth, ninety-seventh, one-hundredth, one-hundred ninth, one-hundred eleventh, and one-hundred twelfth aspects. Further, the data deletion notice corresponds to the utilization prohibition notice according to the sixty-seventh, seventy-second, seventy-ninth, eighty-fourth, eighty-fifth, eighty-seventh, ninety-fourth, ninety-ninth, one-hundredth, one-hundred second, one-hundred ninth, and one-hundred fourteenth aspects.
[0835] Next, a fourth embodiment of the invention will be described with reference to the drawings. FIG. 30 to are diagrams showing the fourth embodiment of an authentication output system, a device utilizing apparatus, a network device, an output data management program, an output control program, and an authentication output method according to the invention.
[0836] In the present embodiment, as shown in FIG. 30 , the authentication output system, the device utilizing apparatus, the network device, the output data management program, the output control program, and the authentication output method according to the invention are applied to a case in which printing is performed by a network printer 200 a or 300 a by using an authentication card. The present embodiment is different from the third embodiment in that a job ticket is managed by the network printer 300 a , not the host terminal 100 a . Moreover, hereinafter, only different parts from the third embodiment will be described. The same parts as those in the third embodiment are represented by the same reference numerals and the descriptions thereof will be omitted.
[0837] First, the functional outline of a network system, to which the invention is applied, will be described with reference to FIG. 30 .
[0838] FIG. 30 is a functional block diagram illustrating the functional outline of the network system.
[0839] As shown in FIG. 30 , the host terminal 100 a , a plurality of network printers 200 a , and the network printer 300 a that manages the job ticket are connected to a network 199 a.
[0840] The host terminal 100 a has a print data generating unit 10 a and a print data transmitting unit 11 a.
[0841] The network printer 300 a has a print data storage unit 30 a , a print data receiving unit 31 a that receives print data, a print data storage unit 32 a that stores print data received by the print data receiving unit 31 a in the print data storage unit 30 a , an authentication information receiving unit 33 a that receives authentication information, a card reader 34 a that reads authentication information from an inserted authentication card, and a user authenticating unit 35 a that performs user authentication on the basis of the authentication information received by the authentication information receiving unit 33 a and the authentication information read by the card reader 34 a.
[0842] In addition, the network printer 300 a also has a job ticket storage unit 36 a that stores the job ticket, a print data utilization managing unit 37 a that manages the utilization of print data, a printer engine 38 a that has a print head, a head driving unit, and other mechanisms required for printing, and a print control unit 39 a that performs a print control of the printer engine 38 a on the basis of print data of the print data storage unit 30 a.
[0843] When the user authentication is accomplished by the user authenticating unit 35 a on the basis of the authentication information received by the authentication information receiving unit 33 a and when it is determined that the job ticket of the job ticket storage unit 36 a is not frozen, the print data utilization managing unit 37 a transmits the print enablement notice to one of the plurality of network printers 200 a , the one being a source having transmitted the authentication information, and freezes the job ticket until the print interruption notice or the print completion notice is received. Further, when the user authentication is accomplished by the user authenticating unit 35 a on the basis of the authentication information read by the card reader 34 a and when it is determined that the job ticket of the job ticket storage unit 36 a is not frozen, the print data utilization managing unit 37 a requests the print control unit 39 a for printing and freezes the job ticket until the printer engine 38 a stops or completes the printing. Then, when the print completion notice is received or when printing is completed by the printer engine 38 a , the print data utilization managing unit 37 a decrements the number of printable copies of the job ticket. Then, when it is determined that the number of printable copies is ‘0’, the print data utilization managing unit 37 a transmits the data deletion notice to all the network printers 200 a and deletes the print data and the job ticket.
[0844] The print control unit 39 a performs printing on the basis of print data of the print data storage unit 30 a according to the print request from the print data utilization managing unit 37 a.
[0845] The network printer 300 a also has a utilization history information generating unit 40 a that generates utilization history information on the basis of the transmission result and the utilization result of the print data utilization managing unit 37 a.
[0846] The present embodiment is different from the third embodiment in that the network printer 200 a communicates with the network printer 300 a , not the host terminal 100 a.
[0847] Next, the configuration of the host terminal 100 a will be described.
[0848] The CPU 50 a runs a predetermined program stored in a predetermined area of the ROM 52 a and executes a print data generating process shown in a flowchart of FIG. 31 , instead of the print data generating process, the print request receiving process, and the print result receiving process shown in the flowcharts of FIGS. 21 , 23 and 24 , according to the program.
[0849] FIG. 31 is the flowchart showing the print data generating process.
[0850] As shown in FIG. 31 , if the print data generating process is executed by the CPU 50 a , first, the process proceeds to step S 500 a.
[0851] In step S 500 a , it is determined whether or not printing is requested from a documentation application or the like. If it is determined that printing is requested (Yes), the process proceeds to step S 502 a . On the other hand, if it is determined that printing is not requested (No), the process is on standby at step S 500 a until printing is requested.
[0852] In step S 502 a , a job ID is issued, and print data including the issued job ID is generated on the basis of document data edited by the documentation application or the like. Then, the process proceeds to step S 504 a . In step S 504 a , user information of a user who uses the host terminal 100 a at present is acquired, and the process proceeds to step S 506 a . Then, in step S 506 a , a job ticket is generated on the basis of the issued job ID and the acquired user information, and the process proceeds to step S 508 a.
[0853] In step S 508 a , a storage request is transmitted to all the network printers 200 a and the network printer 300 a , and the process proceeds to step S 510 a . In step S 510 a , generated print data is transmitted to all the network printers 200 a and the network printer 300 a , and the process proceeds to step S 512 a . In step S 512 a , the generated job ticket is transmitted to the network printer 300 a . After the series of steps are completed, the process returns to the initial step.
[0854] Next, the configuration of the network printer 300 a will be described.
[0855] FIG. 32 is a block diagram illustrating the hardware configuration of the network printer 300 a.
[0856] As shown in FIG. 32 , the network printer 300 a has a CPU 90 a that performs operations and controls the overall system on the basis of a control program, a ROM 92 a that stores the control program of the CPU 90 a or the like in a predetermined area in advance, a RAM 94 a that stores data read from the ROM 92 a or the like and operation results required for the operation process of the CPU 90 a , and an I/F 98 a that intermediates an input/output of data to/from peripheral devices. Those are communicably connected to one another by a bus 99 a , which serves as a signal line for transmitting data.
[0857] To the I/F 98 a , an operation panel 81 a , serving as a human interface, such as a touch panel or the like, through which data can be inputted and displayed, a storage device 83 a for storing data or tables in files, the card reader 34 a , the printer engine 38 a , all of which are peripheral devices, and signal lines for connection with the network 199 a are connected.
[0858] The CPU 90 a has a micro processing unit or the like, runs a predetermined program stored in a predetermined area of the ROM 92 a , and executes a print data storing process, a print control process, and a print state monitoring process shown in flowcharts of FIGS. 33 to 35 according to the program in a time-division manner. Besides, the CPU 90 a executes the same processes as the print request receiving process and the print result receiving process shown in the flowcharts of FIG. 23 and in a time-division manner. However, in the print result receiving process, the step corresponding to step S 218 a becomes the step of deleting print data and the job ticket corresponding to the job ID included in the received print completion notice from the storage device 83 a.
[0859] First, the print data storing process will be described in detail with reference to FIG. 33 .
[0860] FIG. 33 is the flowchart showing the print data storing process.
[0861] The print data storing process is a process of storing print data from the host terminal 100 a . As shown in FIG. 33 , if the print data storing process is executed by the CPU 90 a , first, the process proceeds to step S 600 a.
[0862] In step S 600 a , it is determined whether or not the storage request is received, and when it is determined that the storage request is received (Yes), the process proceeds to step S 602 a . On the other hand, when it is determined that the storage request is not received (No), the process is on standby at step S 600 a until the storage request is received.
[0863] In step S 602 a , print data is received, and the process proceeds to step S 604 a . In step S 604 a , received print data is stored in the storage device 83 a , and the process proceeds to step S 606 a . In step S 606 a , the job ticket is received, and the process proceeds to step S 608 a . In step S 608 a , the received job ticket is stored in the storage device 83 a . After the series of steps are completed, the process returns to the initial step.
[0864] Next, the print control process will be described in detail with reference to FIG. 34 .
[0865] FIG. 34 is the flowchart showing the print control process.
[0866] The print control process is a process of performing the print control of the printer engine 38 a.
[0867] As shown in FIG. 34 , if the print control process is executed by the CPU 90 a , first, the process proceeds to step S 650 a.
[0868] In step S 650 a , it is determined whether or not the authentication card is inserted into the card reader 34 a , and when it is determined that the authentication card is inserted (Yes), the process proceeds to step S 652 a . On the other hand, when it is determined that the authentication card is not inserted (No), the process is on standby at step S 650 a until the authentication card is inserted.
[0869] In step S 652 a , the authentication information is read from the authentication card by the card reader 34 a , and the process proceeds to step S 654 a . In step S 654 a , a user authentication process for performing the user authentication is executed on the basis of the read authentication information. In the user authentication process, the job ticket corresponding to the job ID included in the read authentication information is retrieved from the storage device 83 a . As a result, when the corresponding job ticket is retrieved, it is determined whether or not the user information of the retrieved job ticket and the user information included in the read authentication information correspond with each other. When it is determined that the user information of the job ticket and the user information included in the authentication information correspond with each other, it is determined that the user is eligible to use the print data. On the other hand, when the corresponding job ticket is not retrieved or when the user information of the job ticket and the user information included in the authentication information correspond with each other, it is determined that the user is not eligible to use the print data.
[0870] Next, the process proceeds to step S 656 a , the result of the user authentication process is determined. At this time, when it is determined that the user is eligible to use the print data (Yes), the process proceeds to step S 658 a , and it is determined whether or not the exclusive flag of the retrieved job ticket is set. When it is determined that the exclusive flag is not set (No), it is determined that the job ticket is not frozen, and the process proceeds to step S 660 a.
[0871] In step S 660 a , the exclusive flag of the retrieved job ticket is set, and the process proceeds to step S 662 a . In step S 662 a , print data corresponding to the job ID of the retrieved job ticket is read out from the storage device 83 a , and the process proceeds to step S 664 a . In step S 664 a , a print process for performing the print control of the printer engine 38 a is executed on the basis of print data read out from the storage device 83 a . After the series of steps are completed, the process returns to the initial step.
[0872] In step S 658 a , when it is determined that the exclusive flag of the retrieved job ticket is set (Yes), it is determined that the job ticket is frozen, and the process proceeds to step S 666 a . In step S 666 a , an error message is displayed on the operation panel 81 a . After the series of steps are completed, the process returns to the initial step.
[0873] In step S 656 a , when it is determined that the user is not eligible to use the print data (No), the process proceeds to step S 666 a.
[0874] Next, the print state monitoring process will be described in detail with reference to FIG. 35 .
[0875] FIG. 35 is the flowchart showing the print state monitoring process.
[0876] The print state monitoring process is a process of monitoring the print situation of the printer engine 38 a . As shown in FIG. 35 , if the print state monitoring process is executed by the CPU 90 a , first, the process proceeds to step S 700 a.
[0877] In step S 700 a , it is determined whether or not printing is completed by the printer engine 38 a , and when it is determined that printing is completed (Yes), the process proceeds to step S 702 a . In step S 702 a , the job ticket corresponding to the job ID of the print-completed print data is retrieved from the storage device 83 a , the exclusive flag of the retrieved job ticket is reset, and the process proceeds to step S 704 a . In step S 704 a , the number of printable copies of the retrieved job ticket is decremented by ‘1’, and the process proceeds to step S 706 a.
[0878] In step S 706 a , it is determined whether or not the number of printable copies is ‘0’, and when it is determined that the number of printable copies is not ‘0’ (No), the process proceeds to step S 708 a . In step S 708 a , the utilization history information including the printed date and time is generated, and the process proceeds to step S 710 a . In step S 710 a , the generated utilization history information is stored in the storage device 83 a while being added to the retrieved job ticket, and the process proceeds to step S 712 a.
[0879] In step S 712 a , it is determined whether or not the printer engine 38 a has stopped printing, and when it is determined that the printer engine 38 a has stopped printing (Yes), the process proceeds to step S 714 a . In step S 714 a , the job ticket corresponding to the job ID of the print-interrupted print data is retrieved from the storage device 83 a , the exclusive flag of the retrieved job ticket is reset, and the process proceeds to step S 716 a . In step S 716 a , an error message is displayed on the operation panel 81 a . After the series of steps are completed, the process returns to the initial step.
[0880] In step S 712 a , when it is determined that the printer engine 38 a has not stopped printing (No), the series of steps are completed, and then the process returns to the initial step.
[0881] In step S 706 a , when it is determined that the number of printable copies is ‘0’ (Yes), the process proceeds to step S 718 a . In step S 718 a , the data deletion notice including the job ID of the print-completed print data is transmitted to all the network printers 200 a , and the process proceeds to step S 720 a . In step S 720 a , print data corresponding to the job ID of the print-completed print data is deleted from the storage device 83 a , and the process proceeds to step S 712 a.
[0882] In step S 700 a , when it is determined that printing is not completed by the printer engine 38 a (No), the process proceeds to step S 712 a.
[0883] Next, the operation of the present embodiment will be described.
[0884] In the host terminal 100 a , the user edits document data by using the documentation application or the like and requests to print it.
[0885] In the host terminal 100 a , if printing is requested, through steps S 502 a to S 512 a , print data and the job ticket are generated and generated print data and the storage request are transmitted to all the network printers 200 a , and simultaneously print data and the job ticket generated are transmitted to the network printer 300 a , together with the storage request.
[0886] In the network printer 200 a , when print data and the storage request are received, through step S 304 a , received print data is stored in the storage device 82 a.
[0887] In the network printer 300 a , when print data and the job ticket and the storage request are received, through steps S 604 a and S 606 a , print data and the job ticket received are stored in the storage device 83 a.
[0888] First, a case in which printing is performed by the network printer 200 a will be described.
[0889] The user goes to one of the network printers 200 a and inserts the authentication card into the card reader 23 a.
[0890] In the network printer 200 a , if the authentication card is inserted, through steps S 352 a to S 356 a , the authentication information is read from the authentication card by the card reader 23 a , and the read authentication information and the print request are transmitted to the network printer 300 a.
[0891] In the network printer 300 a , if the authentication information and the print request are received, through step S 154 a , the user authentication is performed on the basis of the received authentication information. As a result, if the user authentication is accomplished, through steps S 160 a and S 162 a , the job ticket is frozen and the print enablement notice is transmitted to the network printer 200 a , which is a source of the print request.
[0892] In the network printer 200 a , if the print enablement notice is received, through steps S 360 a and S 362 a , print data is read out from the storage device 82 a and the print control is performed on the basis of read print data. Then, if printing is completed, through step S 402 a , the print completion notice is transmitted to the network printer 300 a.
[0893] In the network printer 300 a , if the print completion notice is received, through steps S 202 a and S 204 a , the job ticket is not frozen (e.g., released) and the number of printable copies is decremented. As a result, if the number of printable copies of the job ticket becomes ‘0’, through steps S 208 a and S 210 a , the utilization history information is generated and the generated utilization history information is stored in the storage device 83 a while being added to the job ticket.
[0894] Next, a case in which printing is performed by the network printer 300 a will be described.
[0895] The user goes to the network printer 300 a and inserts the authentication card into the card reader 34 a.
[0896] In the network printer 300 a , if the authentication card is inserted, through steps S 652 a and S 654 a , the authentication information is read from the authentication card by the card reader 34 a , and the user authentication is performed on the basis of the read authentication information. As a result, if the user authentication is accomplished, through steps S 660 a to S 664 a , the job ticket is frozen, print data is read out from the storage device 83 a , and the print control is performed on the basis of read print data. Then, if printing is completed, through steps S 702 a and S 704 a , the job ticket is not frozen and the number of printable copies of the job ticket is decremented. As a result, if the number of printable copies becomes ‘0’, through steps S 708 a and S 710 a , the utilization history information is generated and the generated utilization history information is stored in the storage device 83 a while being added to the job ticket.
[0897] Next, a case in which the network printer 200 a stops printing will be described.
[0898] In the network printer 200 a , if printing is interrupted due to a trouble, such as a paper jam or the like, through steps S 406 a to S 410 a , the print interruption notice is transmitted to the network printer 300 a , print data being printed is removed, and the error message is displayed.
[0899] In the network printer 300 a , if the print interruption notice is received, through step S 214 a , the job ticket is not frozen (e.g., released).
[0900] Next, the user removes the authentication card from the card reader 23 a in the network printer 200 a , in which printing has been interrupted. Then, the user goes to another network printer 200 a and inserts the authentication card into the card reader 23 a . Hereinafter, in another network printer 200 a and the network printer 300 a , the same operation as described above is performed, and printing is performed by another network printer 200 a . The number of printable copies is not decremented even when printing is interrupted. When printing is completed by another network printer 200 a , the number of printable copies is decremented.
[0901] Next, a case in which the network printer 300 a stops printing will be described.
[0902] In the network printer 300 a , if printing is interrupted due to a trouble, such as a paper jam or the like, through steps S 714 a and S 716 a , the job ticket is not frozen (e.g., released) to display an error message.
[0903] Next, the user removes the authentication card from the card reader 34 a in the network printer 300 a . Then, the user goes to another network printer 200 a and inserts the authentication card into the card reader 23 a . Hereinafter, in another network printer 200 a and the network printer 300 a , the same operation as described above is performed, and printing is performed by another network printer 200 a . The number of printable copies is not decremented even when printing is interrupted. When printing is completed by another network printer 200 a , the number of printable copies is decremented.
[0904] Next, a case, in which while one of the network printers 200 a or the network printer 300 a is in a printing operation, the authentication card is removed to be inserted into the card reader 23 a of another network printer 200 a , will be described.
[0905] In the network printer 200 a , if the authentication card is inserted, the authentication information is read from the authentication card by the card reader 23 a , and the read authentication information and the print request are transmitted to the network printer 300 a.
[0906] In the network printer 300 a , if the authentication information and the print request are received, the user authentication is performed on the basis of the received authentication information. In this case, even when the user authentication is accomplished, since the job ticket is frozen during the print process, through step S 164 a , the print prohibition notice is transmitted to the network printer 200 a , which is a source of the print request.
[0907] In the network printer 200 a , if the print prohibition notice is received, through step S 366 a , the error message is displayed. That is, printing is not performed.
[0908] Next, a case, in which while one of the network printers 200 a is in a printing operation, the authentication card is removed to be inserted into the card reader 34 a of the network printer 300 a , will be described.
[0909] In the network printer 300 a , if the authentication card is inserted, the authentication information is read from the authentication card by the card reader 34 a , and the user authentication is performed on the basis of the read authentication information. In this case, even when the user authentication is accomplished, since the job ticket is frozen during the print process, through step S 666 a , the error message is displayed. That is, printing is not performed.
[0910] Moreover, when an authentication card in which incorrect authentication information is stored is used, in the network printer 300 a , the user authentication is not accomplished, and thus the print prohibition notice is transmitted to the network printer 200 a , which is a source of the print request, or the error message is displayed.
[0911] Further, when the number of printable copies becomes ‘0’, in the network printer 300 a , through steps S 216 a and S 218 a or steps S 718 a to S 722 a , the data deletion notice is transmitted to all the network printers 200 a , and print data and the job ticket are deleted.
[0912] In the network printer 200 a , if the data deletion notice is received, through step S 452 a , print data is deleted.
[0913] In the present embodiment, in such a manner, the host terminal 100 a generates print data and transmits generated print data to all the network printers 200 a and the network printer 300 a , and the network printer 300 a receives print data and stores received print data in the storage device 83 a . When the user authentication is accomplished and it is determined that the job ticket is not frozen, the network printer 300 a transmits the print enablement notice to one of the plurality of network printers 200 a , and freezes the job ticket until the print interruption notice or the print completion notice is received. Further, the network printer 300 a performs the print control on the basis of print data of the storage device 83 a , freezes the job ticket until printing is interrupted or completed, and when the print completion notice is received or when printing is completed, decrements the number of printable copies of the job ticket. Then, when it is determined that the number of printable copies is ‘0’, the network printer 300 a transmits the data deletion notice to all the network printers 200 a and simultaneously deletes print data and the job ticket. Further, the network printer 200 a receives print data and stores received print data in the storage device 82 a . Then, when receiving the print enablement notice, the network printer 200 a performs printing on the basis of print data of the storage device 82 a . When printing is interrupted, the network printer 200 a removes print data being printed and simultaneously transmits the print interruption notice to the network printer 300 a . When printing is completed, the network printer 200 a transmits the print completion notice to the network printer 300 a . In addition, when receiving the data deletion notice, the network printer 200 a deletes print data.
[0914] In such a manner, when printing is completed, the number of printable copies is decremented, and thus, even when any one of the network printers 200 a and 300 a stops printing due to a trouble, such as a paper jam or the like, the printed contents can be obtained from the other of the network printers 200 a and 300 a . Therefore, only an authorized user can acquire the printed matter.
[0915] Further, since the print enablement notice is transmitted to the network printer 200 a or print data is used by the network printer 300 a , the possibility that the same printed contents are printed with the network printers 200 a and 300 a at one time can be reduced. In addition, even when the network printer 200 a or 300 a , in which printing has been interrupted, is recovered, since print data being printed is removed, the possibility that the printed contents are printed with the recovered network printer 200 a or 300 a can be reduced. Therefore, the possibility that printing is performed in excess of the number of printable copies can be reduced, and thus secrecy of the printed contents can be protected, as compared with the related art.
[0916] In addition, since print data is stored in the respective network printers 200 a and the network printer 300 a , even when one of the network printers 200 a and 300 a stops printing due to a trouble, such as a paper jam or the like, printing can start with the other of the network printers 200 a and 300 a at relatively high speed.
[0917] In addition, in the present embodiment, when the user authentication is accomplished on the basis of the received authentication information and when it is determined that the job ticket is not frozen, the network printer 300 a transmits the print enablement notice to one of the plurality of network printers 200 a , the one being a source having transmitted the authentication information. Further, when the user authentication is accomplished on the basis of the read authentication information and it is determined that the job ticket is not frozen, the network printer 300 a performs the print control on the basis of print data of the storage device 83 a.
[0918] In such a manner, when giving the authentication card with the correct authentication information recorded therein to the network printer 200 a or 300 a in which printing is to be performed, the user can obtain the printed contents with the network printer 200 a or 300 a.
[0919] In addition, in the present embodiment, the network printer 300 a generates the utilization history information whenever print data is used.
[0920] In such a manner, it is possible to see how the print data has been used by referring to the utilization history information.
[0921] In addition, in the present embodiment, when it is determined that the number of printable copies is ‘0’, the network printer 300 a transmits the data deletion notice to all the network printers 200 a and simultaneously deletes print data and the job ticket. Further, when receiving the data deletion notice, the network printer 200 a deletes print data.
[0922] In such a manner, the possibility that print data and the job ticket are incorrectly used can be reduced, and thus secrecy of the printed contents can be protected more reliably.
[0923] In the fourth embodiment described above, the host terminal 100 a corresponds to the device utilization apparatus of the seventy-third or one-hundred fifteenth aspect, the print data transmitting unit 11 a , the I/F 58 a , and step S 510 a correspond to the output data transmitting unit of the seventy-third aspect, and step S 510 a corresponds to the output data transmitting step of the one-hundred fifteenth aspect. Further, the network printer 300 a corresponds to the first network devices according to the seventy-third, seventy-fifth to seventy-seventh, one-hundred fifteenth, and one-hundred seventeenth to one-hundred nineteenth aspects, and the print data storage unit 30 a and the storage device 83 a correspond to the first output data storage unit of the seventy-third or one-hundred fifteenth aspect or the output data storage units according to the eighty-eighth or one-hundred third aspect.
[0924] Further, in the fourth embodiment described above, the job ticket storage unit 36 a and the storage device 83 a correspond to the job ticket storage units according to the seventy-third, eighty-eighth, one-hundred third, and one-hundred fifteenth aspects, and the print data receiving unit 31 a , the I/F 98 a , and step S 602 a correspond to the first output data receiving unit of the seventy-third aspect or the output data receiving unit of the eighty-eighth aspect. Further, step S 602 a corresponds to the first output data receiving step of the one-hundred fifteenth aspect or the output data receiving step of the one-hundred third aspect, the print data holding unit 32 a and step S 604 a correspond to the first output data holding unit of the seventy-third aspect, or the output data holding unit of the eighty-eighth aspect.
[0925] Further, in the fourth embodiment described above, and step S 604 a corresponds to the first output data storing step of the one-hundred fifteenth aspect or the output data storing step of the one-hundred third aspect, and the authentication information receiving unit 33 a , the I/F 98 a , and step S 152 a correspond to the authentication information receiving units according to the seventy-fifth, seventy-sixth, ninetieth, and ninety-first aspects. Further, step S 152 a corresponds to the authentication information receiving steps according to the one-hundred fifth, one-hundred sixth, one-hundred seventeenth, and one-hundred eighteenth aspects, and the card reader 34 a and step S 652 a correspond to the first authentication information acquiring unit of the seventy-fifth or seventy-sixth aspect, or the authentication information acquiring unit of the ninetieth or ninety-first aspect.
[0926] Further, in the fourth embodiment described above, step S 652 a corresponds to the first authentication information acquiring step of the one-hundred seventeenth or one-hundred eighteenth aspect, or the authentication information acquiring step of the one-hundred fifth or one-hundred sixth aspect, and the user authenticating unit 35 a and steps S 154 a and S 654 a correspond to the authenticating units according to the seventy-fifth, seventy-sixth, ninetieth, and ninety-first aspects. Further, steps S 154 a and S 654 a correspond to the authenticating steps according to the one-hundred third, one-hundred fifth, one-hundred sixth, one-hundred fifteenth, one-hundred seventeenth, and one-hundred eighteenth aspects, the print data utilization managing unit 37 a , the I/F 98 a , and steps S 156 a to S 162 a , S 200 a to S 206 a , S 212 a to S 218 a , S 656 a to S 660 a , S 700 a to S 706 a , and S 712 a to S 722 a correspond to the output data utilization managing units according to the seventy-third, seventy-fifth to seventy-eighth, eighty-eighth, and ninetieth to ninety-third aspects.
[0927] Further, in the fourth embodiment described above, steps S 156 a to S 162 a , S 200 a to S 206 a , S 212 a to S 218 a , S 656 a to S 660 a , S 700 a to S 706 a , and S 712 a to S 722 a correspond to the output data utilization managing steps according to the one-hundred third, one-hundred fifth to one-hundred eighth, one-hundred fifteenth, and one-hundred seventeenth to one-hundred twentieth aspects. Further, the print control unit 39 a and steps S 662 a and S 664 a correspond to the first output control unit of the seventy-third or seventy-fifth aspect, or the output control unit of the eighty-eighth or ninetieth aspect, and steps S 662 a and S 664 a corresponds to the first output control step of the one-hundred fifteenth or one-hundred seventeenth aspect or the output control step of the one-hundred third or one-hundred fifth aspect.
[0928] Further, in the fourth embodiment described above, the utilization history information generating unit 40 a and steps S 208 a and S 708 a correspond to the utilization history information generating unit of the seventy-seventh or ninety-second aspect, steps S 208 a and S 708 a correspond to the utilization history information generating step of the one-hundred seventh or one-hundred nineteenth aspect, and the network printer 200 a corresponds to the second network devices according to the seventy-third, seventy-fifth, one-hundred fifteenth, and one-hundred seventeenth aspects. Further, the print data storage unit 20 a and the storage device 82 a correspond to the second output data storage unit of the seventy-third or one-hundred fifteenth aspect, the print data receiving unit 21 a , the I/F 78 a , and step S 302 a correspond to the second output data receiving unit of the seventy-third aspect, and step 302 a corresponds to the second output data receiving step of the one-hundred fifteenth aspect.
[0929] Further, in the fourth embodiment described above, the print data storage unit 22 a and step S 304 a correspond to the second output data holding unit of the seventy-third aspect, step S 304 a corresponds to the second output data storing step of the one-hundred fifteenth aspect, and the card reader 23 a and step S 352 a correspond to the second authentication information acquiring unit of the seventy-fifth aspect. Further, step S 352 a corresponds to the second authentication information acquiring step of the one-hundred seventeenth aspect, the authentication information transmitting unit 24 a , the I/F 78 a , and step S 356 a correspond to the authentication information transmitting unit of the seventy-fifth aspect, and step S 356 a corresponds to the authentication information transmitting step of the one-hundred seventeenth aspect.
[0930] Further, in the fourth embodiment described above, the print control unit 26 a , the I/F 78 a , and steps S 360 a and S 362 a correspond to the second output control unit of the seventy-third or seventy-eighth aspect, steps S 360 a and S 362 a correspond to the second output control step of the one-hundred fifteenth or one-hundred twentieth aspect, and print data corresponds to output data according to the seventy-third, seventy-fifth to seventy-eighth, eighty-eighth, ninetieth to ninety-third, one-hundred third, one-hundred fifth to one-hundred eighth, one-hundred fifteenth, and one-hundred seventeenth to one-hundred twentieth aspects. Further, the print interruption notice corresponds to the output interruption notice according to the seventy-third, seventy-sixth, eighty-eighth, ninety-first, one-hundred third, one-hundred sixth, one-hundred fifteenth, and one-hundred eighteenth aspects, the print completion notice corresponds to the output completion notice according to the seventy-third, seventy-sixth, eighty-eighth, ninety-first, one-hundred third, one-hundred sixth, one-hundred fifteenth, and one-hundred eighteenth aspects, and the print enablement notice corresponds to the output enablement notice according to the seventy-third, seventy-fifth, seventy-sixth, eighty-eighth, ninetieth, ninety-first, one-hundred third, one-hundred fifth, one-hundred sixth, one-hundred fifteenth, one-hundred seventeenth, and one-hundred eighteenth aspects.
[0931] Further, in the fourth embodiment described above, the data deletion notice corresponds to the utilization prohibition notice according to the seventy-third, seventy-eighth, eighty-eighth, ninety-third, one-hundred third, one-hundred eighth, one-hundred fifteenth, and one-hundred twentieth aspects.
[0932] Moreover, in the third and fourth embodiments described above, the number of printable copies of the job ticket is decremented, and when the number of printable copies becomes ‘0’, print data and the job ticket are deleted. However, the invention is not limited thereto. For example, the number of printable copies and the number of printed copies may be specified in the job ticket, the number of printed copies of the job ticket may be incremented, and when the number of printed copies reaches the number of printable copies, print data and the job ticket may be deleted. Specifically, the job ticket is constituted as shown in FIG. 36 .
[0933] FIG. 36 is a view illustrating the data structure of the job ticket 400 a.
[0934] As shown in FIG. 36 , the job ticket 400 a includes a field 402 a that stores the job ID, a field 404 a that stores the exclusive flag, a field 406 a that stores the number of printable copies, a field 412 a that stores the number of printed copies, and a field 408 a that stores the user information.
[0935] In the example of FIG. 36 , ‘8’ and ‘5’ are stored as the number of printable copies and the number of printed copies, respectively. This indicates that the number of printable copies is eight and print data of the job ID of ‘001’ has been already printed by five copies.
[0936] Further, in the third and fourth embodiments described above, the user information is specified in the job ticket and the user authentication is performed on the basis of the authentication information and the job ticket. However, the invention is not limited thereto. For example, any user may print, without performing the user authentication. In this case, the user information and the printed date and time as the utilization history information are preferably recorded. Specifically, the job ticket is constituted as shown in FIG. 37 .
[0937] FIG. 37 is a view illustrating the data structure of the job ticket 400 a.
[0938] As shown in FIG. 37 , the job ticket 400 a includes the field 402 a that stores the job ID, the field 404 a that stores the exclusive flag, the field 406 a that stores the number of printable copies, and the field 412 a that stores the number of printed copies. In addition, the job ticket 400 a also includes a field 414 a that stores the utilization history information whenever print data is used.
[0939] In the example of FIG. 37 , five records are stored as the utilization history information. This indicates that print data of the job ID of ‘001’ has been already printed by five copies. In this case, as the utilization history, the user information and the printed date and time are shown. Here, as the user information, for example, a host ID of the host terminal 100 a and an IP address may be set, in addition to the user ID.
[0940] Further, in the third and fourth embodiments described above, after printing is interrupted or completed, the number of printable copies of the job ticket is decremented. However, the invention is not limited thereto. For example, before the job ticket is frozen, the number of printable copies of the job ticket may be decremented. Specifically, a job ticket updating process shown in a flowchart of FIG. 38 is executed.
[0941] FIG. 38 is the flowchart of the job ticket updating process.
[0942] As shown in FIG. 38 , if the job ticket updating process is executed by the CPU 50 a or 90 a , first, the process proceeds to step S 800 a.
[0943] In step S 800 a , the number of printable copies of the job ticket is decremented by ‘1’, and the process proceeds to step S 802 a . In step S 802 a , the job ticket is frozen, and the process proceeds to step S 804 a . In step S 804 a , it is determined whether or not printing has been interrupted, and when it is determined that the printing has not been interrupted (No), the process proceeds to step S 806 a.
[0944] In step S 806 a , it is determined whether or not printing is completed, and when it is determined that printing is completed (Yes), the process proceeds to step S 808 a . In step S 808 a , the job ticket is not frozen (e.g., released), and the process proceeds to step S 810 a . In step S 810 a , it is determined whether or not the number of printable copies is ‘0’, and when it is determined that the number of printable copies is not ‘0’ (No), the series of steps are completed and then the process returns to the initial step.
[0945] In step S 810 a , when it is determined that the number of printable copies is ‘0’ (Yes), the process proceeds to step S 812 a . In step S 812 a , print data is deleted, and the process proceeds to step S 814 a . In step S 814 a , the job ticket is deleted. After the series of steps are completed, the process returns to the initial step.
[0946] In step S 806 a , when it is determined that printing is not completed (No), the process proceeds to step S 804 a.
[0947] In step S 804 a , when it is determined that printing has been interrupted (Yes), the process proceeds to step S 816 a . In step S 816 a , the job ticket is not frozen (e.g., released), and the process proceeds to step S 818 a . In step S 818 a , the number of printable copies of the job ticket is incremented by ‘1’. After the series of steps are completed, the process returns to the initial step.
[0948] In this case, steps S 800 a to S 818 a correspond to the output data utilization managing units according to the sixty-eighth, seventy-fourth, eightieth, and eighty-ninth aspects or the output data utilization managing steps according to the ninety-fifth, one-hundred fourth, one-hundred tenth, and one-hundred sixteenth aspects.
[0949] Further, in the third and fourth embodiments described above, the number of printable copies is specified in the job ticket to limit the number of printable copies. However, the invention is not limited thereto. For example, the number of printable pages may be specified in the job ticket and the number of printed pages may be restricted.
[0950] Further, in the third and fourth embodiments described above, the host terminal 100 a is used, but the invention is not limited thereto. For example, instead of the host terminal 100 a , a printer server may be used.
[0951] Further, in the third and fourth embodiments described above, the authentication information is read from the authentication card by the card reader 23 a or 34 a , but the invention is not limited thereto. For example, the authentication information may be inputted from the operation panel 80 a or 81 a . In this case, the card reader 23 a or 34 a does not need to be provided.
[0952] Further, in the third and fourth embodiments described above, the card reader 23 a or 34 a is integrally provided in the network printer 200 a or 300 a , but the invention is not limited thereto. For example, the card reader 23 a or 34 a may be separately provided from the network printer 200 a or 300 a . Specifically, a user authenticating device having the card reader 23 a or 34 a is communicably connected to the network printer 200 a or 300 a , and the network printer 200 a or 300 a inputs the authentication information by receiving the authentication information from the user authenticating device.
[0953] Further, in the third and fourth embodiments described above, in order to execute each of the processes shown in the flowcharts of FIGS. 21 , 23 , 24 , 26 to 29 , 31 , 33 to 35 , and 38 , the control program stored in the ROM 52 a , 72 a , or 92 a in advance is executed, but the invention is not limited thereto. For example, programs indicating these procedures may be stored in a storage medium. Then, each program may be read in the RAM 54 a , 74 a , or 94 a to be executed.
[0954] Here, as the storage medium, a semiconductor storage medium, such as the RAM, the ROM, or the like, a magnetic recordable storage medium, such as the FD, the HD, or the like, an optical readable storage medium, such as the CD, the CDV, the LD, the DVD, or the like, and a magnetic recordable/optical readable storage medium, such as the MO or the like may be used. Specifically, any storage medium may be used as long as it is a computer readable storage medium, regardless of reading methods such as electronic, magnetic, or optical.
[0955] Further, in the third and fourth embodiments described above, the authentication output system, the device utilizing apparatus, the network device, the output data management program, the output control program, and the authentication output method according to the invention are applied to the case in which printing is performed by the network printer 200 a or 300 a by using the authentication card. However, the invention is not limited thereto, and, for example, the application to other cases can be made without departing from the subject matter of the invention. Instead of the network printer 200 a or 300 a , for example, the invention can be applied to a projector, a home gateway, a personal computer, a PDA, a network storage, an audio apparatus, a mobile phone, PHS, a watch-type PDA, a STB, a POS terminal, a facsimile machine, a phone (including an IP phone or the like), and other output devices.
[0956] Next, a fifth embodiment of the invention will be described with reference to the accompanying drawings. FIGS. 39 to 53 are views illustrating a fifth embodiment of an output system, a network device, and an output method according to the invention.
[0957] In the present embodiment, as shown in FIG. 39 , the output system, the network device, and the output method according to the invention are applied to a case in which printing is performed by a network printer 200 b or 300 b by using an authentication card.
[0958] First, a functional outline of a network system to which the invention is applied will be described with reference to FIG. 39 .
[0959] FIG. 39 is a block diagram illustrating the functional outline of the network system.
[0960] As shown in FIG. 39 , a host terminal 100 b , a network printer 200 b for controlling a job ticket specifying the number of printable copies, and a plurality of network printers 300 b are connected to a network 199 b.
[0961] The host terminal 100 b includes a print data generating unit 10 b for generating print data, a print data holding unit 11 b for storing the print data generated by the print data generating unit 10 b , a print data supplying unit 12 b for supplying the print data of the print data holding unit 11 b to the network printer 200 b according to the request from the network printer 200 b , and a data deleting unit 13 b for deleting the print data of the print data holding unit 11 b according to a data deletion notice from the network printer 200 b.
[0962] The network printer 200 b includes a job ticket holding unit 20 b for storing the job ticket, an authentication information receiving unit 21 b for receiving the authentication information, a card reader 22 b for reading out the authentication information from an inserted authentication card, a user authenticating unit 23 b for performing a user authentication on the basis of the authentication information received from the authentication information receiving unit 21 b and the authentication information read from the card reader 22 b.
[0963] Also, the network printer 200 b further includes a print data utilization managing unit 24 b for managing the use of the print data, a printer engine 25 b composed of a print head, a head driving unit, and other mechanism necessary for printing, and a print control unit 26 b for controlling the printing of the print engine 25 b on the basis of the print data.
[0964] When the print data utilization managing unit 24 b determines that the user authentication from the user authenticating unit 23 b is accomplished on the basis of the authentication information received from the authentication information receiving unit 21 b and the job ticket of the job ticket holding unit 20 b is not frozen, the print data utilization managing unit 24 b acquires the print data from the host terminal 100 b to transmit the acquired print data to one of the plurality of network printers 300 b , the one being a source from which the authentication information has been transmitted, and does not freeze the job ticket until it receives a print interruption notice or a print completion notice. Further, when the print data utilization managing unit 24 b determines that the user authentication from the user authenticating unit 23 b is accomplished on the basis of the authentication information read from the card reader 22 b and the job ticket of the job ticket holding unit 20 b is not frozen, the print data utilization managing unit 24 b acquires the print data from the host terminal 100 b to transmit the acquired print data to the print control unit 26 b , and does not freeze the job ticket until printing performed by the printer engine 25 b is interrupted or completed. Furthermore, the print data utilization managing unit 24 b decrements the number of printable copies of the job ticket when the print completion notice is received or the printing by the printer engine 25 b is completed, and the print data utilization managing unit 24 b transmits the data deletion notice to the host terminal 100 b and deletes the job ticket when it is determined that the number of printable copies is ‘0’.
[0965] The print control unit 26 b performs printing on the basis of the print data received from the print data utilization managing unit 24 b.
[0966] Also, the network printer 200 b further includes a utilization history information generating unit 27 b which generates utilization history information indicating the use history of the print data on the basis of data on a utilization result received from the print data utilization managing unit 24 b.
[0967] The network printer 300 b includes a card reader 30 b for reading out authentication information from an inserted authentication card, an authentication information transmitting unit 31 b for transmitting the authentication information read from the card reader 30 b to the network printer 200 b , a print data receiving unit 32 b for receiving the print data, a printer engine 33 b composed of a print head, a head driving unit, and other mechanism necessary for printing, and a print control unit 34 b for controlling the printing of the print engine 33 b on the basis of the print data received from the print data receiving unit 32 b.
[0968] When printing performed by the printer engine 33 b is interrupted, the print control unit 34 b removes the print data being printed and transmits a print interruption notice to the network printer 200 b , and when the printing performed by the printer engine 33 b is completed, the print control unit 34 b transmits a print completion notice to the network printer 200 b.
[0969] Next, a configuration of the host terminal 100 b will be described.
[0970] FIG. 40 is a block diagram illustrating the hardware configuration of the host terminal 100 b.
[0971] As shown in FIG. 40 , the host terminal 100 b includes a CPU 50 b for controlling overall system and operations on the basis of a control program, a ROM 52 b for storing the control program of the CPU 50 b and the like in a predetermined area in advance, a RAM 54 b for storing data read from the ROM 52 b or an operation result necessary for an operation process of the CPU 50 b , and an I/F 58 b for intermediating an input/output of data to/from peripheral devices, and those are communicably connected to one another through a bus 59 b , which serves as a signal line for transmitting data.
[0972] To the IF 58 b , an input device 60 b , serving as a human interface, such as a keyboard or a mouse through which data can be input, a storage device 62 b for storing data or tables as a file, a display device 64 b for displaying images on the basis of image signals, a card writer 66 b for writing authentication information into an inserted authentication card, all of which are peripheral devices, and signal lines for connection with the network 199 b are connected.
[0973] The CPU 50 b includes a micro processing unit. The CPU 50 b runs a predetermined program stored in the predetermined area of the ROM 52 b , and then according to the program, executes a print data generating process, a print data supplying process, and a print data deleting process shown in flowcharts of FIGS. 41 , 43 , and 44 in a time-division manner.
[0974] FIG. 41 is a flowchart illustrating the print data generating process.
[0975] If the print data generating process is executed by the CPU 50 b , first, the process proceeds to step S 100 b , as shown in FIG. 41 .
[0976] In step S 100 b , it is determined whether or not printing has been requested by a documentation application or the like, and when it is determined that the printing has been requested (Yes), the process proceeds to step S 102 b , but when it is determined that the printing has not been requested (No), the process is on standby at step S 100 b until the printing is requested.
[0977] In step S 102 b , a job ID for unique identification on print data is issued, and print data including the issued job ID is generated on the basis of document data edited by the documentation application or the like. Then, the process proceeds to step S 104 b.
[0978] In step S 104 b , information on a user who uses the host terminal 100 b at present is acquired, and then in step S 106 b , a job ticket is generated on the basis of the issued job ID and the acquired user information.
[0979] FIG. 42 is a view illustrating a data structure of the job ticket 400 b.
[0980] As shown in FIG. 42 , the job ticket 400 b includes a field 402 b for storing a job ID, a field 404 b for storing an exclusive flag indicating whether the job ticket 400 b is frozen or not, a field 406 b for storing the number of printable copies, and a field 408 b for storing the user information. The job ticket 400 b is added with a field 410 b for storing utilization history information whenever the print data is used.
[0981] In an example shown in FIG. 42 , ‘001’ is stored as the Job ID, ‘0’ is stored as the exclusive flag, ‘3’ is stored as the number of printable copies, and ‘UserA’ is stored as the user information. This indicates that the print data of the job ID of ‘001’ can be printed only by the user information ‘UserA’ and the number of printable copies is three. In addition, the exclusive flag is reset, which indicates that a current job ticket is not frozen. Here, the number of printable copies may be optionally set by the user or may be set to a predetermined value.
[0982] Further, five records are stored as the utilization history information. This indicates that the print data of the job ID of ‘001’ has been already printed by five copies, and the five records show printing dates and times as the use history.
[0983] Thereafter, in step S 108 b , the generated print data is stored in the storage device 62 b , then in step S 110 b , a request for storing the generated print data is transmitted to the network printer 200 b , and then in step S 112 b , the generated job ticket is transmitted to the network printer 200 b . After the series of steps are completed, the process returns to the initial step.
[0984] Next, a print data supplying process will be described in detail with reference to FIG. 43 .
[0985] FIG. 43 is a flowchart illustrating the print data supplying process.
[0986] The print data supplying process is a process of supplying the print data in response to the acquisition request from the network printer 200 b , and if the print data supplying process is executed by the CPU 50 b , the process proceeds to step S 150 b , as shown in FIG. 43 .
[0987] In step S 150 b , it is determined whether or not the acquisition request has been received, and when it is determined that the acquisition request has been received (Yes), the process proceeds to step S 152 b , but when it is determined that the acquisition request has not been requested (No), the process is on standby at step S 150 b until the acquisition request is received.
[0988] In step S 152 b , the print data corresponding to the job ID included in the received acquisition request is read from the storage device 62 b , and then in step S 154 b , the read print data is transmitted to the network printer 200 b . After the series of steps are completed, the process returns to the initial step.
[0989] Next, a print data deleting process will be described in detail with reference to FIG. 44 .
[0990] First, if the print data deleting process is executed by the CPU 50 b , the process proceeds to step S 200 b , as shown in FIG. 44 .
[0991] In step S 200 b , it is determined whether or not the data deletion notice has been received, and when it is determined that the data deletion notice has been received (Yes), the process proceeds to step S 202 b , but when it is determined that the acquisition request has not been requested (No), the process is on standby at step S 200 b until the acquisition request is received.
[0992] In step S 202 b , the print data corresponding to the job ID included in the received data deletion notice is deleted from the storage device 62 b . After the series of steps are completed, the process returns to the initial step.
[0993] Next, a configuration of the network printer 200 b will be described.
[0994] FIG. 45 is a block diagram illustrating a hardware configuration of the network printer 200 b.
[0995] As shown in FIG. 45 , the network printer 200 b includes a CPU 70 b for controlling overall system and operations on the basis of a control program, a ROM 72 b for storing the control program of the CPU 70 b or the like in a predetermined area in advance, a RAM 74 b for storing data read from the ROM 72 b or an operation result required for an operation process of the CPU 70 b , and an I/F 78 b for intermediating an input/output of data to/from peripheral devices, and those are communicably connected to one another through a bus 79 b , which serves as a signal line for transmitting data.
[0996] To the IF 78 b , an operation panel 80 b , serving as a human interface, such as a touch panel through which data can be input and displayed, a storage device 82 b for storing data or tables as a file, a card reader 22 b , a printer engine 25 b , all of which are peripheral devices, and signal lines for connection with the network 199 b are connected.
[0997] The CPU 70 b includes a micro processing unit. The CPU 70 b runs a predetermined program stored in the predetermined area of the ROM 72 b , and then according to the program, executes a job ticket storing process, a print control process, a print state monitoring process, a print request accepting process, and a print result receiving process shown in a flowchart of FIG. 46 or 50 , in a time-division manner.
[0998] First, the job ticket storing process will be described in detail with reference to FIG. 46 .
[0999] FIG. 46 is a flowchart illustrating the job ticket storing process.
[1000] The job ticket storing process is a process of storing the job ticket from the host terminal 100 b , and if the job ticket storing process is executed by the CPU 70 b , the process proceeds to step S 300 b , as shown in FIG. 46 .
[1001] In step S 300 b , it is determined whether or not the storing request has been received, and when it is determined that the storing request has been requested (Yes), the process proceeds to step S 302 b , but when it is determined that the storing request has not been requested (No), the process is on standby at step S 300 b until the storing request is received.
[1002] In step S 302 b , the job ticket is received, and then in step S 304 b , the received job ticket is stored in the storage device 82 b . After the series of steps are completed, the process returns to the initial step.
[1003] Next, the print control process will be described in detail with reference to FIG. 47 .
[1004] FIG. 47 is a flowchart illustrating the print control process.
[1005] The print control process is a process of performing the print control of the printer engine 25 b , and if the print control process is executed by the CPU 70 b , the process proceeds to step S 350 b , as shown in FIG. 47 .
[1006] In step S 350 b , it is determined whether or not the authentication card has been inserted into the card reader 22 b , and when it is determined that the authentication card has been inserted into the card reader 22 b (Yes), the process proceeds to step S 352 b , but when it is determined that the authentication card is not inserted into the card reader 22 b (No), the process is on standby at step S 350 b until the authentication card is inserted.
[1007] In step S 352 b , the authentication information including the job ID and the user information is read from the authentication card by the card reader 22 b , and then in step S 354 b , a user authenticating process is performed on the basis of the read authentication information. In the user authenticating process, the job ticket corresponding to the job ID included in the read authentication information is retrieved from the storage device 82 b . As a result, when the corresponding job ticket has been retrieved, it is determined whether or not the user information of the retrieved job ticket matches the user information included in the read authentication information and then they match each other, it is determined that the user is eligible to use the print data. On the other hand, when it is determined that the corresponding job ticket has not been retrieved or the user information of the retrieved job ticket does not match the user information included in the read authentication information, it is determined that the user is not eligible to use the print data. Step S 352 b is the same as step S 452 b to be described below.
[1008] Subsequently, in step S 356 b , a result of the user authenticating process is determined, and when it is determined that the user is eligible to use the print data (Yes), the process proceeds to step S 358 b in which it is determined whether or not an exclusive flag of the retrieved job ticket is set. When it is determined that the exclusive flag is not set (No), it is determined that the job ticket is not frozen, and the process proceeds to step S 360 b.
[1009] In step S 360 , the exclusive flag of the retrieved job ticket is set, and then in step S 362 b , the acquisition request including the job ID included in the read authentication information is transmitted to the host terminal 100 b . In step S 364 b , the print data is received, and then in step S 366 b , a printing process of performing the print control of the printer engine 25 b is carried out on the basis of the received print data. After the series of steps are completed, the process returns to the initial step.
[1010] Further, in step S 358 b , when it is determined that the exclusive flag of the retrieved job ticket is set (Yes), it is determined that the job ticket is frozen, and the process proceeds to step S 368 b in which an error message is displayed on the operation panel 80 b . After the series of steps are completed, the process returns to the initial step.
[1011] Meanwhile, in step S 356 b , when it is determined that the user is not eligible to use the print data (No), the process proceeds to step S 368 b.
[1012] Next, the print state monitoring process will be described in detail with reference to FIG. 48 .
[1013] FIG. 48 is a flowchart illustrating the print state monitoring process.
[1014] The print state monitoring process is a process of monitoring the print state of the printer engine 25 b , and if the print state monitoring process is executed by the CPU 70 b , the process proceeds to step S 400 b , as shown in FIG. 48 .
[1015] In step S 400 b , it is determined whether the printing has been completed in the printer engine 25 b , and when it is determined that the printing has been completed (Yes), the process proceeds to step S 402 b in which the job ticket corresponding to the job ID of the print-completed print data is retrieved from the storage device 82 b and the exclusive flag of the retrieved job ticket is reset. Then, in step S 404 b , the number of printable copies of the retrieved job ticket is decremented by ‘1’ to proceed to step S 406 b.
[1016] In step S 406 b , it is determined whether or not the number of printable copies is ‘0’, and when it is determined that the number of printable copies is not ‘0’ (No), the process proceeds to step S 408 b in which the utilization history information including the print dates and times is generated. In step S 410 b , the generated utilization history information and the retrieved job ticket are stored in the storage device 82 b to proceed to step S 412 b.
[1017] In step S 412 b , it is determined whether or not the printer engine 25 b has stopped printing, and when it is determined that the printing has been interrupted (Yes), the process proceeds to step S 414 b in which the job ticket corresponding to the job ID of the print-interrupted print data is retrieved from the storage device 82 b and the exclusive flag of the retrieved job ticket is reset. Then, in step S 416 b , the print data being printed is removed to proceed to step S 418 b in which an error message is displayed on the operation panel 80 b . After the series of steps are completed, the process returns to the initial step.
[1018] On the other hand, in step S 412 b , when it is determined that the printing has not been interrupted (No) in the printer engine 25 b , the series of processes are completed to return to the first step.
[1019] Further, in step S 406 b , when it is determined that the number of printable copies is ‘0’ (Yes), step S 406 b proceeds to step S 420 b in which the data deletion notice including the job ID of the print-completed print data is transmitted to the host terminal 100 b . In step S 422 b , the job ticket corresponding to the job ID of the print-completed print data is deleted from the storage device 82 b to proceed to step S 412 b.
[1020] Further, in step S 400 b , when it is determined that the printer engine 25 b has not completed the printing (No), the process proceeds to step S 412 b.
[1021] Next, the print request receiving process will be described in detail with reference to FIG. 49 .
[1022] FIG. 49 is a flowchart illustrating the print request receiving process.
[1023] The print request receiving process is a process of receiving a printer request from the network printer 300 b , and if the print request receiving process is executed by the CPU 70 b , the process proceeds to step S 450 b , as shown in FIG. 49 .
[1024] In step S 450 b , it is determined whether or not the printer request has been received, and when it is determined that the printer request has been received (Yes), the process proceeds to step S 452 b , but when it is determined that the printer request has not been received (No), the process is on standby at step S 450 b until the printer request is received.
[1025] In step S 452 b , the authentication information is received, and then in step S 454 b , a user authenticating process is performed on the basis of the received authentication information to proceed to step S 456 b.
[1026] In step S 456 b , a result of the user authenticating process is determined, and then when it is determined that the user is eligible to use the print data (Yes), the process proceeds to step S 458 b in which it is determined whether or not an exclusive flag of the retrieved job ticket is set. When it is determined that the exclusive flag is not set (No), it is determined that the job ticket is not frozen, and the process proceeds to step S 460 b.
[1027] In step S 460 b , the exclusive flag of the retrieved job ticket is set, and then in step S 462 b , the acquisition request including the job ID included in the received authentication information is transmitted to the host terminal 100 b . In step S 464 b , the print data is received, and then in step S 466 b , the received print data is transmitted to the network printer 300 b which is a source of the request. After the series of steps are completed, the process returns to the initial step.
[1028] Further, in step S 458 b , when it is determined that the exclusive flag of the retrieved job ticket is set (Yes), it is determined that the job ticket is frozen to proceed to step S 468 b in which a print prohibition notice is transmitted to the network printer 300 b which is a source of the request. After the series of steps are completed, the process returns to the initial step.
[1029] Meanwhile, in step S 456 b , when it is determined that the user is not eligible to use the print data (No), the process proceeds to step S 468 b.
[1030] Next, the print result receiving process will be described in detail with reference to FIG. 50 .
[1031] FIG. 50 is a flowchart illustrating the print result receiving process.
[1032] The print result receiving process is a process of receiving the print result from the network printer 300 b , and if the print result receiving process is executed by the CPU 70 b , the process proceeds to step S 500 b , as shown in FIG. 50 .
[1033] In step S 500 b , it is determined whether or not a print completion notice including the job ID has been received, and when it is determined that the print completion notice has been received (Yes), the process proceeds to step S 502 b in which the job ticket corresponding to the job ID included in the received print completion notice is retrieved from the storage device 82 b to reset the exclusive flag of the retrieved job ticket, and then in step S 504 b , the number of printable copies of the retrieved job ticket is decremented by ‘1’ to proceed to step S 506 b.
[1034] In step S 506 b , it is determined that the number of printable copies is ‘0’, and when it is determined that the number of printable copies is not ‘0’ (No), the process proceeds to step S 508 b in which the utilization history information including print dates and times is generated, and then in step S 510 b , the generated utilization history information and the retrieved job ticket are stored in the storage device 82 b to proceed to step S 512 b.
[1035] In step S 512 b , it is determined whether or not the print interruption notice has been received, and when it is determined that the print interruption notice has been received (Yes), the process proceeds to step S 514 b in which the job ticket corresponding to the job ID included in the received print completion notice is retrieved from the storage device 82 b and the exclusive flag of the retrieved job ticket is reset. After the series of steps are completed, the process returns to the initial step.
[1036] On the other hand, in step S 512 b , when it is determined that the print interruption notice has not been received (No), the series of processes are completed to return to the initial step.
[1037] Further, in step S 506 b , when it is determined that the number of printable copies is ‘0’ (Yes), the process proceeds to step S 516 b in which the data deletion notice including the job ID included in the received print completion notice is transmitted to the host terminal 100 b . Then, in step S 518 b , the job ticket corresponding to the job ID included in the received print completion notice is deleted from the storage device 82 b to proceed to step S 512 b.
[1038] On the other hand, in step S 500 b , when it is determined that the print completion notice has not been received (No), the process proceeds to step S 512 b.
[1039] Next, a configuration of the network printer 300 b will be described.
[1040] FIG. 51 is a block diagram illustrating a hardware configuration of the network printer 300 b.
[1041] As shown in FIG. 51 , the network printer 300 b includes a CPU 90 b for controlling overall system and operations on the basis of a control program, a ROM 92 b for storing the control program of the CPU 90 b or the like in a predetermined area in advance, a RAM 94 b for storing data read from the ROM 92 b or an operation result necessary for an operation process of the CPU 90 b , and an I/F 98 b for intermediating an input/output of data to/from peripheral devices, and those are communicably connected to one another through a bus 99 b , which serves as a signal line for transmitting data.
[1042] To the IF 98 b , an operation panel 81 b , serving as a human interface, such as a touch panel through which data can be input and displayed, a storage device 83 b for storing data or tables as a file, a card reader 30 b , a printer engine 33 b , all of which are peripheral devices, and signal lines for connection with the network 199 b are connected.
[1043] The CPU 90 b includes a micro processing unit. The CPU 90 b runs a predetermined program stored in the predetermined area of the ROM 92 b , and then according to the program, executes a print control process and a print state monitoring process shown in flowcharts of FIGS. 52 and 53 , in a time-division manner.
[1044] First, the print control process will be described in detail with reference to FIG. 52 .
[1045] FIG. 52 is a flowchart illustrating the print control process.
[1046] The print control process is a process of performing the print control of the printer engine 33 b , and if the print control process is executed by the CPU 90 b , the process proceeds to step S 600 b , as shown in FIG. 52 .
[1047] In step S 600 b , it is determined whether or not the authentication card has been inserted into the card reader 30 b , and when it is determined that the authentication card has been inserted into the card reader 30 b (Yes), the process proceeds to step S 602 b , but when it is determined that the authentication card has not been inserted into the card reader 30 b (No), the process is on standby at step S 600 b until the authentication card is inserted.
[1048] In step S 602 b , the card reader 30 b reads the authentication information from the authentication card to proceed to step S 604 b in which the network printer 200 b transmits a print request. Then, in step S 606 b , the read authentication information is transmitted to the network printer 200 b to proceed to step S 608 b.
[1049] In step S 608 b , it is determined whether or not the print data has been received, and when it is determined that the print data has been received (Yes), the process proceeds to step S 610 b in which a printing process of performing the printing control of the printer engine 33 b on the basis of the received print data is carried out. After the series of steps are completed, the process returns to the initial step.
[1050] On the other hand, in step S 608 b , when it is determined that the print data has not been received (No), the process proceeds to step S 612 b in which it is determined whether or not a print prohibition notice has been received, and when it is determined that the print prohibition notice has been received (Yes), the process proceeds to step S 614 b in which an error message is displayed on the operation panel 81 b . After the series of steps are completed, the process returns to the initial step.
[1051] Meanwhile, in step S 612 b , when it is determined that the print prohibition notice has not been received (No), the process proceeds to step S 608 b.
[1052] Next, the print state monitoring process will be described in detail with reference to FIG. 53 .
[1053] FIG. 53 is a flowchart illustrating the print state monitoring process.
[1054] The print state monitoring process is a process of monitoring the printing state of the printer engine 33 b , and if the print state monitoring process is executed by the CPU 90 b , the process proceeds to step S 650 b , as shown in FIG. 53 .
[1055] In step S 650 b , it is determined whether or not the printer engine 33 b has completed printing, and when it is determined that the printing has been completed (Yes), the process proceeds to step S 652 b in which the print completion notice including the job ID of the print-completed print data is transmitted to the network printer 200 b , and then the process proceeds to step S 654 b.
[1056] In step S 654 b , it is determined whether or not the printer engine 33 b has stopped printing, and when it is determined that the printing has been interrupted (Yes), the process proceeds to step S 656 b in which the print interruption notice including the job ID of the print-completed print data is transmitted to the network printer 200 b , and then the process proceeds to step S 658 b . In step S 658 b , the print data being printed is removed to proceed to step S 660 b in which an error message is displayed on the operation panel 81 b . After the series of steps are completed, the process returns to the initial step.
[1057] On the other hand, in step S 654 b , when it is determined that the printer engine 33 b has not stopped the printing (No), the series of processes are completed to return to the initial step.
[1058] Further, in step S 650 b , when it is determined that the printer engine 33 b has not stopped the printing (No), the process proceeds to Step S 654 b.
[1059] Next, an operation of the present embodiment will be described.
[1060] A user requests the host terminal 100 b to edit document data by using a documentation application and to print it.
[1061] In the host terminal 100 b , when the printing is requested, print data and a job ticket are generated, the generated print data is stored in the storage device 62 b , and the generated job ticket and a storage request are transmitted to the network printer 200 b , in steps S 102 b through S 112 b.
[1062] In the network printer 200 b , when the job ticket and the storage request are received, the received job ticket is stored in the storage device 82 b in step 304 b.
[1063] First, a case in which printing is performed in the network printer 200 b will be described.
[1064] The user inserts an authentication card into the card reader 66 b , and the card reader 66 b records the job ID and user information in an authentication card, in the host terminal 100 b . Further, the user goes to the network printer 200 b to insert the authentication card into the card reader 22 b.
[1065] In the network printer 200 b , when the authentication card is inserted, the authentication information is read from the authentication card by the card reader 22 b and a user authentication operation is performed on the basis of the read authentication information in steps S 352 b and S 354 b . As a result, when the user authentication is accomplished, the job ticket is frozen and then an acquisition request is transmitted to the host terminal 100 b in steps S 360 b and S 362 b.
[1066] In the host terminal 100 b , when the acquisition request is received, the print data is read from the storage device 62 b and then the read print data is transmitted to the network printer 200 b in steps S 152 b and S 154 b.
[1067] In the network printer 200 b , when the print data is received, the print control is performed on the basis of the received print data in step S 366 b . Then, when the printing is completed, the job ticket is not frozen and the number of printable copies of the job ticket is decremented in steps S 402 b and S 404 b . As a result, if the number of printable copies is not ‘0’, utilization history information is generated and then the generated utilization history information is added to the job ticket to be stored in the storage device 82 b in steps S 408 and S 410 b.
[1068] Next, a case in which printing is performed in the network printer 300 b will be described.
[1069] A user goes to one of the network printers 300 b to insert an authentication card into the card reader 30 b.
[1070] In the network printer 300 b , when the authentication card is inserted, the authentication information is read from the authentication card by the card reader 30 b , and then the read authentication information and a printing request are transmitted to the network printer 200 b in steps S 602 b through S 606 b.
[1071] In the network printer 200 b , when the printing request and the authentication information are received, a user authentication operation is performed on the basis of the received authentication information in step S 454 b . As a result, the user authentication is accomplished, the job ticket is frozen and an acquisition request is transmitted to the host terminal 100 b in steps S 460 b and S 462 b.
[1072] In the host terminal 100 b , when the acquisition request is received, the print data is read from the storage device 62 b and the read print data is transmitted to the network printer 200 b.
[1073] In the network printer 200 b , when the print data is received, the received print data is transmitted to the network printer 300 b which is a requestor in step S 466 b.
[1074] In the network printer 300 b , when the print data is received, the print control is performed on the basis of the received print data in step S 610 b . Then, when the printing is completed, a print completion notice is transmitted to the network printer 200 b in step S 652 b.
[1075] In the network printer 200 b , when the print completion notice is received, the job ticket is not frozen and the number of printable copies of the job ticket is decremented in steps S 502 b and S 504 b . As a result, if the number of printable copies is not ‘0’, utilization history information is generated and then the generated utilization history information is added to the job ticket to be stored in the storage device 82 b in steps S 508 and S 510 b.
[1076] Next, a case in which printing is interrupted in the network printer 200 b will be described.
[1077] In the network printer 200 b , the printing is interrupted due to a trouble such as a paper jam, the job ticket is not frozen and then the print data being printed is removed to display an error message in steps S 414 b through S 418 b.
[1078] Next, the user removes the authentication card from the card reader 22 b in the network printer 200 b . Also, the user goes to another network printer 300 b to insert the authentication card into the card reader 30 b . Hereinafter, the same operations as described above are performed in the network printer 200 b and another network printer 300 b , and the printing is performed by the network printer 300 b . The number of printable copies is not decremented even though the printing is interrupted until the printing is completed by another network printer 300 b.
[1079] Next, a case in which printing is interrupted in the network printer 300 b will be described.
[1080] In the network printer 300 b , the printing is interrupted due to a trouble such as a paper jam, a printing interruption notice is transmitted to the network printer 200 b , and the print data being printed is removed to display an error message in steps S 656 b through S 660 b.
[1081] In the network printer 200 b , when the printing interruption notice is received, the job ticket is not frozen in step S 514 b.
[1082] Next, a user removes the authentication card from the card reader 30 b in the network printer 300 b in which the printing has been interrupted. Also, the user goes to another network printer 300 b to insert the authentication card into the card reader 30 b . Hereinafter, the same operations as described above are performed in the network printer 200 b and another network printer 300 b , and the printing is performed by the network printer 300 b . The number of printable copies is not decremented even though the printing is interrupted until the printing is completed by another network printer 300 b.
[1083] Next, a case in which an authentication card is removed while the network printer 200 b or one of the network printers 300 b performs printing and the authentication card is inserted into the card reader 30 b will be described.
[1084] In the network printer 300 b , when the authentication card is inserted, the authentication information is read out from the authentication card by the card reader 30 b , and then the read authentication information and a printing request are transmitted to the network printer 200 b.
[1085] In the network printer 200 b , when the printing request and the authentication information are received, a user authentication operation is performed on the basis of the received authentication information. As a result, even though the user authentication is accomplished, since the job ticket is frozen, a print prohibition notice is transmitted to the network printer 300 b , which is a source of the request, in step S 468 b.
[1086] In the network printer 300 b , when the print prohibition notice is received, an error message is displayed in step S 614 b and printing is not performed.
[1087] Next, a case in which an authentication card is removed while one of the network printers 300 b performs printing and the authentication card is inserted into the card reader 22 b in the network printer 200 b will be described.
[1088] In the network printer 200 b , when the authentication card is inserted, the authentication information is read from the authentication card by the card reader 22 b , and then a user authentication operation is performed on the basis of the read authentication information. As a result, even though the user authentication is accomplished, since the job ticket is frozen, an error message is displayed in step S 368 b and printing is not performed.
[1089] Further, in a case in which an authentication card having unauthorized authentication information is used, since the user authentication can not be accomplished, a print prohibition notice is transmitted to the network printer 300 b , which is a source of the request, or an error message is displayed in the network printer 200 b.
[1090] Furthermore, when the number of printable copies becomes ‘0’, in the network printer 200 b , a data deletion notice is transmitted to the host terminal 100 b to delete the job ticket in steps S 420 b and S 422 b or S 516 b and S 518 b.
[1091] In the host terminal 100 b , when the data deletion notice is received, the print data is deleted in step S 202 b.
[1092] As such, in the present embodiment, the host terminal 100 b supplies the print data to the network printer 200 b in response to the acquisition request and deletes the print data in response to the data deletion notice. Further, in the network printer 200 b , when the user authentication is accomplished and it is determined that the job ticket is not frozen, the print data is acquired from the host terminal 100 b , the acquired print data is transmitted to one of the plurality of network printers 300 b , the job ticket is frozen until the print interruption notice or the print completion notice is received, or the print control is performed on the basis of the acquired print data to make the job ticket frozen until the printing is interrupted or completed, and when the print completion notice is received or the printing has been completed, the number of printable copies of the job ticket is decremented, and as a result, when it is determined that the number of printable copies is ‘0’, the data deletion notice is transmitted to the host terminal 100 b and the job ticket is deleted. Furthermore, in the network printer 300 b , the print data is received and the print control is performed on the basis of the received print data, and when the printing operation has been interrupted, the print data being printed is removed and the print interruption notice is transmitted to the network printer 200 b and when the printing operation has been completed, the print completion notice is transmitted to the network printer 200 b.
[1093] Accordingly, since the number of printable copies is decremented only when printing has been completed, even though the printing is interrupted due to a trouble, such as a paper jam, at one of the network printers 200 b and 300 b , the printing can be performed by other network printers 200 b and 300 b . Therefore, only an authorized user can acquire the printed matter.
[1094] Further, since either the print data is supplied to the network printer 300 b or the print data is used in the network printer 200 b , it is possible to reduce a possibility that the same printed contents will be printed simultaneously at the network printers 200 b and 300 b . Furthermore, even though the print-interrupted network printers 200 b and 300 b are fixed, the print data being printed is removed, so that it is possible to reduce a possibility that the print data being printed will be printed by the print-interrupted network printers 200 b and 300 b . As a result, since a possibility that the printing will be performed exceeding the number of printable copies can be reduced, it is possible to protect the secrecy of printed contents and to protect a literary work when the print data is the literary work, as compared with the related art.
[1095] Furthermore, in the network printer 200 b of the present embodiment, when the user authentication is accomplished on the basis of the received authentication information and it is determined that the job ticket is not frozen, the print data is transmitted to one of the plurality of network printers 300 b , the one having transmitted the authentication information, and the user authentication is accomplished on the basis of the read authentication information and when it is determined that the job ticket is frozen, the print control is performed on the basis of the acquired print data.
[1096] As such, a user can perform printing at one of the network printers 200 b and 300 b by presenting an authentication card recorded with the authentication information to one of the network printers 200 b and 300 b that the user wants to use.
[1097] In addition, in the present embodiment, the network printer 200 b generates utilization history information whenever the print data is used.
[1098] Accordingly, it is possible to see how the print data has been used by referring to the utilization history information.
[1099] Further, in the present embodiment, the network printer 200 b transmits a data deletion notice to the host terminal 100 b and deletes the job ticket when the number of printable copies is ‘0’, and the host terminal 100 b deletes the print data when the data deletion notice is received.
[1100] Accordingly, a possibility that the print data and the job ticket will be used by an unauthorized user is reduced, so that the secrecy of the printed contents and the literary work can be reliably protected.
[1101] In the fifth embodiment, the host terminal 100 b corresponds to the data managing units according to the one-hundred twenty-first, one-hundred twenty-sixth, one-hundred twenty-seventh, one-hundred thirty-second, one-hundred thirty-third, one-hundred thirty-eighth, one-hundred thirty-ninth, and one-hundred forty-fourth aspects, and the print data holding unit 11 b and the storage device 62 b correspond to the output data holding unit according to the one-hundred twenty-first or one-hundred thirty-ninth aspect. Also, the print data supplying unit 12 b , the I/F 58 b , and step S 150 b to S 154 b correspond to the output data supplying unit according to the one-hundred twenty-first aspect, steps S 150 b to S 154 b correspond to the output data supplying steps according to the one-hundred thirty-ninth aspect, and the print data deletion unit 13 b , the I/F 58 b , and step S 200 b or S 202 b correspond to the output data deletion unit according to the one-hundred twenty-sixth aspect.
[1102] Further, in the fifth embodiment, step S 200 b or S 202 b correspond to the output data deletion step according to the one-hundred forty-fourth aspect, the network printer 200 b corresponds to the first network devices according to the one-hundred twenty-first, one-hundred twenty-third to one-hundred twenty-fifth, one-hundred thirty-ninth, and one-hundred forty-first to one-hundred forty-third aspects, and the job ticket holding unit 20 b and the storage device 82 b correspond to the job ticket holding units according to the one-hundred twenty-first, one-hundred twenty-seventh, one-hundred thirty-third, and one-hundred thirty-ninth aspects. Moreover, the authentication information receiving unit 21 b , the I/F 78 b , and step S 452 b correspond to the authentication information receiving units according to the one-hundred twenty-third, one-hundred twenty-fourth, one-hundred twenty-ninth, and one-hundred thirtieth aspects, and step S 452 b corresponds to the authentication information receiving steps according to the one-hundred thirty-fifth, one-hundred thirty-sixth, one-hundred forty-first, or one-hundred forty-second aspects.
[1103] Furthermore, in the fifth embodiment, the card reader 22 b and step S 352 b correspond to the first authentication information acquiring unit according to the one-hundred twenty-third or the one-hundred twenty-fourth aspect, or correspond to the authentication information acquiring unit according to the one-hundred twenty-ninth or one-hundred thirtieth aspect. Also, step S 352 b corresponds to the first authentication information acquiring step according to the one-hundred forty-first or one-hundred forty-second aspect, or corresponds to the authentication information acquiring step according to the one-hundred thirty-fifth or one-hundred thirty-sixth aspect. Also, the user authentication unit 23 b and step S 354 b or S 454 b correspond to the authentication units according to the one-hundred twenty-third, one-hundred twenty-fourth, one-hundred twenty-ninth, and one-hundred thirtieth aspects, and step S 354 b or S 454 b correspond to the authentication steps according to the one-hundred thirty-fifth, one-hundred thirty-sixth, one-hundred forty-first, and one-hundred forty-second aspects. Also, the print data utilization managing unit 24 b , the I/F 78 b , and steps S 356 b to S 364 b , S 400 b to S 406 b , S 412 b to S 422 b , S 456 b to S 466 b , S 500 b to S 506 b , and S 512 b to S 518 b correspond to the output data use managing units according to the one-hundred twenty-first, one-hundred twenty-third to one-hundred twenty-seventh, and one-hundred twenty-ninth to one-hundred thirty-second aspects.
[1104] In addition, in the fifth embodiment, steps S 356 b to S 364 b , S 400 b to S 406 b , S 412 b to S 422 b , S 456 b to S 466 b , S 500 b to S 506 b , and S 512 b to S 518 b correspond to the output data use managing steps according to the one-hundred thirty-third, one-hundred thirty-fifth to one-hundred thirty-ninth, one-hundred forty-first to one-hundred forty-fourth aspects. Also, the print control unit 26 b and step S 366 b correspond to the first output control units according to the one-hundred twenty-first, one-hundred twenty-third, and one-hundred twenty-fourth aspects, or correspond to the output control units according to the one-hundred twenty-seventh, one-hundred twenty-ninth, and one-hundred thirtieth aspects. Also, step S 366 b corresponds to the first output control steps according to the one-hundred thirty-ninth, one-hundred forty-first, and one-hundred forty-second aspects, or corresponds to the output control steps according to the one-hundred thirty-third, one-hundred thirty-fifth, and one-hundred thirty-sixth aspects.
[1105] Moreover, in the fifth embodiment, the utilization history information generating unit 27 b and step S 408 b correspond to the utilization history information generating unit according to the one-hundred twenty-fifth or the one-hundred thirty-first aspect, step S 408 b corresponds to the utilization history information generating unit according to the one-hundred thirty-seventh or the one-hundred forty-third aspect, and the network printer 300 b corresponds to the second network devices according to the one-hundred twenty-first, one-hundred twenty-third, one-hundred twenty-fourth, one-hundred thirty-ninth, one-hundred forty-first, and the one-hundred forty-seconds. Also, the card reader 30 b and step S 602 b correspond to the second authentication information acquiring unit according to the one-hundred twenty-third aspect, step S 602 b corresponds to the second authentication information acquiring unit according to the one-hundred forty-first aspect, and the authentication information transmitting unit 31 b , the I/F 98 b , and step S 606 b correspond to the authentication information transmitting unit according to the one-hundred twenty-third aspect.
[1106] Further, in the fifth embodiment, step S 606 b corresponds to the authentication information transmitting step according to the one-hundred forty-first aspect, the print data receiving unit 32 b , the I/F 98 b , and step S 608 b correspond to the output data receiving unit according to the one-hundred twenty-first aspect, and step S 608 b corresponds to the output data receiving step according to the one-hundred thirty-ninth aspect. Also, the print control unit 34 b , the I/F 98 b , and step S 610 b correspond to the second output control unit according to the one-hundred twenty-first aspect, step S 610 b corresponds to the second output control step according to the one-hundred thirty-ninth aspect, and the print data corresponds to the output data according to the one-hundred twenty-first, one-hundred twenty-third to one-hundred twenty-seventh, one-hundred twenty-ninth to one-hundred thirty-first, one-hundred thirty-third, one-hundred thirty-fifth to one-hundred thirty-seventh, one-hundred thirty-ninth, and one-hundred forty-first to one-hundred forty-fourth aspects.
[1107] Furthermore, in the fifth embodiment, the print interruption notice corresponds to the output interruption notice according to the one-hundred twenty-first, one-hundred twenty-fourth, one-hundred twenty-seventh, one-hundred thirtieth, one-hundred thirty-third, one-hundred thirty-sixth, one-hundred thirty-ninth, and one-hundred forty-second aspects, and the print completion notice corresponds to the output completion notice according to the one-hundred twenty-first, one-hundred twenty-fourth, one-hundred twenty-seventh, one-hundred thirtieth, one-hundred thirty-third, one-hundred thirty-sixth, one-hundred thirty-ninth, and one-hundred forty-second aspects. Also, the data deletion notice corresponds to use prohibition notice according to the one-hundred twenty-sixth, one-hundred thirty-second, one-hundred thirty-eighth, and one-hundred forty-fourth aspects.
[1108] In addition, in the fifth embodiment described above, the number of printable copies is decremented and the print data and the job ticket are deleted when the number of printable copies becomes ‘0’. However, the invention is not limited thereto. For example, the number of print-completed copies is incremented with the number of printable copies and the number of print-completed copies specified in the job ticket, and when the number of print-completed copies reaches the number of printable copies, the print data and the job ticket may be deleted. Specifically, the job ticket is configured as shown in FIG. 54 .
[1109] FIG. 54 is a view illustrating a data structure of the job ticket 400 b.
[1110] As shown in FIG. 54 , the job ticket 400 b includes a field 402 b for storing a job ID, a field 404 b for storing an exclusive flag, a field 406 b for storing the number of printable copies, a field 412 b for storing the number of print-completed copies, and a field 408 b for storing the user information.
[1111] In an example shown in FIG. 54 , ‘8’ is stored as the number of printable copies, and ‘5’ is stored as the number of print-completed copies. This indicates that the number of printable copies with respect to the print data of the job ID of ‘001’ is eight and five of them have been already printed.
[1112] Further, in the fifth embodiment described above, the user authentication operation is carried out on the basis of the authentication information and the job ticket with the user information specified in the job ticket. However, the invention is not limited thereto. For example, any user may perform printing by omitting the user authentication. In this case, it is preferable that the user information and the print dates and times be recorded as the utilization history information. Specifically, the job ticket is configured as shown in FIG. 55 .
[1113] FIG. 55 is a view illustrating a data structure of the job ticket 400 b.
[1114] As shown in FIG. 55 , the job ticket 400 b includes a field 402 b for storing a job ID, a field 404 b for storing an exclusive flag, a field 406 b for storing the number of printable copies, and a field 412 b for storing the number of print-completed copies. Further, a field 414 b for storing the utilization history information whenever the print data is used is added thereto.
[1115] In an example shown in FIG. 55 , five records are stored as the utilization history information. This indicates that the print data of the job ID of ‘001’ has been already printed by five copies, and the five records show, as the use history, the user information and the print dates and times when the respective printing operations are performed. Here, as the user information, for example, an IP address and a host ID of the host terminal 100 b other than the user ID may be set.
[1116] Furthermore, in the fifth embodiment described above, the number of printable copies is decremented when the printing has been interrupted or after the printing has been completed. However, the invention is not limited thereto. For example, the number of printable copies may be decremented before the job ticket is frozen. Specifically, a job ticket updating process shown in a flowchart of FIG. 56 is performed.
[1117] FIG. 56 is a flowchart illustrating the job ticket updating process.
[1118] First, if the job ticket updating process is executed by the CPU 70 b , the process proceeds to step S 700 b , as shown in FIG. 56 .
[1119] In step S 700 b , the number of printable copies of the job ticket is decremented by ‘1’ to proceed to step S 702 b in which the job ticket is frozen. Then, in step S 704 b , it is determined whether printing has been interrupted, and when it is determined that the printing has not been interrupted (No), the process proceeds to step S 706 b.
[1120] In step S 706 b , it is determined whether or not the printing has been completed, and when it is determined that the printing has been completed (Yes), the process proceeds to step S 708 b in which the job ticket is not frozen (e.g., released). Then, in step S 710 b , it is determined whether the number of printable copies is ‘0’, and when it is determined that the number of printable copies is not ‘0’ (No), the series of processes are completed to return to the initial step.
[1121] On the other hand, in step S 710 b , when it is determined that the number of printable copies is ‘0’ (Yes), the process proceeds to step S 712 b in which the print data is deleted. Then, in step S 714 b , the job ticket is deleted and the series of processes are completed to return to the initial step.
[1122] On the other hand, in step S 706 b , when it is determined that the printing has not been completed (No), the process proceeds to step S 704 b.
[1123] In step S 704 b , when it is determined that the printing has been interrupted (Yes), the process proceeds to step S 716 b , and the job ticket is not frozen (e.g., released). Then, in step S 718 b , the number of printable copies is incremented by ‘1’ and the series of processes are completed to return to the initial step.
[1124] In this case, steps S 700 b to S 718 b correspond to the output data use managing unit according to the one-hundred twenty-second or one-hundred twenty-eighth aspect, or correspond to the output data use managing step according to the one-hundred thirty-fourth or one-hundred fortieth aspect.
[1125] Further, in the fifth embodiment described above, the host terminal 100 b generates the job ticket and the print data simultaneously. However, the invention is not limited thereto. For example, when literary works, such as documents or images which can be obtained on network 199 b , are printed, a job ticket issuing device which issues a job ticket may be connected to the network 199 b so that the job ticket issuing device can issue the job ticket at the time of payment of an expense. In this case, for example, the issued job ticket is recorded in the authentication card to be written into the network printer 200 b through the card reader 22 b . Also, in this case, since unspecified persons print literary works, the user authentication is not required. Accordingly, it does not need to prepare the user authenticating process at step S 354 b or S 454 b.
[1126] Furthermore, in the fifth embodiment described above, the number of printable copies is specified in the job ticket so as to limit the number of printable copies. However, the invention is not limited thereto. For example, the number of printable pages may be specified in the job ticket to restrict the number of printed pages.
[1127] Further, in the fifth embodiment described above, the host terminal 100 b is used, but the invention is not limited thereto. For example, a printer server, a file server, or other data servers may be used instead of the host terminal 100 b.
[1128] Further, in the fifth embodiment described above, the authentication information is read from the authentication card by the card reader 22 b or 30 b , but the invention is not limited thereto. For example, the authentication information may be input from the operating panel 80 b or 81 b . In this case, the card reader 22 b or 30 b is not required.
[1129] Further, in the fifth embodiment described above, the card reader 22 b or 30 b is integrally provided in the network printer 200 b or 300 b , but the invention is not limited thereto. For example, the card reader 22 b or 30 b may be provided separately from the network printer 200 b or 300 b . Specifically, a user authenticating device having the card reader 22 b or 30 b is communicably connected to the network printer 200 b or 300 b , and the network printer 200 b or 300 b inputs the authentication information by receiving the authentication information from the user authenticating device.
[1130] Further, in the fifth embodiment described above, in order to execute the processes shown in the flowcharts of FIGS. 41 , 43 , 44 , 46 to 50 , 52 , 53 , and 56 , the control program stored in the ROM 52 b , 72 b , or 92 b in advance is executed, but the invention is not limited thereto. For example, a program instructing these procedures may be read out from storage media which store the program, and then the program may be read in the RAM 54 b , 74 b , or 94 b to be executed.
[1131] Here, the storage media include a semiconductor storage medium, such as a RAM, a ROM, or the like, a magnetic recordable storage medium, such as an FD, an HD, or the like, an optical readable storage medium, such as a CD, a CDV, an LD, a DVD, or the like, and a magnetic recordable/optical readable storage medium, such as an MO or the like. Specifically, the storage medium includes all storage media as long as it is a computer readable storage medium, regardless of reading methods such as electronic, magnetic, or optical.
[1132] Further, in the fifth embodiment described above, the output system, the network device, and the output method according to the invention are applied to the case in which printing is performed by the network printer 200 b or 300 b by using the authentication card, however, the invention is not limited thereto. For example, the invention can be applied to other cases without departing from the subject matter of the invention. Instead of the network printer 200 b or 300 b , for example, the invention can be applied to a projector, a home gateway, a personal computer, a personal digital assistant (PDA), a network storage, an audio apparatus, a mobile phone, PHS (Personal Handyphone System), a watch-type PDA, a set top box (STB), a POS terminal, a facsimile machine, a phone (including an IP phone or the like), and other output devices. | An authenticator includes: network devices performing output; and an apparatus communicably using the network devices. The apparatus includes: first storage storing the output data; second storage storing tickets specifying whether to permit or restrict output data use; and a utilization manager managing output data use. When the authentication succeeds, the manager supplies output data stored in the first storage to any network device, and prohibits supplying output data until a print completion notice is received. When the print completion notice is received, the manager updates the tickets stored in the second storage, and when the tickets satisfy predetermined conditions, the manager prohibits supplying output data. Each network device includes: a receiver receiving output data; and a controller performing output control based on the output data received by the receiver. The controller transmits the print completion notice to the apparatus when the network device completely outputs the output data. | 6 |
FIELD OF THE INVENTION
[0001] The present invention relates to a method for producing 7-methoxy-3-desacetylcefalotin (I),
[0000]
[0000] a cefoxitin synthesis intermediate, in accordance with an innovative process using a biocatalyst.
[0002] Cefoxitin pertains to the class of cephamycins, i.e. β-lactam antibiotics characterised by the presence of a methoxy group in position 7 of the cephalosporanic ring.
BACKGROUND OF THE INVENTION
[0003] This antibiotic is described in U.S. Pat. No. 4,297,488, which illustrates different synthesis paths comprising carbamoylation of various desacetylated intermediates with various agents, using different protective groups on the carboxyl and/or on the amino group. It also describes the passage of enzymatic hydrolysis to produce certain of these derivatives, using acetil-esterase from citrus fruit peel, although with very slow reactions (6-15 hours) and without commenting on the quality of the products obtained. A similar process is also described by the same authors in Tetrahedron Lett 46, 4653-6 (1973), using protected intermediates such as p-nitrobenzyl esters, on which a deprotection and an enzymatic hydrolysis are carried out, to hence obtain 7-methoxy-3-desacetylcefalotin in carboxylic acid form. The product is then treated with chlorosulphonyl isocyanate to obtain cefoxitin.
[0004] The synthesis paths generally used on an industrial scale in modern chemistry produce optically pure cefoxitin, using 7-ACA (7-aminocephalosporanic acid) as raw material, and comprise four main steps, preferably carried out in the following order:
1. acylation of the amino group in position 7 2. introduction of the methoxy group in position 7α 3. removal of the acetyl group in position 3 4. carbamoylation of the hydroxyl group in 3 obtained in the preceding step.
[0009] Step 1 corresponds to the synthesis of cefalotin, a cephalosporin. This is then transformed into the corresponding cephalomycin by methoxylation to give the intermediate II (step 2):
[0000]
[0000] and then desacetylated to give the compound I.
[0010] Although other sequences are possible, the aforedescribed is advantageous as it does not use protective groups either for the amino group or for the carboxyl group, and hence enables the number of necessary operations to be minimized, while enabling a raw material saving.
[0011] For example WO2004/083217A1 (page 6) describes the saponification of the intermediate II with sodium hydroxide in a water-methanol mixture cooling to −45° C.; this temperature is maintained for the entire duration of hydrolysis, and can be raised only on termination of the reaction, after neutralizing the base with acid.
[0012] The compound I is then isolated as the benzathine salt, after removing the methanol by distillation at moderate temperature; it is thus evident that 1) the use of methanol is justified by the need to reach very low temperatures for the reaction and 2) it is necessary to remove the solvent before isolating the product.
[0013] Alternatively the product can be extracted in solvent either in the undissociated form by acidification, or as a basic salt, for example tetrabutylammonium, as described in EP 1748049A2.
[0014] Cefoxitin can be obtained from the compound I by carbamoylation of the isiocyanate group, as described in the aforesaid patents, or with other isocyanates, as described for example in U.S. Pat. No. 4292427.
[0015] In all cases, given the lability of β-lactam structures and the need to operate under extremely basic conditions, the desacetylation of compound I to give compound II is conducted at very low temperature to prevent product degradation; consequently organic solvents are used to lower the freezing point of the solutions.
[0016] These are therefore methods requiring the cooling of thousands of liters of solutions to a temperature of the order of −45° C., these temperatures to be maintained for the entire duration of the reaction, by using refrigeration machines or refrigerant fluids (such as liquid nitrogen); this results in a considerable energy cost. The solvent is then removed by distillation under vacuum by heating to +30/+40° C., with further considerable energy consumption (both for heating the solution and for the operation of the vacuum pump and condenser cooling).
[0017] It must also be considered that the use of solvents such as methanol involves danger due to solvent inflammability, possible operator intoxication, release of vapours into the environment, and drawbacks due to the production of methanol-containing aqueous effluents, which must be suitably disposed off.
[0018] A more ecocompatible path is therefore highly desirable, such as hydrolysis taking place only in water at ambient temperature. To effect such hydrolysis in a reasonable time and avoid product degradation a catalyst is required, for example an enzyme.
[0019] Enzymatic desacetylation of cephalosporins (not of cephamycins as in compound II) has been known for some time and has been described with enzymes of various origins.
[0020] For example acetyl esterase from wheat germ was described by Gilbert et al. in GB1121308 (Glaxo, 1964), the enzyme present in citrus fruit peel was described by Jeffery et al in Biochem. J. 81, pages 591-6 (1961).
[0021] The aforesaid U.S. Pat. No. 4,297,488 describes the enzymatic hydrolysis of various cefoxitin synthesis intermediates, catalyzed by acetyl esterase from citrus fruit; however the method described therein is not applicable on an industrial scale, because of the poor performance of the catalyst. This is an enzyme of low specific activity involving very lengthy reaction times (6-15 hours described), difficult to produce as it derives from a poorly reproducible source subject to seasonal variations. Moreover it is applied in soluble form, is not recycled, and neither the purification nor the immobilization of the enzyme is described. Neither the yields of the acetyl derivatives obtained nor their quality are described.
[0022] Other enzymes active on cephalosporins have been discovered, starting from those involved in the biosynthesis path of cephalosporin C in Acremonium chrysogenum (or Cephalosporium acremonium ) and in Streptomyces clavuligerus ; these are considered as undesirable enzymatic activities, which lead to the formation of desacetyl cephalosporin C, a fermentation by-product. It should be noted that the biosynthesis of cephamycins in Nocardia lactamodurans and in Streptomyces clavuligerus does not comprise the hydrolysis of the acetyl group on a cephamycin (P. Liras, Antonie van Leeuwenhoek 75, 1999, pages 109-24); acetyl esterase activity on cephamycins is therefore not known, not even in cephamycin producer microorganisms.
[0023] Enzyme catalized hydrolyses of the acetyl group on 7-ACA or on cephalosporin C have been described, but not on cephamycins; in particular:
[0024] 1) an esterase produced by Bacillus subtilis (Abbott and Fukuda, Antimicrob Agents Chemother 8, 3, pages 282-8, 1975 and Appl Microbiol, 30,3, pages 413-8 1975) is used in immobilized form for hydrolyzing 7-ACA to 3-desacetyl-7-ACA. The enzyme is sufficiently active and stable but tends to become detached from the immobilization support. Other authors (Takimoto et al. Appl Microbiol Technol 65, pages 263-7, 2004) describe the fermentation of this enzyme in recombinant Escherichia coli , its purification and immobilization on solid support and its use for producing 3-desacetyl-7-ACA.
[0025] 2) The Rhodosporidium toruloides described by Politino et al. in Appl Environm Microbiol 63, 12, pages 4807-11, 1997, produces an enzyme active on 7-ACA, which can be used as catalyst in this reaction both in the form of a non-fermenting biomass (resting cells) and as an isolated and purified enzyme. The hydrolytic activity manifested by this enzyme on cefalotin is however low, only 34% of that on 7-ACA; Hydrolysis of cephamycins is not described. The same enzyme is also used by Chiang et al. (US 2002/0048781BMS, 2002) who describe a strain of recombinant Acremonium creysogenum , able to express acetyl esterase from Rhodosporidium , used to produce desacetylcephalosporin C directly in fermentation broths.
[0026] 3) Another acetyl esterase is described by Venturi et al. in Appl Environ Microbiol 64, 2, pages 789-92, 1998: this is a xylan esterase produced by Bacillus pumilus , an enzyme connected with the degradation of xylans, which also shows activity on 7-ACA and on cephalosporin C; other publications describe expression of the same enzyme in coli . Activity on cephamycins is not described.
[0027] Hence enzymatic hydrolysis of the acetyl group of cephamycins has never been applied on an industrial scale in the state of the art; moreover, notwithstanding the wide literature available on a similar reaction in cephalosporins, an enzyme has not been described which is sufficiently active and stable for use on cephamycins.
SUMMARY OF THE INVENTION
[0028] An aspect of the present invention is a method for preparing the compound of formula I in which a compound of formula II is subjected to hydrolysis of the acetyl group, characterised in that said hydrolysis is conducted in water in the presence of a biocatalyst consisting of at least one enzyme possessing acetyl-hydrolasic activity, at a temperature between −10° C. and +45° C. (preferably between 0° C. and +20° C.), at pH between 5 and 9 (preferably between 6 and 8), and finally separating the enzyme from the reaction medium by known methods.
[0029] In particular, this biocatalyst can be obtained from microorganisms chosen from the group consisting of Rhodosporidium toruloides, Bacillus pumilus, Escherichia coli, Acremonium chrysogenum , and Streptomyces clavuligerus , and can be presented in the form of free protein or immobilized on a solid support, or can consist of the microbic cells themselves. On termination of the reaction the biocatalysts can be separated and reused, while the compound I can be isolated from the aqueous solution by precipitation as the salt of an organic base or by extraction in solvent. It has been found that, preferably, said organic base is selected from the group consisting of benzathine and its salts.
[0030] Compared with the state of the art, the new method presents various advantages which can be summarized as follows:
greater working safety, by avoiding the use of harmful solvents (e.g. methanol) and strongly caustic solutions (e.g. sodium hydroxide), considerable energy saving by working at ambient temperature, so avoiding the considerable energy consumption necessary to reach and maintain the low temperatures generally used in these cases (e.g. less than −45° C.), greater process productivity, by avoiding solvent distillation under vacuum, a working step which requires considerable time.
[0034] A product is obtained which is of quality equal to or greater than that obtainable by the procedures known up to the present time.
BRIEF DESCRIPTION OF THE DRAWINGS
[0035] FIG. 1 Acetylesterase activity as a function of temperature;
[0036] FIG. 2 Acetylesterase activity as a function of pH; and
[0037] FIG. 3 . Hydrolysis kinetics of 7-methoxy-cefalotin as function of pH and temperature.
DETAILED DESCRIPTION OF THE INVENTION
[0038] The intermediate II can be prepared starting from cefalotin, a commercially available raw material of good quality and low price; the same cefalotin can be produced from 7-ACA by known methods. The methoxylation reaction is conducted at very low temperature, using a chlorinating agent and sodium methoxide and operating by known methods. On termination of the reaction the compound II can be isolated as a salt, either of alkaline metals or of organic bases, or can be extracted in water in the form of carboxylate.
[0039] A convenient synthesis path is described in WO2004/083217, Example 1, step i.
[0040] For the enzymatic desacetylation various catalysts were used, prepared by known methods or as described in the following examples.
[0041] The reaction product (compound I) was isolated as the benzathine salt, as described in WO2004/083217, or extracted in organic solvent, either a) as acid in undissociated form, or b) as tetrabutylammonium salt, following the procedure described in EP 1748049A2.
[0042] Cefoxitin was obtained from the compound I by reaction with chlorosulphonyl isocyanate, operating by known methods, to obtain a good quality product suitable for use as a drug.
[0043] The process is illustrated in the following examples, which however are to be considered as non-limiting.
EXAMPLE 1
Chemical Synthesis of 7-methoxy-3-desacetylcefalotin
[0044] 300 g of 7-methoxy cefalotin in cyclohexylamine salt form (solution A), prepared by known procedures and having a titre of about 69% as acid, equal to about 500 mmoles, are added to a mixture of 1.0 liters of water and 1.15 liters of methanol. The mixture is cooled to −37° C.
[0045] Separately, a solution of 160 g of 30% sodium hydroxide in water in 300 ml of water is prepared and cooled to +5° C., them poured slowly into solution A, while maintaining the temperature between −45/−35° C. for about one hour after finishing the addition. The reaction kinetics are monitored by HPLC analysis: when the residual 7-methoxy cefalotin is less than 0.7 g/l the reaction is interrupted by adding 90 g of 80% acetic acid while maintaining the temperature within −5° C. The pH, which must be neutral, is monitored, correcting to 6.8-7.0 if necessary. The mixture is distilled under vacuum by heating to +30/+35° C., until a concentration of about 100 g/l of 7-methoxy-3-desacetylcefalotin is obtained, after which decolorization with carbon is applied. The volume is diluted to about 1.9 liters to achieve a concentration of about 80 g/l, then 300 ml of ethyl acetate and 130 g of benzathine diacetate are added, adding a little solid product to trigger the precipitation. The mixture is cooled to 0/+5° C. and the temperature maintained until a product concentration in the mother liquors of less than 10 g/l is achieved, after which it is filtered through a Buchner funnel. The solid is washed with water and then with ethyl acetate, after which it is mashed in an ethyl acetate 85%/acetone 15% mixture to achieve an anhydrous product.
[0046] About 208 g of 7-methoxy-3-desacetylcefalotin benzathine salt are obtained, of titre about 70% as acid, equal to 380 mmoles, for a molar yield of 76%.
EXAMPLE 2
Enzymatic Hydrolysis of 7-methoxy-3-desacetylcefalotin with Rhodosporidium toruloides Biomass
[0047] Rhodosporidium toruloides ATCC 10657 is grown in a flask or fermenter for 72 hours from inoculation as described in the literature, withdrawing whole broth samples for monitoring the quantity of acetyl esterase produced. The enzymatic activity is expressed in international Units (IU), equal to the micromoles of substrate converted per minute, and is determined by hydrolysis of 7-ACA (20 g/l in water); the reaction is temperature controlled at +25° C. and pH-controlled at 6.5 by adding 0.1 M NaOH by automatic titration (pH-stat, Crison Instruments SA, Barcelona, Spain). The growth broth is centrifuged at 10000 r.p.m. for 15 minutes, the pellet is resuspended in phosphate buffer and again centrifuged, to obtain a paste of wet cells with specific activity of about 6-10 IU per gram.
[0048] 40.8 g of 7-methoxy cefalotin cyclohexylamine salt are dissolved in about 250 ml of water, correcting the pH to 7.0 with 3N ammonium hydroxide. The titrator is set to maintain pH 7.0, temperature is controlled at +20° C. and 50 g of Rhodosporidium cell paste are added. After about 1 hour 30 minutes the reaction is complete, the cells are separated by centrifugation to obtain about 340 ml of 7-methoxy-3-desacetylcefalotin solution, which is decolorized with carbon and filtered through paper. 55 ml of ethyl acetate and 17.7 g of benzathine diacetate are added, the product being isolated as described in Example 1.
[0049] 28 g of 7-methoxy-3-desacetylcefalotin benzathine salt are obtained, of titre about 70% as acid, equal to 51 mmoles, molar yield of 77%.
[0050] The Rhodosporidium cells can be reused for various hydrolysis cycles.
EXAMPLE 3
Enzymatic Hydrolysis of 7-methoxy-3-desacetylcefalotin with Acetyl-Esterase from Rhodosporidium toruloides
[0051] The Rhodosporidium toruloides biomass obtained as described in Example 1 is lysed by treatment with EDTA (ethylenediaminotetraacetic acid), to obtain an aqueous solution containing the acetyl esterase activity, which is purified by chromatography with carboxymethyl Sepharose , following the procedures known in the literature (Politino et al, Appl. Environ. Microbiol. 63, 12, pages 4807-11, 1997).
[0052] 870 g of 7-methoxy-cefalotin benzathine salt prepared as in Example 1 are dissolved, the pH is corrected to 7.0 and the volume diluted to a total of 6000 ml, then 200 ml of a solution of acetyl esterase are added and the pH maintained at 7 by automatic titration with 3N ammonium hydroxide. On termination of the reaction the enzyme is separated from the product by ultrafiltration using the Millipore ProScale apparatus with Nanomax membrane and 10000Da cut-off. From the permeate, about 5 liters of a solution of 7-methoxy-3-desacetylcefalotin are obtained, which is isolated as described in Example 1, while the concentrate containing the enzyme is reused for the next hydrolysis cycle. The compound I is isolated as described in Example 1.
EXAMPLE 4
Enzymatic Hydrolysis of 7-methoxy-3-desacetylcefalotin with Recombinant Escherichia coli Biomass
[0053] The enzyme acetyl xylan esterase from Bacillus pumilus was expressed in recombinant Escherichia coli obtained by the procedures described by Venturi et al. in Microbiology 146, pages 1585-91 (2000).
[0054] The 7-methoxy-cefalotin was hydrolyzed as described in Example 3, using 340 g of E. coli biomass as catalyst; on termination of the reaction the 7-methoxy-3-desacetylcefalotin solution was separated by ultrafiltration, isolating the product in the form of benzathine salt as described in Example 1.
[0055] The ultrafiltration retentate is a suspension of partially lysed coli cells and free enzyme, which can be reused in subsequent cycles.
EXAMPLE 5
Enzymatic Hydrolysis of 7-methoxy-3-desacetylcefalotin with Acetyl-Esterase Immobilized on Epoxy Resin
[0056] The xylan esterase produced in recombinant coli as described in Example 4 was partially purified by destroying the cells with a cell disruptor press (Constant Systems Ltd.) at 1000 bar, then centrifuging at 20000 r.p.m. for 30 minutes. The supernatant thus obtained is dialyzed by ultrafiltration with a 10 KDa membrane ProScale Millipore apparatus then chromatographed on Sepharose Q Fast Flow resin as described in the literature (Venturi et al., Microbiology 146, pages 1585-91, 2000).
[0057] The partially purified enzyme was concentrated by ultrafiltration and then diluted with 10 volumes of a 1.2 M K 2 HPO 4 solution at pH 8.0, then immobilized on the epoxy resin Sepabeads EC-EP (Diaion SpA, Mitsubishi) with a load of 120 IU per gram of resin. The resin suspension is agitated for 48 hours, then filtered through a Buchner funnel and washed with 10 volumes of water (10 ml per gram of resin); a solid catalyst is obtained having an activity of about 70 IU per gram.
[0058] 100 g of 7-methoxy-cefalotin cyclohexylamine salt are dissolved in water to a total volume of 450 ml, then hydrolysis is carried out using as catalyst 66 g of immobilized enzyme, maintaining the pH constant at 7 by automatic titration with 3N ammonium hydroxide.
[0059] After 2.5 hours the reaction is complete, the enzyme is filtered through a sintered glass funnel and the 7-methoxy-3-desacetylcefalotin isolated by adding 50 g of benzathine diacetate and operating as described in Example 1.
[0060] 69.6 g of product are obtained with titre 70.8% as acid 7-methoxy-3-desacetylcefalotin for a molar yield of 78%.
[0061] The catalyst can be reused for numerous reaction cycles.
EXAMPLE 6
Enzymatic Hydrolysis of 7-methoxy-3-desacetylcefalotin with Acetyl-Esterase Immobilized on Amino Resin
[0062] The enzyme acetyl esterase from B. pumilis produced in recombinant coli as described in Example 4 is purified as described in Example 5.
[0063] 100 g of Sepabeads EC-HA resin (Diaion) are abundantly washed with water, then suspended in 100 ml of 0.2 M phosphate buffer at pH 7. 170 ml of 25% glutaraldehyde-in-water solution are added and left under agitation for 16 hours, then the purified enzyme solution is added to a total of 12000 IU. After 3 hours the mixture is filtered through a Buchner funnel, washing abundantly with water. A catalyst with activity 55 IU/gram is obtained.
[0064] Hydrolysis is conducted as described in Example 5, using 84 grams of immobilized acetyl-esterase. After three hours of reaction the enzyme is filtered off and the benzathine salt precipitated as described in Example 1. The product obtained is suspended in four volumes of isopropanol (weight/volume) and then filtered, to obtain 68 g of 7-methoxy-3-desacetylcefalotin benzathine salt of titre 70.5%, equal to a molar yield of 76%.
[0065] The catalyst can be reused for numerous reaction cycles.
EXAMPLE 7
Enzymatic Hydrolysis of 7-methoxy-3-desacetylcefalotin with Acetyl-Esterase Immobilized on Glyoxyl Resin
[0066] 100 g of Sepabeads EC-HA resin (Diaion) are abundantly washed with water, then 800 ml of a 0.05M sodium metaperiodate solution are added; after 1.5 hours the mixture is filtered through a Buchner funnel, with abundant washing with water. The resin is suspended in 700 ml of 50 mM bicarbonate buffer at pH 10, then 12000 IU of enzyme, purified as described in example 5, are added.
[0067] After one hour 1400 ml of a 1 mg/ml sodium borohydride solution in water are added, left to react for 30 minutes and then filtered through a porous baffle, with abundant washing with water. A catalyst with activity 38 IU/gram is obtained.
[0068] The hydrolysis reaction is conducted as described in Example 5; after 3.5 hours the reaction is interrupted and the product isolated. 65 g of 7-methoxy-3-desacetylcefalotin benzathine salt of titre 70% are obtained, equal to a molar yield of 73%.
[0069] The catalyst can be reused for numerous reaction cycles.
EXAMPLE 8
Enzymatic Hydrolysis of 7-methoxy-cefalotin from Methylene Solution
[0070] The cefalotin methoxylation reaction is conducted using N-chloro-succinimide and sodium methylate in methylene chloride and methanol, as described in WO2004/083217A1; after washing with aqueous solutions, an 82 g/l solution of acid 7-methoxy-cefalotin in methylene chloride is obtained.
[0071] 500 ml of methylene solution are extracted with about 300 ml of water, titrating with a 10% (w/v) sodium carbonate aqueous solution to obtain a final pH of 8.0; the phases are separated, and the methylene phase is washed with a little water to obtain 355 ml of an aqueous 109 g/l product solution, equal to an extraction yield of 94%. The aqueous phase is distilled under vacuum at +25° C., to eliminate solvent residues.
[0072] The aqueous phase is hydrolyzed with 40 grams of enzyme described in Example 6, controlling the pH with a 10% (w/v) sodium carbonate aqueous solution; after two hours the reaction is interrupted and the product isolated.
[0073] 33 g of 7-methoxy-3-desacetylcefalotin benzathine salt are obtained of titre 70.8%. The catalyst can be reused for numerous reaction cycles.
EXAMPLE 9
Synthesis of Cefoxitin without Isolating Intermediates
[0074] 7-methoxy-3-desacetylcefalotin is prepared as described in Example 8, to obtain an aqueous solution of concentration 80 g/l which is decolorized with 2 g of carbon; after filtration, solid NaCl is added until saturation and the solution extracted with a solution of tetrabutylammonium bromide in methylene chloride, following the procedure described in EP 1748049A2. Carbomoylation is effected in tetrahydrofuran with chlorosulphonyl isocyanate, isolating acid cefoxitin which is then transformed into the corresponding sodium salt as described in the same patent.
[0075] 13 g of sodium cefoxitin are obtained.
EXAMPLE 10
Isolation of 7-methoxy-3-desacetylcefalotin as Acid or Sodium Salt
[0076] The reaction is conducted as described in Example 6; on termination of hydrolysis the catalyst is filtered off and reused, and the aqueous solution is acidified until the 7-methoxy-3-desacetylcefalotin begins to precipitate, precipitation is allowed to continue for 30 minutes and then hydrochloric acid is added until pH 2.5, cooling to +4° C. The mixture is filtered through a Buchner funnel to obtain 7-methoxy-3-desacetylcefalotin as a white solid.
[0077] The mother liquors are extracted with ethyl acetate, the phases are separated and sodium 2-ethylhexanoate is added to the organic phase, to obtain precipitation of 7-methoxy-3-desacetylcefalotin sodium salt.
EXAMPLE 11
Enzymatic Hydrolysis of 7-methoxy-cefalotin in Aqueous Suspension
[0078] 130 g of 7-methoxy cefalotin cyclohexylamine salt are suspended in 300 ml of water, then a 10% (w/v) sodium carbonate aqueous solution is added to pH 7; a suspension is obtained to which 100 g of immobilized enzyme are added, prepared as described in Example 6. The reaction is carried out under pH-stat conditions, temperature controlling at +20° C.; complete dissolution of the substrate is observed as hydrolysis proceeds. The procedure is continued until a 7-methoxy-cefalotin residue of less than 0.5 g/l is obtained, then the catalyst is filtered off and the product isolated as described in Example 1. 98.3 g of 7-methoxy-3-desacetylcefalotin benzathine salt are obtained of titre 70%, for a molar yield of 85%.
EXAMPLE 12
Isolation of 7-methoxy-3-desacetylcefalotin by Hot Precipitation of its Benzathine Salt
[0079] The reaction is conducted as described in Example 11. with the only difference that the water/ethyl acetate mixture is heated to +35° C. before adding the benzathine diacetate; on triggering precipitation of the 7-methoxy-3-desacetylcefalotin benzathine salt the temperature is maintained at +30/35° C. for about 30 minutes, with cooling gradually to +4° C. before filtering. A molar yield of about 85% is obtained.
EXAMPLE 13
Use of Benzathine for Precipitating 7-methoxy-3-desacetylcefalotin
[0080] The reaction is conducted as described in Example 11. with the only difference that 10 vol % of methanol is added to the aqueous 7-methoxy-3-desacetylcefalotin solution, then ethyl acetate is added, heating to +30/35° C. before adding benzathine base. The mixture is cooled gradually to +4° C. before filtering. A molar yield of about 85% is obtained.
[0081] Similar results are obtained using ethanol, isopropanol or glycerine instead of methanol.
EXAMPLE 14
Acetyl Esterase Activity as a Function of Temperature
[0082] A solution of ethyl acetate (0.5 ml) in 50 mM phosphate buffer at pH 7 (50 ml) is prepared, then hydrolysis is effected with 100 microliters of acetyl xylan esterase from recombinant Bacillus pumilus in E. coli , prepared as described in Example 5, using the free non-immobilized protein.
[0083] Various tests are conducted at constant pH by automatic titration, at temperatures from +10° C. to +35° C., calculating for each test the enzyme hydrolytic activity on the basis of the base addition rate during the first 10 minutes of reaction.
[0084] The activity is expressed in International Units (IU) per ml of solution by titrating with 0.1 N NaOH the acetic acid quantity released by the ester hydrolysis, and is calculated by the formula:
[0000] IU =[mean NaOH consumption (ml/min)×100×f]/sample volume (ml) where f=correction factor for the 0.1 N soda titre mean consumption=0.1 N NaOH consumption during the first 10 minutes of titration, expressed in ml/min sample volume=volume of acetyl esterase solution, expressed in ml.
[0088] By plotting the expressed enzymatic activity against reaction temperature the graph shown in FIG. 1 is obtained.
[0089] Similar results are obtained using the protein immobilized on resin as described in Examples from 5 to 7.
EXAMPLE 15
Acetyl Esterase Activity as a Function of pH
[0090] The procedure described in Example 14 is followed, with solutions temperature controlled at +25° C., maintaining the pH constant by automatic titration at values between 5 and 9. The hydrolytic activity is calculated as described in Example 14, plotting the activity in IU/ml against the operating pH to obtain the curve of FIG. 2 .
EXAMPLE 16
Hydrolysis Kinetics of 7-methoxy-cefalotin as a Function of pH and Temperature
[0091] A 200 g/l solution of 7-methoxy-cefalotin is prepared and hydrolyzed with acetyl xylan esterase from recombinant B. pumilis in E. coli as described in Example 6, but operating at pH from 5.0 to 9.0 and temperature from −10 to +35° C. In the case of temperatures below 0° C., 10 vol % of glycerin is added to the aqueous solution.
[0092] The reactions are conducted to termination, until a 7-methoxy-cefalotin residue of less than 1 g/l is obtained.
[0093] FIG. 3 shows just some of the reaction kinetics. The product yields and quantities obtainable are influenced by possible product degradation, depending on the reaction conditions.
EXAMPLE 17
Hydrolysis of 7-methoxy-cefalotin with Immobilized Acetyl Esterase
[0094] The procedure described in Example 5 is followed, using acetyl esterase immobilized on resin as described in Examples from 5 to 7 and operating at pH 5, at +35° C. On termination of the reaction the agitation is halted and the catalyst allowed to decant, then the solution is separated by siphoning and the compound I is isolated as described in Example 11, to obtain 7-methoxy-3-desacetylcefalotin of titre 69%. A similar result is obtained operating at pH 9, at −10° C., adding 10% of glycerine to the aqueous solution.
EXAMPLE 18
Synthesis of Cefoxitin from 7-methoxy-3-desacetylcefalotin
[0095] Two samples of 7-methoxy-3-desacetylcefalotin benzathine salt obtained by the procedure described in Example 1 (sample A) and Example 12 (sample B) are transformed into cefoxitin by reaction with chlorosulphonyl isocyanate, as described for example in WO2004/083217A1. An identical molar yield is obtained. | Process for producing 7-methoxy-3-desacetylcefalotin by a hydrolysis process which takes place in water and is catalyzed by an enzyme. Cefoxitin can be obtained from this compound by known methods. | 2 |
FIELD OF THE INVENTION
The present invention relates to a pharmaceutical composition for treating or preventing corneal injury, comprising thymosin β4 and citric acid as active ingredients.
BACKGROUND OF THE INVENTION
The cornea is a transparent tissue without blood vessels on the front surface of an eyeball, which is often called the dark part of an eye. More particularly, the cornea protects the eye from external conditions, and plays a significant role of refracting and transmitting lights to get a sight of objects. It has well-developed nerve fibers to sensitively respond to foreign substances. The cornea is composed of five layers including a corneal epithelium, Bowman's membrane, corneal stroma, Descemet's membrane and corneal endothelium.
The surface of the cornea is directly exposed to the outside and vulnerable to wound or scratch. Therefore, corneal injuries often occur in patients suffering from ophthalmic diseases such as dry eye syndrome because a shortage of tear drastically deteriorates eyeball protection function of tears. The corneal injuries may cause symptoms such as a feeling of stimulus, a feeling of irritation or dryness and, lead to corneitis when getting worse. Therefore, in order to keep the eyeball healthy and preserve the eyesight, it is necessary to prevent the cornea from being injured, prevent trivial corneal injuries from being worse or treat the injured cornea.
Meanwhile, it is well known that, when the cornea is injured, in particular, by alkali burns, broad infiltration of polymorphonuclear leukocytes (PMN) occurs (Invest. Ophthalmology & Vis. Sci., 1987, 28, pp. 295-304). Such PMN infiltration is part of general inflammatory responses in association with tissue injury. However, in case of the chemical burns of the cornea, PMN infiltration is not only a primary inflammatory response but also leads to ulcer, or may even cause corneal perforation (Trans. Am. Acad. Ophthalmol. Otolaryngol., 1970, 74. pp. 375-383, Invest. Ophthalmology & Vis. Sci., 1979, 18, pp. 570-587). In fact, PMN is known as a major source of collagenase to destroy corneal collagen tissues. Therefore, it is understood that expansion of lesions is stopped by preventing infiltration of PMN, and that the progress of a corneal injury to ulcer may be delayed by inhibiting PMN metabolism. A number of studies have reported that citric acid is effective in reducing PMN infiltration (Exp. Eye. Res., 1984, 39, pp. 701-708).
Meanwhile, thymosin β4 is a protein first discovered in the thymus gland in 1981, which comprises 41 to 43 amino acids and has an isoelectric point of 5.1. In 1991, thymosin β4 was identified by Liva et al. as an actin-sequestering molecule from animal cells, and thereafter, found to be involved in the immune regulation and neuro-endocrine system. Recently, Korean Laid-open Patent Publication No. 10-2008-33939 discloses an eye drop composition comprising thymosin β4 and an amino acid stabilizer, which may further comprise a bulking agent, a buffer and a pH modifier. However, this publication does not describe any desired combination and contents of individual components to optimize or enhance the efficacy of thymosin β4.
As a result of extensive efforts to find out an optimum combination and contents of components, the present inventors have found that a specific organic acid may influence upon the activity of thymosin β4 and a composition containing acid could be used for treating corneal injuries, thereby accomplishing the present invention.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a composition for treating a corneal injury, comprising thymosin β4 and an organic acid.
In accordance with one aspect of the present invention, there is provided a composition for treating an injured cornea or for preventing a corneal injury, which comprises thymosin β4 and citric acid.
In accordance with another aspect of the present invention, there is provided a composition for treating an injured cornea or for preventing a corneal injury, which comprises thymosin β4, citric acid and acetic acid.
The composition of the present invention comprising thymosin β4 and citric acid promotes migration and proliferation of corneal epithelial cells and inhibits PMN infiltration in the injured cornea so as to facilitate the recovery of the corneal injury, when compared with the use of thymosin β4 alone. Further, the simultaneous use of thymosin β4, citric acid and acetic acid produces superior effects over the use of thymosin β4 alone in terms of cell migration and proliferation, and better effects than the individual use of the components in terms of PMN infiltration. Accordingly, the composition of the present invention enhances the effects of thymosin β4, thereby being useful for the treatment or prevention of corneal injuries.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objects and features of the present invention will become apparent from the following description of the invention, when taken in conjunction with the accompanying drawings, which respectively show:
FIGS. 1 to 3 provide the results of cell migration after treating the cells with the compositions comprising thymosin β4 and an organic acid;
FIG. 4 presents the extent of cell proliferation in the cells treated with the compositions comprising thymosin β4 and an organic acid; and
FIG. 5 shows the inhibitory effects of the present compositions on PMN infiltration.
DETAILED DESCRIPTION OF THE INVENTION
The present invention provides a composition for the treatment or prevention of a corneal injury, which comprises thymosin β4 and citric acid or its salt as active ingredients.
The term “thymosin β4” as used herein refers to a polypeptide composed of 43 amino acids having 4.9 kDa occasionally called thymosin beta-4 or Tβ4, which was first isolated from thymus and then identified from various tissues. This protein is upregulated during in vitro migration and differentiation of endothelial cells. A number of thymosin β4 iso-types have been identified and found to have homology of about 70% or more, about 75% or more, or about 80% or more with the known amino acid sequences of thymosin β4. Thymosin β4 of the present invention may also be an N-terminal mutant or C-terminal mutant of wild-type thymosin β4. Preferably, thymosin β4 of the present invention refers to the protein having an amino acid sequence of SEQ ID NO: 1.
Citric acid used herein is a compound represented by formula C 6 H 8 O 7 . In the present invention, this may also be used in the form of citrate. The citrate indicates derivatives of citric acid including sodium citrate and trisodium citrate. Although citric acid and its salt is generally used as a buffer to reduce a pH change, the present invention needs quite a larger amount of citric acid or its salt than that commonly used in the art. In the present invention, citric acid or its salt may be included in an amount of 1% (w/v) to 15% (w/v) based on the total volume of the composition. Further, citric acid or its salt may be included in an amount of 5% (w/v) to 12% (w/v), preferably 10% (w/v) based on the total volume of the composition.
Further, citric acid or its salt may be used in an amount of 10 to 120 parts by weight per 1 part by weight of thymosin β4. Further, it may be used in an amount of 25 to 100 parts by weight per 1 part by weight of thymosin β4. Preferably, citric acid or its salt may be used in an amount of 50 to 80 parts by weight per 1 part by weight of thymosin β4.
The term “corneal injury” as used herein means a wound on the cornea as the surface of an eyeball, and it may be caused by not only an external impact but also any internal factor in the body. Such a wound may be caused in the corneal epithelium, Bowman's membrane, corneal stroma, Descemet's membrane and/or corneal endothelium.
Further, the composition in accordance with the present invention may further comprise at least one organic acid selected from a group consisting of acetic acid, ascorbic acid and salts thereof.
The acetic acid used herein is a weak acid represented by formula CH 3 COOH. In the present invention, this may also be used in the form of acetate. One embodiment of the acetate may be sodium acetate.
Further, the ascorbic acid used herein is a weak acid represented by formula C 6 H 8 O 6 , which is often called vitamin C. In the present invention, this may also be used in the form of ascorbate. One embodiment of the ascorbate may be sodium ascorbate.
Although, the organic acid and its salt according to the present invention is generally used as a buffer to reduce a pH change or an antioxidant, the present invention needs quite a larger amount of an organic acid or its salt than that commonly used in the art. In the present invention, the organic acid or its salt may be included in an amount of 1.0% (w/v) to 8% (w/v), or 1.5% (w/v) to 5% (w/v) based on the total volume of the composition. Preferably, the organic acid or its salt may be included in an amount of 3.5% (w/v) to 5% (w/v) based on the total volume of the composition.
The organic acid or its salt may be included in an amount of 15 to 100 parts by weight per 100 parts by weight of citric acid or its salt. The organic acid or its salt may be also included in an amount of 15 to 70 parts by weight or 30 to 65 parts by weight per 100 parts by weight of citric acid or its salt. Preferably, the organic acid or its salt may be included in an amount of 40 to 60 parts by weight per 100 parts by weight of citric acid or its salt.
Further, the composition described herein may be prepared into a formulation available for ophthalmic application. Particularly, the formulation may include, for example, solution, lotion, plaster, gel, cream, paste, spray, suspension, dispersion, hydrogel, ointment, oil or foaming agent, or the like. In one embodiment, the present composition comprising thymosin β4 and citric acid may be formulated by being mixed with any pharmaceutically acceptable, in particular, ophthalmically acceptable non-toxic excipients or carriers. For instance, carrier, stabilizer, solubilizer, buffer substrate, preservative, thickener and/or other excipients such as those described below may be used. Further, the solution used herein may be adjusted to have a desired pH value.
The carriers used in the present invention may be typically suitable for topical or systemic administration and may include, for example, water; a mixture of water and water-miscible solvents such as C 1 -C 7 alkanols, vegetable oils or mineral oils such as 0.5 to 5 wt. % of hydroxyethyl cellulose, ethyl oleate, carboxymethyl cellulose, polyvinyl pyrrolidone, and other non-toxic water-soluble polymers for ophthalmic use, for example, cellulose derivatives such as methyl cellulose, alkali-metal salts of carboxymethyl cellulose, hydroxymethyl cellulose, hydroxyethyl cellulose, hydroxypropyl methyl cellulose and hydroxypropyl cellulose, acrylates or methacrylates such as salts of polyacrylate or ethyl acrylate, polyacrylamides; natural products such as gelatin, alginate, pectin, tragacanth, karaya gum, xanthan gum, carrageenin, agar, acacia, starch derivatives such as starch acetate and hydroxylpropyl starch; and other synthetic products, for example, polyvinyl alcohol, polyvinyl pyrrolidone, polyvinyl methylether, polyethylene oxide, preferably, cross-linked polyacrylic acid such as neutral carbopol, or mixtures of the above polymers. Preferable carriers may include water, cellulose derivatives, for example, methyl cellulose, alkali-metal salts of carboxymethyl cellulose, hydroxymethyl cellulose, hydroxyethyl cellulose, hydroxypropyl methyl cellulose and hydroxypropyl cellulose, neutral carbopol, or mixtures thereof.
The stabilizers useable in the composition for ophthalmic use according to the present invention may include, for example, tyloxapol, aliphatic glycerol poly-lower alkylene glycol esters, aliphatic poly-lower alkylene glycol esters, polyethylene glycols, glycerol ethers or mixtures of these compounds. They are typically added in an amount sufficient to dissolve active ingredients.
The buffer useable in the composition of the present invention may include borate, hydrocarbonate/carbonate, gluconate, phosphate, propionate and tromethamine (TRIS) buffers. Tromethamine and borate buffers are preferred. The buffer is added, for example, in an amount to ensure and maintain a physiologically acceptable pH range. Such pH may be typically in the range of pH 5 to 9, preferably pH 6 to 8.2, more preferably pH 6.8 to 8.1.
The preservatives useable in the composition of the present invention may include, for example, quaternary ammonium salts such as Cetrimide, benzalkonium chloride or benzoxonium chloride; alkyl-mercury salts of thiosalicylic acid such as thimerosal, phenylmercuric nitrate, phenylmercuric acetate or phenylmercuric borate, parabens such as phenylparaben or propylparaben, alcohols such as chlorobutanol, benzyl alcohol or phenyl ethanol, guanidine derivatives such as chlorohexidine or polyhexamethylene biguanide or sorbic acid. Preferable preservatives may include cetrimide, benzalkonium chloride, benzoxonium chloride and parabens. The preservative may be added in a sufficient amount to prevent secondary contamination caused by bacteria and fungi during the use.
A tonicity agent may be used in the composition of the present invention for adjusting the composition closer to isotonicity (e.g., 0.9% saline). For instance, sodium chloride, potassium chloride, calcium chloride, dextrose and/or mannitol may be added to the composition comprising thymosin β4 according to the present invention. An amount of the tonicity agent depends upon the kind of active agents to be added. In general, particular compositions of the present invention may include a tonicity agent therein to enable the final composition to have an osmolality acceptable for ophthalmic use, i.e., preferably in a range of 150 to 450 mOsm, and more preferably in a range of 250 to 350 mOsm. Preferable tonicity agents may include, for example, sodium salts and potassium salts, in particular, sodium chloride and potassium chloride. Most preferably, the tonicity agent is sodium chloride.
Further, in order to maintain a proper viscosity in the ophthalmic formulation, the following formulations may be, but not be limited to: (a) monomeric polyols, for example, tyloxapol, glycerol, propylene glycol, ethylene glycol; (b) polymeric polyols, for example, polyethylene glycol (e.g., PEG 300, PEG 400); (c) cellulose derivatives (cellulose-based polymers), for example, hydroxyethyl cellulose, hypromellose, hydroxypropyl methyl cellulose, methyl cellulose, sodium carboxymethyl cellulose, hydroxypropyl cellulose; (d) dextrans, for example, dextran 70; (e) water-soluble proteins, for example, gelatin; (f) vinyl polymers, for example, polyvinyl alcohol, polyvinyl pyrrolidine; (g) other polyols, for example, polysorbate 80, povidone; (h) carbomers, for example, carbomer 934P, carbomer 941, carbomer 940 and carbomer 974P; and (i) polysaccharides/glycosaminoglycans, for example, hyaluronan (hyaluronaic acid/hyaluronate), condroitin sulfate. In addition, at least one viscosity enhancer may be added to the compositions of the present invention, in order to increase the viscosity of the carrier (vehicle).
Although the amount and type of excipient(s) added may be varied depending on specific requirements, the excipient(s) is generally used in a range of about 0.0001 to about 90 wt. %, and within the range commonly used in ophthalmic fields. Further, a pH value of ophthalmic formulations may range from pH 3.5 to 9, preferably from pH 4.5 to 8, and most preferably from pH 5.5 to 7.8, and may be about pH 7.0.
In another aspect of the present invention, there is provided a method for the treatment or prevention of a corneal injury, comprising administering thymosin β4, and citric acid or its salt to a subject.
Further, the present invention provides a treatment method which comprises contacting an eye tissue with an effective amount of a composition comprising thymosin β4 and citric acid as active ingredients. Examples of direct administration may include directly applying to a subject, for example, a solution, lotion, plaster, gel, cream, paste, spray, suspension, dispersion, hydrogel, ointment, oil or foaming agent that contains thymosin β4 described herein, thereby contacting same with tissues.
Further, thymosin β4, and citric acid or its salt may be administered concurrently or sequentially with suitably divided doses several times a day. However, the simultaneous administration of thymosin β4, and citric acid or its salt is most preferred.
An amount of thymosin β4 in the composition may range from 0.05 to 0.5% (w/v) or from 0.1 to 0.4% (w/v) based on the total volume of the composition, which may be administered with a total daily dose of 0.08 to 2.0 ml. It may be administered once a day or with divided doses several times a day, preferably, twice to five times a day. Further, the citric acid or its salt may be included in an amount of 1.5% (w/v) to 10% (w/v) based on the total volume of the composition. Further, it may be administered with a total daily dose of 0.1 to 4.0 ml. Citric acid or its salt may be administered once a day or with divided doses several times a day, preferably, twice to five times a day.
Further, acetic acid, ascorbic acid or salts thereof may be administered concurrently or sequentially along with thymosin β4, and citric acid or its salt. Preferably, the acetic acid, ascorbic acid or salts thereof are administered simultaneously with thymosin β4 and citric acid or its salt. Further, the acetic acid, ascorbic acid or salts thereof may be included in an amount of 1.0% (w/v) to 8% (w/v), or 3.5% (w/v) to 5% (w/v) based on the total volume of the composition, which may be administered with a total daily dose of 0.10 to 4.0 ml. The acetic acid, ascorbic acid or salts thereof may be administered once a day or with divided doses several times a day, preferably, twice to five times a day.
The pharmaceutical composition according to the present invention is preferably administered transdermally (e.g., topically) and may be administered, for example, via parenteral or intranasal (e.g., inhalation) route, or through a mucous membrane, or the like, however, not be particularly limited thereto.
Hereinafter, in order to more clearly understand the present invention, the present invention will be described in more details by the following examples. However, the examples of the present invention may include different variations or modifications and it is not construed that the scope of the present invention is limited within the scope of the following examples.
EXAMPLE 1
Preparation of a Composition Comprising Thymosin β4
Sodium citrate was added in sterile purified water in an amount of 1.5% (w/v) based on the total volume of the composition and mixed to be completely dissolved therein. Then 0.1% (w/v) of thymosin β4 (Bachem., US, SEQ ID No. 1) was added to the mixture and mixed until it was completely dissolved therein. The pH value of the resulting solution was adjusted to pH 7.0 by using sodium hydroxide and hydrochloric acid. Thereafter, the solution was filtered through a 0.2 μm filter, and then, the mixture filtered was filled in a low density polyethylene container, followed by sealing same.
EXAMPLES 2 to 17
Preparation of a Composition Comprising Thymosin β4
The compositions shown in Table 1 below were prepared in accordance with the same procedures as described in Example 1. Unless otherwise indicated, numerical values in Table 1 have the unit of % (w/v) based on the total volume of the composition.
TABLE 1
Sterile
Thymosin
Sodium
Sodium
Sodium
Hydrochloric
Sodium
purified
β4
citrate
acetate
ascorbate
acid
hydroxide
water
Control
0.1
—
—
—
Added if
Added if
Amount
Ex. 2
0.1
5.0
—
—
required for
require for
necessary to
Ex. 3
0.1
10.0
—
—
adjusting to
adjusting to
make
Ex. 4
0.1
—
0.5
—
pH 7.0
pH 7.0
100% (w/v)
Ex. 5
0.1
—
1.5
—
Ex. 6
0.1
—
5.0
—
Ex. 7
0.1
—
—
0.5
Ex. 8
0.1
—
—
1.5
Ex. 9
0.1
—
—
5.0
Further, the compositions shown in Table 2 below were prepared in accordance with the same procedures as described in Example 1. Unless otherwise indicated, numerical values in Table 2 have the unit of % (w/v) based on the total volume of the composition.
TABLE 2
Sterile
Thymosin
Sodium
Sodium
Sodium
Hydrochloric
Sodium
purified
β4
citrate
acetate
ascorbate
acid
hydroxide
water
Ex. 10
0.1
10.0
5.0
—
Added if
Added if
Amount
Ex. 11
0.1
10.0
1.5
—
required for
required for
necessary to
Ex. 12
0.1
10.0
—
5.0
adjusting to
adjusting to
make
Ex. 13
0.1
10.0
—
1.5
pH 7.0
pH 7.0
100% (w/v)
Ex. 14
0.1
1.5
5.0
—
Ex. 15
0.1
1.5
1.5
—
Ex. 16
0.1
1.5
—
5.0
Ex. 17
0.1
1.5
—
1.5
EXPERIMENTAL EXAMPLE 1
Cell Migration Experiment
A single cell layer was formed, by inoculating primary human corneal epithelial cells (HCEC)(ATCC, US) onto 6-well plate (Thermo, Ltd.) with 3×10 5 cells per well. Then, some scratches with similar sizes were formed at the middle of each well by using a 1 ml sterile pipette tip. After washing the wells with the culture medium to remove cell debris, the composition comprising thymosin β4 prepared in each of the above examples was added to the plate.
After 0 h, 6 h, 12 h and 24 h, each well was photographed with an inverted microscope combined with a digital camera. The size of scratch was decreased by cell migration and this was determined to show the treatment effects of the corneal injury.
As shown in FIGS. 1 to 3 , the results of the present experiments demonstrate that the compositions comprising citric acid together with thymosin β4 promoted cell migration, as compared with the composition comprising thymosin β4 alone as an active ingredient. Further, it was found that the compositions comprising thymosin β4, citric acid and acetic acid most noticeably promoted migration of corneal epithelial cells.
EXPERIMENTAL EXAMPLE 2
Cell Proliferation Experiment
In order to confirm whether the composition comprising thymosin β4 promotes proliferation of primary human corneal epithelial cells, cells were stained using CCK-8 kit (Dojindo, Japan). After inoculating 3×10 3 cells in 100 μL onto each well of a 96-well plate (Thermo, Ltd.), the compositions comprising thymosin β4 in accordance with Control, Example 1, Example 3, Example 6 and Example 10 were added on the plate.
12 h, 24 h and 48 h after administering the compositions comprising thymosin β4, 10 μl of CCK-8 reagent was added to the plate, followed by incubation at 37° C. for 2 hours. Optical density (OD 450 ) at 450 nm was measured by using a microplate reader.
As a result, it was observed that the compositions comprising citric acid as well as thymosin β4, and the compositions comprising citric acid and acetic acid as well as thymosin β4 markedly promoted cell proliferation, as compared to the composition comprising thymosin β4 only (see FIG. 4 ).
EXPERIMENTAL EXAMPLE 3
Determination of Treatment Effects of Thymosin β4 Citric Acid and Mixture thereof in Animal Model
3.1. Preparation of Animal Model with Chemical Burns
For experiments of wound treatment effects, 6 to 8-weeks old mice (BALB/c) were anesthetized with ether, and then a round filter paper (2 mm diameter) dipped in 1N NaOH contacted on the center of the cornea for 30 seconds to induce an injury in the corneal epithelium. After washing the injured part with 0.9% saline for 5 seconds, 0.9% saline, and the compositions in Example 3, Example 10 and Control were respectively dropped into the eye at 5 minutes after inducing the corneal injury. Thereafter, the above compositions and 0.9% saline were respectively dropped into the eye four times a day (20 μL/each time).
3.2. Examination of Myeloperoxidase (MPO) Activity
According to the methods reported in Exp. Eye Res., 1984, 39, 261-265 myeloperoxidase activity analysis was conducted on the cornea on which the above compositions (0.9% saline, Example 3, Example 10 and Control) were respectively administered in order to quantify PMN. The activity of MPO is proportionate to the number of PMN.
1, 7 and 14 days after the corneal injury, the cornea was removed from the mice to which the respective compositions (n=3/group, each time) were administered, chopped into small pieces in a vial containing 1 mL of 50 mM phosphate buffer (pH 6.0) with 0.5% hexadecyl trimethyl ammonium bromide (HTAB), and homogenized by means of a Polytron homogenizer on ice. After homogenization, the homogenizer was washed with the HTAB solution. The homogenate was adjusted to have 100 mg tissues per 1 mL by adding the HTAB solution thereto, and subjected to ultrasonication for 10 seconds, freezing and thawing three times, and centrifugation at 4° C. and 14,000 rpm. 0.1 mL of supernatant was mixed with 2.9 mL of 50 mM phosphate buffer (pH 6.0) containing 0.167 mg/mL o-diansidine dihydrochloride and 0.0005% hydrogen peroxide. A change in absorbance at 460 nm was determined by means of a UV spectrometer at 25° C. for 5 minutes. 1 Unit of MPO activity denoted degradation of 1 mol of peroxides per minute at 25° C.
As a result of the determination, it was confirmed that, as compared with the composition comprising saline or thymosin β4 only, the compositions comprising citric acid as well as thymosin β4, and the compositions comprising citric acid and acetic acid as well as thymosin β4 significantly inhibited PMN infiltration (see FIG. 5 ). | The present invention relates to a composition for the treatment or prevention of a corneal injury, which comprises thymosin β4, and citric acid or its salt as active ingredients. The composition may further comprise at least one organic acid selected from acetic acid, ascorbic acid or salts thereof. The composition can maintain or increase the activity of thymosin β4 conventionally used to effectively treat wounds on the cornea, and thus, is useful as an ophthalmic formulation for treating the corneal injury. | 0 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This is a divisional application of application Ser. No. 11/536,000 filed on Sep. 28, 2006, which claims priority upon Japanese Patent Application No. 2005-358534 filed on Dec. 13, 2005, of which are herein incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a fixing member of solar battery modules.
[0004] 2. Background of the Invention
[0005] A conventional solar battery module can be mounted directly on a roofboard without the use of a roofing agent. As shown in FIG. 10 , frame bodies of two solar battery modules are adjacent in a flowing direction and a vertical direction, a joint portion 62 formed on a ridge-side frame body 61 of an eaves-side solar battery module is connected to a roofboard 31 , and a ridge-side fitting portion 64 formed on a ridge-side frame body 61 of an eaves-side solar battery module is fitted into an eaves-side fitting portion 63 formed on an eaves-side frame body 60 of a ridge-side solar battery module. This conventional solar battery module is disclosed in the Japanese Patent Application Laid-open No. 2000-297509.
[0006] However, the conventional solar battery module is integrally created with joint portions 62 for mounting a frame body thereof on the roof board 31 . Therefore, in some cases the position of the rafters which support the roofboard 31 at predetermined intervals and the position of the joint portion 62 of the solar battery module are not aligned with each other, which creates problems such as the joint portion 62 not being fixed to the rafter and the deterioration of the fixing strength of the solar battery module.
[0007] The eaves-side frame body 60 and the ridge-side frame body 61 of the solar battery module have different shapes, complicated machining operation is required to form the joint portion 62 , which connects to an increase the cost.
[0008] Hence, to solve the problems of the conventional solar battery module, it is an object of the present invention to provide a fixing member of solar battery modules configured to be slidable and allow the number of parts of the frame body of the solar battery module to be reduced, thereby reducing cost.
SUMMARY OF THE INVENTION
[0009] A fixing member of solar battery modules for fixing solar battery modules, each having an outer peripheral edge of a polygonal solar battery panel main body supported by a frame body, to a predetermined support member, comprises: a to-be connected portion configured to restrict an upward movement of frame bodies of solar battery modules disposed adjacent to each other; a pedestal configured to restrict a downward movement of the frame bodies restricted by the to-be connected portion from moving upward; a portion connecting the pedestal and the to-be connected portion, the portion configured to restrict an outward movement of each solar battery module in a direction perpendicular to a longitudinal direction of the frame body and along a surface of the solar battery module restricted from moving downward and upward by the pedestal and the to-be connected portion through the frame body; and a plate-like portion extending outward farther than either one of sides of the pedestal with respect to the portion connecting the pedestal and the to-be connected portion, the fixing member of solar battery modules being fixed to the predetermined support member through the plate-like portion extending farther outward than the pedestal, and being configured to be supported on both sides of the portion connecting the pedestal and the to-be connected portion such that upper surfaces of adjacent solar battery modules are substantially flush with each other, and being configured to slide along the frame body of solar battery modules. In addition to the above-described structures, in the fixing member of solar battery modules according to the present invention, the pedestal is formed with a gap through which a module cable connecting solar battery modules with each other can be inserted between the solar battery modules and the support member. In addition to the above-described structures, the fixing member of solar battery modules according to the present invention further comprises cutoff rubber at a bottom of the fixing member of solar battery modules. In addition to the above-described structures, in the fixing member of solar battery modules, the to-be connected portion, the pedestal, and the portion connecting the pedestal and the to-be connected portion are further configured to restrict a first frame body from moving upward, downward, and outward along a surface of solar battery modules in a direction perpendicular to a longitudinal direction of the first frame body supporting edges of solar battery modules, which are located respectively on a ridge-side and an eaves-side of the solar battery panel main body. In addition to the above-described structures, the fixing member of solar battery modules further comprises at least one fixing screw hole formed in a predetermined position on the plate-like portion extending farther outward than the pedestal. In addition to the above-described structures, in the fixing member of solar battery modules, the portion connecting the pedestal and the to-be connected portion extends farther upward than the center of the pedestal, and the to-be connected portion and the portion connecting the pedestal and the to-be connected portion form a T-shape.
[0010] According to the present invention, the position of the fixing member can freely be moved with respect to the first frame body. Therefore, when fixed to a roofboard of a roof as the support member, the fixing member can be slid and mounted into a position where there is a structure member such as a rafter which supports the roofboard at predetermined intervals, and thereby can be mounted more securely, which enables the solar battery module to be fixed more securely. Since the first frame bodies adjacent to each other across the fixing member are connected to each other by the pedestal and the to-be connected portion, the adjacent two first frame bodies can be fixed by the fixing member, the labor required for mounting the solar battery module can be reduced, and any solar battery module can be fixed to the support member.
[0011] According to the present invention, the fixing member of solar battery modules comprises a portion that connects the pedestal and the to-be connected portion and is configured to restrict outward movement of the solar battery module along a surface thereof, and therefore, the fixing member can be slid freely along the first frame body but restricted from relative movement in a perpendicular direction. As a result, for example, the fixing member can be mounted near a predetermined target position of the solar battery module, and the solar battery module can be fixed at the time of mounting while the fixing member is in a state where it does not disconnect from the first frame body, and therefore, the labor required for mounting the solar battery module can be reduced.
[0012] The first frame bodies disposed adjacent to each other may be connected such that their cross sectional shapes are symmetrical to each other. In such a manner, the shape of the first frame body can be symmetrical and the same with respect to the eaves side and ridge side, and therefore, parts of the first frame body and molds of the first frame body can be commonly used, which can lead to the reduction of cost of the solar battery module main body.
[0013] The fixing member of solar battery modules may further comprise movement-restricting means including an engaging portion formed on the first frame body and a to-be engaged portion formed on the fixing member. In such a manner, the first frame body and the fixing member are engaged with each other though the engaging portion and the to-be engaged portion, and therefore, the relative movement of the first frame body in a direction perpendicular to a longitudinal direction can be restricted. As compared with butting objects only, the solar battery module main body can be prevented from disconnecting even when a force in a direction opposite to the direction of butting is applied by the engagement. For example, when the engaging portion formed on the first frame body and the to-be engaged portion formed on the fixing member are in a hook shape and are engaged in a resilient manner, they can be engaged at predetermined positions without inserting the first frame body from the end surface thereof. Therefore, the labor required for mounting the solar battery module can be reduced. On the other hand, when the engaging portion formed on the first frame body and the to-be engaged portion formed on the fixing member are engaged in an L-shape, the first frame body is supposed to be slid from the end surface and moved to predetermined positions. These portions in an L-shape can be fixed more securely compared to those in a hook shape.
[0014] According to the present invention, the pedestal provided in the fixing member enables the upper-and-lower as well as left-and-right connection of module cables required between the solar battery modules, and therefore, the labor required for mounting the solar battery module can be reduced. By adjusting the height of the fixing member, the solar battery module is consistent in appearance with its surroundings and does not defile the aesthetics. Ventilation can be secured at the lower portion of the solar battery module frame body, which can prevent the power generating efficiency from decreasing due to the temperature rise of the solar battery module.
[0015] The solar battery module frame body may further comprise a second frame body which supports an edge different from the edge supported by the first frame body of the solar battery panel. In such a manner, the solar battery module can be formed into a polygonal shape, and further, the shape of the second frame body is symmetric. Therefore, the left and right parts of the second frame body and molds of the second frame body can be commonly used, which can lead the reduction of cost of the solar battery module.
[0016] According to the present invention, the fixing member of solar battery modules is configured to be slidable and allow the number of parts of the frame body of the solar battery module to be reduced, thereby reducing cost, can be provided.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] The above and other objects of the present invention will become readily apparent with reference to the following detailed description when considered in conjunction with the accompanying drawings wherein:
[0018] FIG. 1A is a schematic plan view showing a state where a solar battery module frame body of an embodiment of the present invention is disposed, FIG. 1B is a right side view of FIG. 1A and FIG. 1C is a rear view of FIG. 1A ;
[0019] FIG. 2 is a sectional view used for explaining the portion of the line A-A in FIG. 1 in detail;
[0020] FIG. 3 is an exploded sectional view of various parts of the solar battery module frame body in FIG. 1 ;
[0021] FIG. 4 is a sectional view showing the portion B in FIG. 2 in detail;
[0022] FIG. 5 is an enlarged view of an essential portion of the solar battery module frame body in FIG. 1 and is a schematic sectional view showing procedure;
[0023] FIG. 6 is a schematic sectional view of procedure following the procedure shown in FIG. 5 ;
[0024] FIG. 7 is a schematic sectional view of procedure following the procedure shown in FIG. 6 ;
[0025] FIG. 8 is a sectional view used for explaining the portion C in FIG. 2 in detail;
[0026] FIG. 9 is a plan view showing the portion B in FIG. 2 ;
[0027] FIG. 10 is a sectional view used for explaining one example of a conventional solar battery module;
[0028] FIG. 11 is a sectional view used for explaining the outline of another shape of a fixing member of the present invention;
[0029] FIG. 12 is a sectional view used for explaining the outline of another shape of a fixing member of the present invention;
[0030] FIG. 13 is a plan view used for explaining the outline of another shape of a fixing member of the present invention;
[0031] FIG. 14 is a plan view used for explaining the outline of another shape of a fixing member of the present invention; and
[0032] FIG. 15 is a sectional view used for explaining FIG. 14 in detail.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0033] An embodiment of a solar battery module frame body which is the best mode for carrying out the invention will be explained based on the drawings. FIG. 1A is a schematic plan view showing a state where a solar battery module frame body of an embodiment of the present invention is disposed, FIG. 1B is a right side view of FIG. 1A and FIG. 1C is a rear view of FIG. 1A . FIG. 2 is a sectional view used for explaining the portion of the line A-A in FIG. 1 in detail. FIG. 3 is an exploded sectional view of various parts of the solar battery module frame body in FIG. 1 . FIG. 4 is a sectional view showing the portion B in FIG. 2 in detail. FIGS. 5 to 7 are enlarged views of an essential portion of the solar battery module frame body in FIG. 2 and are schematic sectional views showing procedure. FIG. 8 is a sectional view used for explaining the portion C in FIG. 2 in detail. FIG. 9 is a perspective view showing the portion B in FIG. 2 .
[0034] As shown in FIG. 1 , according to the solar battery module frame body of the embodiment, a first frame body 1 and a second frame body 2 form a polygonal solar battery module main body 9 . A fixing member 3 is fixed to a ridge-side of each of solar battery module main bodies 9 by a main body fixing screw 5 . As shown in FIG. 1A , first frame bodies 1 and second frame bodies 2 are adjacent to each other, frontage dressing covers 6 can be disposed on the eaves-side, and the outward appearance can be taken into consideration. As shown in FIG. 1B , in the solar battery module main body 9 , the first frame body 1 and the second frame body 2 intersect with each other perpendicularly to each other, and they are assembled by frame body fixing screws 16 . The frontage dressing cover 6 is provided at its end surface with an end surface dressing-cover 7 for enhancing the outward appearance, and the end surface dressing cover 7 can be fixed by an end surface dressing cover screw 18 . As shown in FIG. 1C , the fixing member 3 slides along the first frame body 1 , and structure members 32 (e.g., rafters) which support the roofboard 31 at predetermined intervals can be fixed by main body fixing screws 5 .
[0035] As shown in FIG. 2 , module cables 22 can be connected to each other between upper and lower portions and between left and right sides due to the height of the fixing member 3 , ventilation can be secured at the lower portion of the solar battery module frame body, and it is possible to prevent the power generating efficiency from being deteriorated by the temperature rise of the solar battery module.
[0036] Next, the first frame bodies 1 will be explained based on FIG. 3 . Here, a first frame body 1 (a ridge-side first frame body 1 ) shown on the left side in FIG. 3 will be explained. Another first frame body 1 (an eaves-side first frame body 1 ) shown on the right side in FIG. 3 has a shape which is laterally symmetric, detailed explanation thereof will be omitted. As shown in FIG. 3 , the cross sectional shape of the first frame body 1 is vertically long and has a rectangular shape, a portion thereof exceeding the U-shaped rectangular central portion is recessed toward an inner side of the rectangular shape from the outer side of the frame body around the center of the right side, an intersection between U-shaped upper and right sides has one chamfered connecting portion 10 , and two frame body fixing screw holes 15 are formed in two locations of the rectangular shape, i.e., on a diagonal line and a corner thereof. Further, the right side of the rectangular shape extending downward from the slightly left side from the center of the bottom side has an L-shaped engaging portion 12 with an opening. The left side of the rectangular shape extending straightly upward from an upper portion of the right side of the rectangular shape is formed with an L-shape with an opening. Module glass 23 , having solar battery cells which are necessary for generating power can be sandwiched in the L-shape from the left side while maintaining water resistance by spumous EPDM (ethylene propylene diene methylene) resin 24 . The material of the first frame body 1 is an aluminum extrusion material, and its color is black.
[0037] Each of the fixing members 3 is laterally long and has a rectangular shape, and a vertical cross piece is provided as a reinforcing member at the center between upper and bottom sides inside of the rectangular shape. Since the vertical side and the center reinforcing side of the rectangular shape can adjust the height as a height adjusting pedestal 14 , the height of the solar battery module main body 9 can be adjusted. Two main body fixing screw holes 25 are formed in a depth direction extending from the bottom side to the right side of the rectangular shape for fixing the fixing member 3 . Further, a T-shape with an axis extending upward from the center of the upper side of the rectangular shape is provided, and there are to-be connected portions 11 extending from both sides of the upper side of the T-shape. There is an L-shaped to-be engaged portion 13 with an opening at the bottom side provided on the slightly lower left side from the center of the vertical side of the T-shape. There is a recessed frontage dressing cover recess 20 at a location slightly inside the left side of the upper side of the rectangular shape. The material of the fixing member 3 is aluminum extrusion material or stainless steel, and its color is silver.
[0038] There is cutoff rubber 4 at the bottom of the fixing member 3 . The cutoff rubber 4 prevents rain from leaking from the main body fixing screw 5 . Further, there is an effect of absorbing the pits and projections on the surface of the roof. The material of the cutoff rubber 4 is butyl rubber, and its color is black.
[0039] As shown in FIG. 4 , the solar battery module frame body according to the embodiment of the invention is assembled. The first frames body 1 are vertically symmetric, and they are opposed to each other. The opposed first frame bodies 1 are fixed by the fixing member 3 , and the fixing member 3 is fixed on a roofing member 30 . The roofing member 30 has both a waterproof function and a fire protection function.
[0040] FIGS. 5 to 7 are enlarged views of an essential portion of the solar battery module frame body in FIG. 2 and are schematic sectional views showing the procedure. First, as shown in FIG. 5 , the fixing member 3 is disposed at a location corresponding to a target predetermined position where the fixing member 3 is to be retained, and the eaves-side to-be connected portion 11 of the fixing member 3 and the connecting portion 10 of the ridge-side first frame body 1 of the eaves-side solar battery module are connected to each other. The engaging portion 12 of the ridge-side first frame body 1 and the to-be engaged portion 13 of the fixing member 3 are engaged with each other.
[0041] Next, as shown in FIG. 6 , the fixing members 3 are allowed to slide to positions of at least two or more structure members 32 with respect to the solar battery module main body 9 , the remaining fixing members 3 are allowed to slide to such positions that force is applied to the solar battery module main body 9 substantially equally and the remaining fixing members 3 are placed on the roofing member 30 and are fixed by the main body fixing screws 5 . The main body fixing screw 5 can keep the fixing strength through the roofboard 31 and the structure member 32 .
[0042] As shown in FIG. 7 , since grounding is required between the solar battery modules, at least one grounding hardware 17 is disposed with respect to a side to which the first frame body 1 is opposed. The grounding hardware 17 can become electrically grounded by damaging an alumite layer of an aluminum material of the surface of the first frame body 1 by repulsion when first the frame bodies 1 are joined to each other due to the strong resilient properties of stainless steel material. After the fixing member 3 is fixed by the fixing screw 5 , the grounding hardware 17 is engaged with the L-shaped engaging portion 12 with the opening of the eaves-side solar battery module main body 9 and is connected by the connecting portion 10 of the eaves-side first frame body 1 of the ridge-side solar battery module and the to-be connected portion 11 of the fixing member 3 .
[0043] As shown in FIG. 8 , a frontage dressing cover 6 which enhances the outward appearance can be disposed on the side of the frontage of the solar battery module array 8 . The shape of the frontage dressing cover 6 is a curved one-fourth circle whose curved side faces eaves-side, and there is an L-shaped engaging portion 26 with an opening on the right side which extends downward from a slightly right side from the center of the bottom side of the curved one-fourth circle. The connecting portion 10 and an end surface dressing cover screw hole 19 are located at positions which are symmetric to the connecting portion 10 of the first frame body 1 and the frame body fixing screw hole 15 . An R-member extends downward from the curved one-fourth circle, and its length can be adjusted by a dressing or a rain-preventing member. The material of the R-member is aluminum extrusion material and its color is black.
[0044] As shown in FIG. 9 , the length of the fixing member 3 in the direction parallel to the first frame body 1 is short, but the fixing member 3 can freely slide along the first frame body 1 . The fixing member 3 is fixed using two main body fixing screws 5 .
[0045] According to the solar battery module frame body of the embodiment, the position of the fixing member 3 can be moved freely with respect to the first frame body 1 . Therefore, when the fixing member 3 is fixed to the roofboard 31 of the roof, the fixing member 3 is slid to a position where there is the structure member 32 , such as the rafter which supports the roofboard 31 at predetermined intervals, and then mounted at that position, the fixing member 3 can be mounted more securely, and the solar battery module can be fixed more securely. Since the first frame bodies 1 which are adjacent to each other through the fixing member 3 are connected to each other by the connecting portion 10 and the to-be connected portion 11 , the adjacent two first frame bodies 1 can be fixed by the fixing member 3 , the labor required for disposing the solar battery module can be reduced, and any solar battery module can be fixed to a roof.
[0046] Further, according to the solar battery module frame body of the embodiment, the shape of the first frame body 1 is symmetric with respect to the eaves-side and ridge-side and is the same, parts of the first frame body 1 and molds of the first frame body 1 can be commonly used, and the cost of the solar battery module main body 9 can be reduced.
[0047] Further, according to the solar battery module frame body of the embodiment, the connecting portion 10 of the first frame body 1 and the to-be connected portion 11 of the fixing member 3 can connect the first frame bodies 1 which are adjacently disposed, and the fixing member 3 is fixed. With this, any solar battery module can be fixed to the structure member 32 (e.g., rafter). For example, as the shape of the connecting portion, there is a case where the connecting portion 10 is concave in shape and the to-be connected portion 11 is convex in shape, and a case where the connecting portion 10 is convex in shape and the to-be connected portion 11 is concave in shape.
[0048] Further, since the solar battery module frame body of the embodiment is engaged by the engaging portion 12 formed on the first frame body 1 and the to-be engaged portion 13 formed on the fixing member 3 , the relative movement in a direction perpendicular to the longitudinal direction of the first frame body 1 can be restricted. As compared with butting objects only, it is possible to prevent the solar battery module main body 9 from disconnecting even when a force acting in the direction opposite from the butting object is applied by the engagement. For example, when the engaging portion 12 formed on the first frame body 1 and the to-be engaged portion 13 formed on the fixing member 3 have hook shapes and they are engaged resiliently, since they can be engaged at predetermined positions without insertion from the end surface of the first frame body 1 , the labor required for disposing the solar battery module can be reduced. When the engaging portion 12 formed on the first frame body 1 and the to-be engaged portion 13 formed on the fixing member 3 are engaged by the L-shapes, they are slid from the end surface of the first frame body 1 and moved to predetermined positions, but they can be fixed more securely as compared with the hook shape.
[0049] Although the present invention has been explained based on the preferred embodiments, the invention is not limited to these embodiments, and the invention can variously be modified and the design can be changed within a range not departing from the subject matter of the invention as shown below.
[0050] That is, although the first frame body 1 and the fixing member 3 have the engaging portion 12 and the to-be engaged portion 13 in the embodiment, a fixing member 40 as shown in FIG. 11 may be used. With this, as shown in FIG. 11 , in the conventional solar battery module 41 having no engaging portion, the solar battery module has a connection portion 42 which connects the solar battery modules 41 which are adjacent to each other through the fixing member 40 . Therefore, the solar battery module 41 can be disposed in a building. Further, the position of the fixing member 40 can be moved freely with respect to the solar battery module 41 , the fixing member 40 can be slid to a position where there is the structure member 32 which supports the roofboard 31 at predetermined intervals, and the fixing member 40 can be mounted at that position.
[0051] The fixing member 40 has a shape such that the length of a T-shape of the fixing member 3 is adjusted so that the conventional solar battery module 41 can be sandwiched, and the fixing member 40 has a connecting portion 42 . The material of the fixing member 40 is an aluminum extrusion material, and its color is silver.
[0052] A fixing member 43 shown in FIG. 12 may be used instead of the fixing members 3 and 40 . With this, as shown in FIG. 12 , in the conventional solar battery module formed with the engaging portion 45 , engagement can be established by a to-be engaged portion 46 formed on the fixing member 43 . With this, since the solar battery module 44 and the fixing member 43 are engaged with each other by the engaging portion 45 and the to-be engaged portion 46 , the relative movement in the perpendicular direction can be restricted. As compared with butting objects only, it is possible to prevent the solar battery module 44 from disconnecting even when force acting in the direction opposite from the butt object is applied by the engagement. Further, since the solar battery module frame body has the connecting portion 42 which connects the solar battery modules 44 which are adjacent to each other through the fixing member 43 , the solar battery modules 44 can be disposed in a building. Further, the position of the fixing member 43 can be moved freely with respect to the solar battery module 44 , the fixing member 43 can be slid to a position where there is the structure member 32 which supports the roofboard 31 at predetermined intervals, and the fixing member 43 can be mounted at that position.
[0053] The fixing member 43 has a shape such that the length of a T-shape of the fixing member 3 is adjusted so that the conventional solar battery module 44 can be sandwiched, and the fixing member 43 has a connecting portion 42 . There is a solar battery module frame body having a hook-shaped to-be engaged portion 46 at a location corresponding to the height of the engaging portion 45 of the conventional solar battery module 44 below the upper side of the T-shaped eaves-side. The material of the fixing member 43 is an aluminum extrusion material, and its color is black.
[0054] Further, the fixing member 3 may be a fixing member 50 as shown in FIG. 13 . With this, as shown in FIG. 13 , a portion of the fixing member 50 facing the roof is made thin and long in the flowing direction of the roof as compared with the fixing member 3 , the solar battery module frame body can be disposed in a building more securely even with respect to a roofing 52 having a narrow lateral width. If a main body fixing screw hole 51 deviates from a straight line with respect to the flowing direction of the roof, cracking of the structure member 32 , which is generated when screws are arranged on fiber of the structure member 32 , can be prevented.
[0055] Further, as shown in FIGS. 14 and 15 , the main body fixing screw hole 25 of the fixing member 3 is not directly disposed on the roofing member 30 while using the main body fixing screw 5 by adjusting the size of the main body fixing hole 54 like the fixing member 53 , and the fixing member 53 can be fixed by a main body fixing bolt 55 utilizing fixing hardware 56 for example. With this, the solar battery module main body 9 can be disposed on the roofing member 30 having a waterproof function and a fire protection function, and on the conventional roofing 57 .
[0056] It is readily apparent that the above-described embodiments have the advantage of wide commercial utility. It should be understood that the specific form of the invention hereinabove described is intended to be representative only, as certain modifications within the scope of these teachings will be apparent to those skilled in the art. Accordingly, reference should be made to the following claims in determining the full scope of the invention. | A fixing member of solar battery modules for fixing edges of module glass to a roofboard by solar battery modules supporting a first frame body, including: a to-be connected portion to restrict the first frame body from moving upward; a pedestal to restrict the first frame body from moving downward; a portion connecting the pedestal and to-be connected portion to restrict solar battery modules from moving in a direction perpendicular to a longitudinal direction of the first frame body and outwardly along a surface of solar battery modules; and a plate-like portion extending outward farther than one side of the pedestal, the fixing member being fixed to the roofboard through the plate-like portion, supported on both sides of the portion connecting the pedestal and to-be connected portion such that upper surfaces of adjacent solar battery modules are substantially flush with each other, and slidable along the first frame body. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention pertains to the field of multiple use loop fastening devices having an elasticized cord and a slideable locking element to facilitate the holding and securing of various size structural members.
2. Description of the Prior Art
It is well known to use an elasticized cord as a fastening device. It is also well know to use line locks of various configurations.
U.S. Pat. Nos. 4,328,605, 4,453,292, 4,622,723 and 4,675,948 disclose line locks of the type that are generally useful in the practice of the present invention.
Swedish Patent 70,432 shows a form of a string, wire or thread lock.
French Patent 1.276.059 shows an adjustable loop whose length is controlled by a type of line lock.
U.S. Pat. No. 4,393,550 discloses a safety clasp for footwear wherein a double line lock holds the shoe laces.
U.S. Pat. No. 4,789,070 discloses a clothes airer having a pair of hinged frames whose relative spacing is adjusted by the position of a line lock on a line.
U.S. Pat. No. 5,131,290 discloses a removable steering wheel cover wherein an elastic cord is sewen into the cover, the length of the cord that is trapped within the cover being adjusted by the use of a barrel lock.
While the above devices are generally useful for their limited intended purposes, there is a need in the art for an improved loop fastening device having a loop that is free of other objects and is thus of general utility in surrounding virtually any object that is to be held, wherein manufacturing assembly of the device is simplified, wherein the manual force that is required to move the line lock as the loop size is adjusted is minimized and is not dependent upon a desired loop holding force, and wherein the holding force that is provided by the line lock does not change with cord wear and the like.
SUMMARY OF THE INVENTION
This invention provides a multiple use loop fastening device having a flexible elasticized cord and a manually releasable and slideable locking element that facilitates the holding and securing of various size structural members. The device of the invention provides a simplified manufacturing process, or method, provides a device wherein the manual force that is required to move the locking element along the cord to adjust loop size is minimized by virtue of the fact that the holding force of the locking element is manually releasable during such movement, and wherein the cord holding force of the locking element does not change appreciably with use of the device.
The device of the invention comprises an elongated, flexible, elasticized cord that is formed into a loop, and a manually releasable friction clamp that encircles two parallel runs of the cord and is slideable among the parallel cord runs as the size of the loop is selectively adjusted. As a feature of the invention, the two aligned ends of the cord can be permanently clamped together, such as by the use of a metal crimping device. As a further feature of the invention, the manually releasable friction clamp comprises a manually open barrel-shaped fastener having a spring biased plunger, the plunger operating to allow free movement of the cord runs when the plunger is depressed, and operating to frictionally trap the parallel cord runs within an opening that is formed in the barrel shaped fastener.
In manufacture of the device, the two ends of the cord are first placed in a parallel, side by side, and end-aligned relationship. The two cord ends are then passed through the barrel shaped fastener as the fastener is manually held in its open position. The fastener's spring biased plunger is then released. This operating forms the elasticized cord into a loop having two adjacent parallel runs that pass through the fastener. The two parallel and aligned ends of the cord are then bound together, as by the use of a metal tubular shaped cinch, to form an enlarged end portion that will not pass back through the barrel fastener even when the fastener has been manually opened.
An object of the present invention is to provide a fastening device comprising an elongated and flexible elasticized cord having two ends, the cord being formed into a loop wherein the cord ends are generally end-aligned and extend generally parallel to each other. A manually releasable and slideable locking element has an opening therein that encircles the cord ends, the opening being somewhat larger than the cross-sectional area of the cord ends, the locking element having a manually releasable member that is force biased to frictionally trap the cord ends in the opening, and the locking element being manually releasable to enable the locking element to freely slide along the cord loop as the loop size is adjusted. As a feature of the invention, a nonreleasable cord-binding clamp encircles the cord ends and operates to enlarge the cross-sectional area of the two cord ends so that the cord ends are larger than the size of the opening in the locking element.
A further object of the invention is to provide a method for manufacturing the above-mentioned fastening device comprising the steps of providing an elongated and flexible elasticized cord having two ends, forming the cord into a loop wherein the ends are generally end-aligned and extend generally parallel to each other, and providing a manually releasable and slideable locking element having an opening therein that encircles the cord ends, the opening being somewhat larger than the cross sectional area of the cord ends, the locking element having a manually releasable member that is force biased to frictionally trap the cord ends in the opening, and the locking element being manually releasable to enable the locking element to freely slide along the cord loop to adjust the loop size.
These and other objects and advantages of the invention will be apparent to those of skill in the art upon reference to the following detailed description, which description makes reference to the drawing.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a plan view of a loop fastening device in accordance with the invention.
FIG. 2 is a plan view of the elongated, flexible, elastic cord shown in FIG. 1.
FIG. 3 shows the loop fastening device of FIG. 1 in use to form a loop about an object.
FIG. 4 shows the loop fastening device of FIG. 1 in use to hold a flexible sheet or sign to a metal frame.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 is a plan view of a loop-fastening device 100 in accordance with the present invention. This device as shown in FIG. 2 comprises an elongated, flexible, elasticized cord 10 having two ends 17 and 18. Without limitation thereto, cord 10 is generally circular in cross section. The ends 17,18 of cord 10 are looped and then passed through a generally circular, or elliptical, opening or bore 12 that is formed in the generally cylindrical housing 106 of a locking device 15. Housing 106 has a central axis that is generally identified by broken line 103. The central axis 104 of opening 12 extends generally normal to axis 103. A cylindrical spring biased plunger 16 is spring biased in the direction of axis 103 (by operation of a spring that is internal to the housing 106 of locking device 15), as is shown by arrow 105. Plunger 16 contains an opening, or bore, that mates, or is aligned with, opening 12 when plunger 16 is manually moved to the right, against the above-mentioned spring force, to thus align the opening in plunger 16 with the opening 12 in locking device 15. When these two openings are thus aligned, locking device 15 can be manually moved along the two runs of cord 10 to thus adjust the size of the loop that is formed thereby. This movement requires a minimum of force because the cross-sectional area of the two aligned openings is somewhat larger than the two cord runs that pass therethrough. Once the desired size loop is formed about an object, and cord 10 is stretched a desired amount, plunger 16 is released. The holding force of locking device 15 is dependent only upon the above-mentioned spring bias of plunger 16, and yet the force required to adjust the loop size is minimized greatly because manual movement of plunger 16 to the right, as shown in FIG. 1, operates to align the two above-mentioned openings, and thus allow locking device 15 to freely move along the two runs of the cord loop.
Without limitation thereto, locking device 15 may comprise a well-known barrel-shaped locking device of the Fastex brand by ITW Nexus.
As a feature of the invention, cord ends 17,18 are clamped together by operation of a crimping device 19. In practice, crimping device 19 comprises a metal tube that is crimped down onto cord ends 17,18 to nonreleasably secure the cord ends. In this embodiment of the invention, crimping device resembles a well-known wire clamp.
During manufacture of the device shown in FIG. 1, cord 10 first is formed into a loop wherein cord ends 17,18 are placed in parallel and generally abutting relation, and with cord ends 17,18 generally end-aligned. Plunger 16 is then depressed to align the opening in the plunger with opening 12 in housing 106. The two aligned cord ends 17,18 are now easily passed through these two aligned openings. Plunger 16 is then released. Crimping device 19 is then mounted onto cord ends 17,18. Crimping device 19 operates to increase the cross-sectional area of cord ends 17,18 such that the cord ends cannot freely pass back through aligned openings in locking device 15, thus preventing accidental escape of cord ends 17,18. Crimping device 19 also binds the two cord ends together, and thus provides a means whereby the device may be hung, or stored, on a wall or the like. Within the spirit and scope of the invention, the cross-sectional area of cord ends 101,102 may be increased by other means, such as forming a knot in the cord ends.
Without limitation thereto, embodiments of the invention comprise a cord 10 of generally 1/8 inch diameter. The length of cord 10 is variable and may, for example, comprise 12, 16, 20 and 24 inches.
FIG. 3 shows one loop fastening device 100 of FIG. 1 in use to form a two-run cord loop about an object 20. Object 20 may, for example, comprise a bundle of wires or cables. Arrow 21 of FIG. 3 shows how fastening device 15 is moved to the right to be positioned adjacent to the side of object 20, thus stretching cord 10 and securing the cord to object 20. FIG. 4 shows a plurality of the loop fastening devices 100 of FIG. 1 in use to hold a sheet 36 having eyelets 37,39 therein to a metal frame 35. In both, the use embodiments of FIG. 3 and 4 two-run cord loops have been formed by passing cord ends 17,18 and locking device 15 back through the cord loop. Another use of the invention is to form a one-cord loop by slipping the loop shown in FIG. 1 over an object or objects to be secured.
An important method of using the present invention is shown in FIGS. 3 and 4. In both of these figures, an object, such as 20, is encircled with the free standing loop 50 that is shown in FIG. 1. Free-standing loop 50 is the position adjacent to locking element 15. Locking element 15 is then passed through loop 50. Locking element 15 is now manually released, as by pressing on plunger 16. Locking element 15 is now moved along the two cord runs comprising loop 50 in a manner to stretch loop 50 about object 20. Locking element 15 is now released by releasing plunger 16. In this manner, objects such as 20 and 36, are securely held, and there is no need to slip loop 50 over the object to be held.
While the invention has been described with reference to preferred embodiments thereof, it is recognized that those skilled in the art will readily visualize yet other embodiments that are within the spirit and scope of the invention. Thus, the above-detailed description is not to be taken as a limitation on the invention. | The two ends of an elongated, flexible, elasticized cord are side by side aligned and then passed through a manually opened barrel-shaped fastener having a spring biased plunger. The spring biased plunger is then released. This operating forms a loop from the elasticized cord. The two aligned ends of the cord are then bound together to form an enlarged end portion that will not pass back through the barrel fastener even when the fastener has been manually opened. | 5 |
BACKGROUND
[0001] The present invention relates to a retaining device for a mobile multimedia terminal, such as a pocket pc, a smart phone, a navigation device, or the like, such as an iPhone or iPod touch from the company Apple.
[0002] Furthermore, the present invention relates to a receiving and retaining means for a mobile multimedia terminal, such as a pocket pc, a smart phone, a navigation device, or the like, which preferably is used as a modular component within the retaining device mentioned at the outset.
[0003] Additionally, the present invention relates to a retaining device for a mobile multimedia device, such as a pocket pc, smart phone, navigation device, or the like comprising:
at least one retaining arm; retaining means arranged at a first end of the retaining arm, which are embodied to fasten the retaining arm to the air conditioning register in the area of dashboard or the center console of a motor vehicle; connection means arranged at the other, second end of the retaining arm for the connection to receiving and retaining means for the multimedia terminal.
[0007] Finally the present invention also relates to a retaining arm to connect to receiving and retaining means for a mobile multimedia terminal, such as a pocket pc, smart phone, navigation device, or the like, particularly the receiving and retaining means according to the invention for a mobile multimedia terminal.
[0008] Presently available multimedia terminals provide their users with a wide spectrum of audio-visual content as well as additional gaming and functional applications and are frequently used as a type of substitute television. Overlapping spectra of applications are also possible: for example, smart phones can also be used as navigation devices.
[0009] However, particularly in extended periods of use it must be considered disadvantageous, here, that the user must hold the respective multimedia terminal permanently in a position in his/her field of view considered rather uncomfortable on the long term, which leads to unpleasant stress and/or fatigue of the arm muscles. Additionally, the use of the mobile multimedia terminal mentioned leads to the user only having one hand available over an extended period of time to perform other activities.
[0010] This can be remedied by the mobile multimedia terminal being put down in a suitable fashion on an object, such as a pillow or the like. However, this requires the presence of such a suitable object, which particularly is not always given particularly in mobile applications. Additionally, such a solution requires a relatively static sitting or lying position of the user, which is also undesirable on the mid and long term. Additionally, it has shown that depositions or placing down a mobile multimedia terminal, particularly on a pillow, can negatively influence the quality of audio signals, when for example the installed loud speaker is covered partially or entirely.
[0011] When using the above-mentioned devices in a motor vehicle it must additionally be ensured that the driver is not distracted from his/her primary activity, namely steering the vehicle, and/or that the respective device remains securely in its place, which usually represents an area of the dashboard and/or the center console, even under acceleration or in curves. In this context, retaining devices are already known for mobile phones, which are held by way of snapping and/or via a type of clip connection to the bars of a ventilation or air-conditioning register of the vehicle. However, such devices are expensive and delicately designed, which regularly leads to damages and coincides with a complicated handling, particularly when removing the retainer from the air-conditioning register.
SUMMARY
[0012] On the one hand, the invention is based on the objective to avoid the above-mentioned disadvantages of a retaining device for a mobile multimedia terminal, which is versatile and suitable for daily use due to its simple and cost-effective design, particularly when driving a motor vehicle, and which allows the user to use particularly the video functions of his/her mobile multimedia terminal in a non-tiring fashion over an extended period of time, without here being compromised in his/her manual options and/or the enjoyment of the audio functions of the device. Furthermore, the mobility of the multimedia terminal shall essentially remain uncompromised.
[0013] Furthermore, the invention shall provide a modular component system for retaining multimedia terminals, which allows the flexible use of mobile multimedia terminals in as many possible daily situations as possible without for this purpose in each case a completely different retaining device being required, which would lead to respectively disadvantageous costs and consumption of resources.
[0014] This objective is attained in a retaining device according to the invention for a mobile multimedia terminal, exhibiting receiving and retaining means for a mobile multimedia terminal with the features of the invention, with a retaining device for a mobile multimedia terminal with the features of the invention, as well as with a retaining arm to connect retaining and fastening means for a mobile multimedia terminal with the features of the invention.
[0015] Advantageous further developments of the invention are objectives of dependent claims, with their wording hereby explicitly being included in the description by way of reference in order to largely avoid unnecessary text repetitions.
[0016] According to a first aspect of the present invention a retaining device for a mobile multimedia terminal, such as a pocket pc, smart phone, or the like is embodied as follows: it comprises at least one retaining arm and fastening means arranged at a first end of the retaining arm, which are embodied for the fastening of a retaining arm at a head covering, preferably a common baseball cap or a common headband with a sun visor. Here, the fastening occurs such that the retaining arm extends from the head covering towards the front in the direction of view of the user wearing said head covering. At the other, second end of the retaining arm receiving and retaining means are provided for the multimedia terminal. Furthermore, the receiving and retaining means for the multimedia terminal are arranged or adjustable in reference to the retaining arm such that at least the graphic display device, i.e. the panel of the multimedia terminal received and held in the receiving and retaining means is located essentially centrally in the field of view of the user after the retaining arm was fastened at the head covering.
[0017] According to a second aspect of the present invention this represents a receiving and retaining means for a mobile multimedia terminal, such as a pocket pc, smart phone, navigation device, or the like, which comprise fastening means for a detachable connections to a retaining arm, preferably the retaining arm of the device according to the first aspect of the present invention. The retaining means can particularly be arranged at the rear, while the receiving and retaining means for the multimedia terminal most preferably are embodied as a retaining cup, into which the multimedia terminal can be inserted or clipped in.
[0018] According to a third aspect the present invention represents a retaining device for a mobile multimedia terminal, such as a pocket pc, smart phone, navigation device, or the like, initially comprising the following features:
at least one retaining arm; retaining means arranged at a first end of the retaining arm, embodied to fasten the retaining arm to the air-conditioning register in the area of the dashboard or the center console of a motor vehicle; at the other, second end of the retaining arm connection means are arranged for the connection to receiving and retaining means for the multimedia terminal, which receiving and retaining means preferably being embodied according to a second aspect of the present invention;
[0022] characterized in that the retaining means at least comprising the following elements:
at least one oblong anchoring part with at least one hooked end, which can be guided between two bars of the air-conditioning register, with the hooked end essentially being embodied to encompass the rear narrow side of at least one bar; at least one support part with at least one support element for supporting on the dashboard or a center console, which is displaceable in reference to the hooked end of the anchoring part; locking means for a detachable fixation of the relative arrangement of the hooked end and the support part.
[0026] Within the scope of the above-mentioned modular component system the present invention provides, according to a fourth aspect, an additional retaining arm for the connection to receiving and retaining means for a mobile multimedia terminal, such as a pocket PC, smart phone, navigation device, or the like, particularly for the connection to the above-mentioned receiving and retaining means according to the second aspect of the present invention.
[0027] According to a fundamental idea of the first aspect of the present invention the suggested retaining device comprises therefore at least one retaining arm to be fastened at a head covering. The above-mentioned head covering may here either itself be a part of a retaining device according to the invention or may represent a commercial object, independent and separate therefrom, for example in the form of a baseball cap or the like.
[0028] The retaining arm is therefore fastened at one of its end at the head covering and carries at its other end the above-mentioned receiving and retaining means for the multimedia terminal, by which the latter is fastened to the retaining arm. The multimedia terminal itself is not part of the present invention. In general, any commercially available multimedia terminal may be used with the retaining device according to the invention based on the first aspect of the present invention.
[0029] As already explained, the retaining arm of the retaining device according to the invention based on the first aspect of the present invention, after fastening to the head covering, extends forwardly in the direction of view of the user and the receiving and retaining means for the multimedia terminal are arranged at the front end of the retaining arm and/or appropriately adjustable such that subsequently the display of the multimedia terminal is located in the middle of the field of view of the user so that he/she can easily observe the above-mentioned display with a relaxed position of the head without using his/her hands.
[0030] In this context, the features according to which the above-mentioned fastening means are arranged at one end of the retaining arm shall be understood such that the fastening means are either provided at the retaining arm itself, thus quasi form a part of the retaining arm, or that the fastening means are provided otherwise, e.g., at the head covering, and affect the retaining arm from the outside only, with here they are also arranged thereat.
[0031] In particular with regards to the embodiment of at least one retaining arm, there are various options within the scope of the present invention, which in the following shall be discussed in greater detail also with reference to the attached drawing and the respective description of figures.
[0032] In order for the multimedia-experience to be enjoyed as desired, in light of presently common dimensions of typical multimedia terminals, such as iPhones or iPod tough of the company Apple, a first further development of the fastening device according to the invention based on the first aspect of the present invention provides that the retaining arm, preferably when suitable adjustment options are implemented, particularly an extension of shortening, is embodied such that the receiving and retaining means for the multimedia terminal shows a distance from 10 cm to 40 cm, preferably from 15 cm to 30 cm from the eye of the user.
[0033] Independent therefrom, the retaining device according to the first aspect of the present invention, within the scope of another further development, may have two parallel arranged, essentially identical retaining arms, with the receiving and retaining means for the multimedia terminal being arranged at its second end in order to improve the stability of the arrangement.
[0034] Another further development of the retaining device according to the invention based on a first aspect of the present invention provides that the receiving and retaining means for the multimedia terminal is fastened at the retaining arm in an articulate fashion in order to allow a multitude of adjustment options for the orientation of the display device of the multimedia terminal. In this context, for example the use of a ball-and-socket joint or a pivot joint may be provided between the retaining arm and the above-mentioned receiving and retaining means. Alternatively retaining arms and receiving/retaining means may be embodied in one piece.
[0035] Advantageously the receiving and retaining means are embodied as a receiving cup, in which the multimedia terminal can be laterally inserted and/or clipped in. Separate receiving and retaining means may be provided for each different type of multimedia terminal, sized according to the dimensions of the multimedia terminals.
[0036] Alternatively, it may also be provided that the receiving and retaining means for the multimedia terminal are adjustable to the differently sized multimedia terminals.
[0037] Furthermore, the receiving or retaining means for the multimedia terminal may be fastened to the retaining arm in a detachable fashion, with in this context particularly the use of a screw connection must be considered. However the present invention also includes embodiments in which the above-mentioned receiving and retaining means and at least one retaining arm are connected to each other in one piece, in a form-fitting fashion, or by other means.
[0038] At least one retaining arm may also show a joint within the scope of another embodiment of the first aspect of the present invention, so that the receiving and retaining means for the multimedia terminal can be moved (pivoted) out of the field of view of the user, when necessary.
[0039] Another further development of the retaining device according to the invention based on the first aspect of the present invention provides for the retaining arm being embodied flexibly, at least sectionally, preferably in a bendable, semi-stiff fashion like a gooseneck or the like. This way, a need-based positioning of the multimedia terminal can also be achieved.
[0040] At least one retaining arm must be embodied in a non-straight fashion, but within the scope of a respective further development according to the first aspect of the present invention it may comprise at least one angle or bend in the area of its second end in order for the receiving and retaining means for the multimedia terminal being positioned already in the desired fashion in the field of view of the user. Here, the size of the angle and/or bend preferably ranges from 70° to 110° and most preferably amounts to approximately 90°.
[0041] At least the retaining arm of the retaining device according to the invention based on the first aspect of the present invention, in an appropriate further development, may be embodied at least essentially flat or alternatively showing a round cross-section. Potential materials particularly for the retaining arm of the retaining device according to the invention based on the first aspect of the present invention are plastic and/or metal.
[0042] A particularly preferred further development of the retaining device according to the invention based on the first aspect of the present invention provides for the fastening means to be embodied as clamping means with at least two spring-elastic clamping parts acting opposite each other, by which the retaining arm can be fastened in a clamped position to a visor, shade, brim or the like of a preferably common head covering.
[0043] In the simplest case the retaining device according to the first aspect of the present invention can therefore be pushed upon the visor of a conventional baseball cap, for example. For light devices and/or in general, here a single-arm embodiment of the retaining arm is possible, laterally fastened at the cap visor, with its front end may be bent into the field of view of the user. The retaining arm may additionally exhibit a pivotal joint for a lateral folding away.
[0044] Alternative variants for fastening the retaining device and/or the retaining arms at the head covering comprise according to the first aspect of the present invention, among other things, screw connections, rivet connections, adhesions, VELCRO™ connections, as well as sewed connections, preferably in the area of the visor of a conventional baseball cap.
[0045] Another preferred further development of the retaining device according to the invention based on the first aspect of the present invention provides however that the fastening means show at least one perforation in the retaining arm as well as connection means that can be passed through said penetration, preferably screws, which cooperate with at least one complementary structure, preferably a matching penetration in the visor, shade, or brim area of an otherwise preferably common head covering, in order to fasten the retaining arm at said head covering, with the retaining device most preferably additionally comprising a respectively embodied head covering. Alternatively a suitable structure to be connected to the fastening means may be provided at the head covering, for example a threaded structure or a latching structure for a snap connection with suitable latching means.
[0046] Alternatively, the fastening means, as already indicated, may also be embodied in the form of a VELCRO connection, with for example at the retaining arm a suitable hook material being provided, particularly glued on, while the respective looped material being provided at the head covering, particularly at the top and/or bottom of the visor, sun shade, or the like. Of course, the inverse application is also possible.
[0047] Another further development of the retaining device according to the invention based on the first aspect of the present invention provides that the fastening means comprise a bent, hook-shaped structure in reference to the extension of the retaining arm, which is embodied to engage a suitable structure, preferably an adjustment tape or the like provided in the area of the back of the head covering, in order to fasten the retaining arm at the head covering, with the retaining arm comprising at least one section shaped complementary to the head covering between the fastening means and its second end. Here, too, the retaining device may most preferably comprise additionally an appropriately embodied head covering, which shows the above-mentioned engagement structures.
[0048] Another further development of the retaining device according to the invention based on the first aspect of the present invention is characterized in an otherwise essentially commercial head covering, though, preferably a baseball cap or a headband, each comprising tunnels respectively extending laterally approximately at the height of the temples towards the back of the head, into each of which a retaining arm of the retaining device being inserted, with the retaining arms preferably being mobile within said tunnel, most preferably between an inserted resting position and a projected operating position. The two tunnels may also be combined to a joint tunnel, extending around the area of the back of the head and respectively opening in the frontal lateral area of the head covering.
[0049] Instead of a tunnel, alternative insert means may also be used for the retaining arms, e.g., rings, eyelets, loops, or the like. A VELCRO connection of the retaining arms at the side of the head covering is also possible, with e.g., the hook material being provided at the interior side of the retaining arm and the looped material provided laterally at the head covering, or vice versa.
[0050] All embodiments of the retaining device according to the invention based on the first aspect of the present invention have in common that they may additionally comprise a loud speaker device or a so-called sound system, which is preferably embodied in the form of head phones and which is provided for the fastening at the retaining arm or at the head covering, with the loud speaker device preferably cooperating with the mobile multimedia terminal in a signaling fashion to issue audio signals of the multimedia terminal.
[0051] Within the scope of a particular further development of the retaining device according to the first aspect of the present invention the retaining arm may be embodied, at least partially, by an extended embodied structure of the head covering, such as a visor or the like extended towards the front.
[0052] Another further development of the retaining device according to the first aspect of the present invention provides that for a detachable connection of the receiving and retaining means for the multimedia terminal via the retaining arms at least one pin-like connection part is provided, which can be inserted in aligned penetrations at the receiving and retaining means, on the one side, and at the retaining arm on the other side, in order to couple the retaining arm to the receiving/retaining means in a detachable fashion. Here, it may further be provided that at least one recess is provided at the rear of the receiving and retaining means for a partial receiving (inserting) of the connection part in the direction of its longitudinal extension such that the connection part in its inserted state extends at a finite angle, preferably ranging from 30° to 150°, most preferably from 60° to 120°, or approximately 90° in reference to the back of the receiving and retaining means.
[0053] This way, a support option is provided, with the connection part acting as the support means such that the multimedia terminal, after the removal of the retaining arm, can be placed onto a planar surface together with the receiving and retaining means like a table fastener under a beneficial observation angle. Of course, the support means can also be embodied as a separate component without the above-described connecting function. For reasons of stability an embodiment with more than one support means may also be beneficial.
[0054] Another further development of the retaining device according to the first aspect of the present invention provides that at least one deflectable support part is provided at the rear of the receiving and retaining means, which extends in its deflected state at a finite angle, preferably from 30° to 150°, most preferably from 60° to 120°, or approximately 90° in reference to the rear of the receiving and retaining means. Such a deflected, foldable support part may be used additionally (as a second support part) or as an alternative to the variant described above. Here, particularly the protection from getting lost is advantageous.
[0055] According to one fundamental idea according to the second aspect of the present invention the suggested receiving and retaining means for a mobile multimedia terminal, such as a pocket pc, smart phone, navigation device, or the like comprises connection means for the detachable connection to a retaining arm, preferably the retaining arm of the device according to the first aspect of the present invention described above in greater detail in the sense of the discussed modular system of components. Preferably the above-mentioned connection means are arranged at the rear of the receiving and retaining means, i.e. at the side facing away from the graphic display device of an accepted multimedia terminal. Here, the receiving and retaining means for the multimedia terminal may be embodied as fastening cups into which the multimedia terminal can be inserted or clipped in.
[0056] A further development of the receiving and retaining means according to the second aspect of the present invention provides for the connection means to be embodied for an articulate connection with the retaining arm, preferably like a pivotal or ball-and-socket joint. In this context, for the detachable connection of the retaining arm and the receiving means once more the above-mentioned pin-shaped connection part may be used, as described above.
[0057] Other further developments of the receiving and retaining means according to the second aspect of the present invention provides that a table fastening is also possible via the receiving and retaining means, as described above in greater detail.
[0058] According to the principle idea of the third aspect of the present invention a fastener for an air-conditioning register is created for the use in a motor vehicle, with the components of the respective retaining device, particular the receiving and retaining means for the multimedia terminal can be used here, within the scope of the modular concept of the present invention.
[0059] For the function of the retaining device according to the third aspect of the present invention it is here necessary that it is not only passing through the oblong anchoring part with to at least one hooked end, which can be guided between the bars of the air-conditioning register, with the hooked end being embodied for an essentially form-fitting encompassing of the rear narrow side of at least one bar, in order to be held at the relatively thin bars, as known from prior art, but that at least one additional support part is provided having at least one support element to rest on the dash board or the center console, thus a portion of the retained load is compensated by the considerably more stable components of the dashboard and/or center console. The support part is displaceable in reference to the hooked end of the anchoring part in order to tighten the retaining device in reference to the dashboard and/or center console on the one side and at least one bar at the other side. Here, contrary to the purely bar-based fixation of prior art, particularly the trend for vibration of the arrangement is largely reduced. The above-mentioned fixation means ensure a detachable fixation of the relative arrangement of the anchoring part and/or hooked ends and the support part, depending on the desired strength of retaining force or for the removal of the arrangement.
[0060] A further development of the retaining device according to a third aspect of the present invention provides that the retaining arm and the anchoring part are embodied in one piece, with the retaining arm at its second end being embodied as a hooked element, forming a particularly simple and stable arrangement. In other words, the retaining arm that can be connected within the scope of the modular concept of the invention to the receiving and retaining means and the anchoring part may represent the very same components, with its ends being shaped appropriately. Beneficially, this component extends in a displaceable fashion through the above-mentioned support part in order to this way allowing by a suitable displacing to reach the desired relative arrangement of the anchoring part and/or the hooked end and the support part. This also depends on the type, size, and geometry of the air-conditioning register, the depth of its bars, etc. Alternatively a division of the above-mentioned component into two parts may be advantageous, for example without limitations via interior and/or exterior threads in order to realize a screwed connection, because this way type adjustable lengths of the component can be achieved dependent on the size, and geometry of the air-conditioning register as well as the depth of its bars, which improves the range of application of the suggested retaining device.
[0061] Another further development of the retaining device according to the third aspect of the present invention provides that the anchoring part is arranged rotational in reference to the support part, e.g., via a simple rotary guide. This way, the user can freely decide if the anchoring of the retaining device shall occur at the vertical bars or at the horizontal bars of the air-conditioning register, with here he/she beneficially will select the respective bars embodied stronger, depending on type, size, and geometry of the air-conditioning register.
[0062] Another further development of the retaining device according to the third aspect of the present invention provides that the support part comprises several support arms, preferably three to six support arms, which are mounted to a common fastening structure in a preferably articulate fashion. In this context particularly preferred are four support arms, with two of them each being embodied straight in one piece, so that overall a cross-shaped or X-shaped arrangement with four support points results. According to the fundamental rules of geometry, three support points already define a plane (for example in case of Y-shaped arms) so that this way a secure support is ensured even at greater accelerations. The articulate arrangement allows a flexible adjustment to the geometry of the air-conditioning register, with here within the scope of the invention it is attempted to implement any support for reasons of stability outside the actual air-conditioning register. At the free ends of the above-mentioned arms, at the side facing the dashboard, one support element each may be arranged, with the support elements preferably being cushioned, particularly by a foam rubber element or the like in order to prevent damages of the vehicle interior and to reduce vibrations.
[0063] Another further development of the retaining device according to the third aspect of the present invention provides that the support arms are each embodied adjustable within their length and/or with regards to the angle formed between them, particularly by a pivoting in reference to the fastening structure. This way it is additionally ensured that any support occurs outside the air-conditioning register for reasons of stability.
[0064] Another further development of the retaining device according to the third aspect of the present invention provides that the support part and particularly the support arms are embodied in a spring-elastic fashion in the direction of displacement with regards to the anchoring part, and in order to achieve a secure tightening of the retaining device. Advantageously, for this purpose the arms are embodied in a curved fashion, with the curvature facing the support area (dashboard, console).
[0065] Another further development of the retaining device according to the third aspect of the present invention provides for the anchoring part to comprise a predetermined breaking point in the area of the hooked end. This ensures that no expensive damages of the air-conditioning register develop when for example the retaining device is excessively tightened or is excessively stressed (laterally) during use. The anchoring part may represent a low-cost single-use and/or exchangeable part so that subsequent costs are minimized when damaged.
[0066] Another further development of the retaining device according to the third aspect of the present invention provides that the fastening means are embodied as screw elements, which are preferably arranged on the support part and affect the anchoring part. Alternatively it may be provided that the fastening means are embodied as spring-loaded latching means, which preferably are arranged on the support part and affect complementary structures of the anchoring part. Of course, other possible embodiments may also be used for the detachable fixation of the relative arrangement of the anchoring part and/or the hooked ends and the support part, for example in the form of a clamping mechanism, via fixation pins, magnetic fixation, via geared threads, or the like.
[0067] Another further development of the retaining device according to the third aspect of the present invention provides that the hooked ends comprise a multitude of hooked elements, preferably two hooked elements, which may be arranged side-by-side like the tongue of a snake. This way, the trend for a lateral tipping of the arrangement is reduced. Additionally the respective bar of the air-conditioning register at which the arrangement is tightened to is locally stressed to a lesser extent.
[0068] The hooked end may be sized such that it undercuts more than one bar of the air-conditioning register in order to better distribute the retaining force. Here, another further development of the retaining device according to the third aspect of the present invention provides that the hooked end is embodied in a folding fashion, in particular by the provision of a suitable flip and/or spring mechanism so that after insertion between the bars it is unfolded and thus engages therebehind. Most preferably the above-mentioned folding mechanism is embodied in a reversible fashion, in order to allow removing the hooked end from the air-conditioning register.
[0069] Another further development of the retaining device according to the third aspect of the present invention provides that at least the support part is embodied from plastic, preferably polyamide without fiberglass reinforcement or a similar material, allowing the overall construction to be realizable in a weight saving and cost-effective fashion.
BRIEF DESCRIPTION OF THE DRAWINGS
[0070] Additional features and advantages of the present invention are discernible from the following description of exemplary embodiments with reference to the drawing.
[0071] FIG. 1 a to 1 h show various illustrations and implementations of a first embodiment of the retaining device according to the invention based on the first aspect of the present invention;
[0072] FIG. 2 a to 2 h show various illustrations and implementations of a second embodiment of the retaining device according to the invention based on the first aspect of the present invention;
[0073] FIG. 3 a to 3 h show various illustrations and implementations of a third embodiment of the retaining device according to the invention based on the first aspect of the present invention;
[0074] FIG. 4 a to 4 h show various illustrations and implementations of a fourth embodiment of the retaining device according to the invention based on first aspect of the present invention;
[0075] FIG. 5 a to 5 e show various illustrations and implementations of a fifth embodiment of the retaining device according to the invention based on the first aspect of the present invention;
[0076] FIG. 6 a to 6 g show various illustrations and implementations of a sixth embodiment of the retaining device according to the invention based on the first aspect of the present invention;
[0077] FIG. 7 to 7 i show various illustrations and implementations of a seventh embodiment of the retaining device according to the invention based on the first aspect of the present invention;
[0078] FIG. 8 a to 8 f show various illustrations and implementations of an eighth embodiment of the retaining device according to the invention based on the first aspect of the present invention;
[0079] FIG. 9 a to 9 c show various illustrations and implementations of a ninth embodiment of the retaining device according to the invention based on the first aspect of the present invention;
[0080] FIG. 10 a to 10 c show various illustrations and implementations of an embodiment of the retaining device according to the invention based on the third aspect of the present invention;
[0081] FIG. 11 a to 11 c show various illustrations and implementations of an embodiment of the receiving and retaining means according the second aspect of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0082] When in the following, each time summarizing, “Fig. X” is discussed, here generally all allocated partial figures “Fig. Xy” are included, with y=a, b, c . . . .
[0083] The retaining device according to the invention is marked in FIGS. 1 through 11 overall with the reference character 1 (first aspect of the present invention) and/or 1 ′ (third aspect). It serves to the fastening of a mobile multimedia terminal 2 , such as a pocket pc or a smart phone, which is not a component of the actual retaining device 1 , 1 ′, at a head covering 3 , which preferably and without restriction may essentially be embodied in the form of a commercial baseball cap ( FIGS. 1 through 3 and 5 through 9 ) or like a headband ( FIG. 4 ), and/or fastened at an air-conditioning register of a motor vehicle ( FIG. 10 ).
[0084] A retaining device 1 , 1 ′ according to the invention respectively comprises at least one receiving and retaining means each, in which a multimedia terminal is arranged in a detachable fashion. This receiving and retaining means can be separately sold as a modular system component and is shown in FIG. 11 as a separate unit. Furthermore, each retaining device according to the invention comprises a retaining arm, with fastening means being arranged at one of its ends serving to fastening the retaining arm to a desired fastening object, which may represent either a head covering or an air-conditioning register of a motor vehicle. With its other end the retaining arm is and/or can be connected to the so-called receiving/retaining means. The retaining means may be an integrated component of the retaining arm, or they may be present as a separate and perhaps interchangeable unit. Within the scope of the modular invention concept this way different and flexibly used fastening arrangements can be realized from the (functional) units fastening means, retaining arm, and receiving/retaining means for various applications, which is explained in detail via an example.
[0085] The already discussed head covering 3 may in turn represent a component of the retaining device 1 according to the invention, particularly when special constructive changes are required at the head covering 3 , such as in case of the embodiments according to FIG. 4 and FIG. 5 .
[0086] In particular, the retaining device 1 , 1 ′ according to the invention is suitable for use with an iPod touch or the iPhone of the company Apple, however it is not restricted thereto.
[0087] The retaining device 1 comprises, for example according to FIG. 1 , at least one retaining arm 4 , with fastening means 5 being arranged at one end serving to fasten the retaining arm 4 at the head covering 3 . At the other end of the retaining arm 4 the receiving and retaining means 6 are provided for the multimedia terminal 2 .
[0088] The retaining arm 4 shall be fastened at a head covering 3 with the fastening means 5 such that the retaining arm 4 extends towards the front, from the head covering 3 in the direction of view of the user wearing said head covering 3 . Here, the receiving and retaining means 6 for the multimedia terminal 2 are arranged and/or adjustable in reference to the retaining arm 4 such that at least the graphic display device, i.e. the monitor or the display 2 a of the multimedia terminal 2 is essentially located centered in the field of view of the user after fastening of the retaining arm 4 at the head covering 3 .
[0089] The “free length” of the retaining arm 4 , i.e. the distance between the fastening means 5 and the receiving and retaining means 6 for the multimedia terminal 2 is here preferably measured such that the display device 2 a of the multimedia terminal 2 shows a distance from 10 cm to 40 cm, preferably from 15 cm to 30 cm from the eye of the user when the multimedia terminal 2 is received and retained in the receiving and retaining means 6 .
[0090] These features are present in a functionally similar form in all embodiments of the retaining device 1 according to the invention based on FIGS. 1 through 9 . In the following the individual embodiments of the retaining device according to the invention shall be explained in greater detail using the individual figures and/or details of said figures.
[0091] The embodiment according to FIG. 1 , comprising the details 1 a through 1 h , shows a first, particularly simple embodiment of the present invention.
[0092] According to the side view in FIG. 1 a the individual retaining arm 4 , embodied in the form of a flat tape, comprises at one end fastening means 5 acting as opposite clamping means with at least two oppositely acting spring-elastically clamping parts 5 a and 5 b. Using the clamping parts 5 a, 5 b the retaining arm 4 according to the illustration in FIG. 1 h can be pushed in the direction of the arrow P from the front onto the visor 3 a of an otherwise commercial baseball cap 3 in order to fasten the retaining device 1 in a clamping fashion at the baseball cap 3 . Of course, in this context the invention is not limited to the use with a baseball cap, but in principle it can be fastened at any visor, shade, or brim of an otherwise commercial head covering 3 .
[0093] At its other end, the retaining arm 4 is provided with a bend 4 a such that it extends in this area at an angle of approximately 90° in reference to its primary direction of extension. At the end of the retaining arm 4 opposite the fastening means 5 the above-mentioned receiving and retaining means 6 are arranged for the multimedia terminal 2 . They are embodied like a holding cup, at least partially laterally encompassing the multimedia terminal 2 , such as easily discernible from FIGS. 1 d and 1 e . Preferably, the multimedia terminal 2 can be laterally inserted into the receiving and retaining means 6 according to the arrow P′ in FIG. 1 e , without the invention here being limited to such an embodiment, though. Alternatively the receiving and retaining means 6 may also be embodied in the form of a clamping cup, into which the multimedia terminal 2 can be clipped in. Furthermore, the receiving and retaining means 6 may also be embodied adjustable with regards to their width, for example, in order to quasi fixate any inserted multimedia terminal 2 by a subsequent adjustment of the receiving and retaining means.
[0094] In the present case, the receiving and retaining means 6 are embodied with approximately X-shaped interior penetrations 6 a, 6 b and encompass the inserted multimedia terminal laterally via four slightly inwardly curved retaining projections 6 c, cushioned in an advantageous fashion.
[0095] A bar 6 d arranged in the center of the receiving and retaining means 6 comprises a central penetration 6 e in the form of a bore, according to FIG. 1 e , by which the receiving and retaining means 6 can be fixed via a connection element 6 f , preferably in the form of a screw, at the end of the retaining arm 4 provided for this purpose and appropriately embodied.
[0096] For this purpose, the retaining arm 4 comprises at its end, cooperating with the receiving and retaining means 6 , suitable complementary connection means which are not explicitly shown in the figures for reasons of clarity, for example a bore with an internal thread.
[0097] As discernible for one trained in the art the present invention is by no means restricted to the connection between the retaining arm 4 and the receiving and retaining means 6 shown in FIG. 1 e as an example. Alternatively the connection in this area may also occur by way of adhesion or in any other material-fitting fashion, for example. Furthermore, the receiving and retaining means 6 may also be embodied in one piece with the retaining arm 4 . A connection by way of clamping, insertion, snapping, or via a VELCRO tape may also be considered, here.
[0098] As easily discernible from a review of FIG. 1 b , the retaining arm 4 may be embodied in its straight section (cf. FIG. 1 a ) in several parts so that in the longitudinal direction the retaining arm 4 is embodied in a longitudinally adjustable fashion in the direction of the dual arrow P″. For example, the part of the retaining arm 4 (left in FIG. 1 b ) arranged towards the head covering 3 may be inserted in the remaining part of the retaining arm 4 (right in FIG. 1 b ) so that the above-mentioned ability for displacement and/or adjustment results in the direction of the dual arrow P″. Such an embodiment is discernible from FIG. 1 d , for example. Here, the retaining arm 4 comprises a first part 4 b, which also shows the fastening means 5 , and a second part 4 c, which shows two parallel extending legs, between which the first part 4 b is accepted in a displaceable fashion. Furthermore, according to FIG. 1 d , the above-mentioned bend 4 a of the retaining arm 4 is formed by a link 4 d, adjustable in the direction of the dual arrow P 3 , so that the multimedia terminal 2 , accepted in the receiving and retaining means 6 , can be deflected upwardly out of the field of view of the user, when necessary (cf. the illustration in FIG. 1 h ).
[0099] The perspective views in FIGS. 1 f and 1 g show further developments of the above-described embodiment in which the receiving and retaining means 6 and thus the multimedia terminal 2 is arranged at the retaining arm 4 in a pivotal fashion in the direction of the respective dual arrows. Preferably, for this purpose the receiving and retaining means 6 comprise a link, not shown in greater detail, particularly a hinge or a ball-and-socket joint so that the above-mentioned adjustability results with regards to the retaining arm 4 .
[0100] Again referencing FIG. 1 h , the retaining device 1 may additionally and optionally comprise a sound system 7 , particularly in the form of headphones, cooperating with the multimedia terminal in terms of signaling in order to allow the user receiving audio signals from the multimedia terminal 2 . The cooperation may occur wired or wireless. The sound system 7 may be an integral component of the head covering 3 , which for this purpose is appropriately designed. Alternatively the sound system 7 may also be provided as a separate component of the retaining device 1 , apart from the head covering 3 .
[0101] Advantageously, based on FIGS. 1 a through 1 h , the essential components of the retaining device 1 according to the invention are made from plastic to the extent possible and useful without the present invention being limited thereto, though. However, for certain components of the invention an embodiment comprising (light) metal is also possible. Particularly the receiving and retaining means 6 may also be made from metal, particularly aluminum, in a preferred embodiment of the present invention (cf. FIG. 8 ).
[0102] Particularly FIG. 1 b shows other optional fastening means 5 c, 5 d in the form of penetrations (holes) in the retaining arm 4 and/or the upper clamping part 5 b. Connection means, e.g., in the form of screws, can be inserted through the holes 5 c, 5 d into suitable complementary structures in the head covering 3 , e.g., in respective penetrations in the visor 3 a ( FIG. 1 b ) in order to fixate the retaining arm 4 at the head covering 3 . The bottom clamping part 5 a may here be waived. Furthermore, the above-mentioned connection means can also be used in a conventional head covering, of course, in order to increase the clamping force.
[0103] When using the device 1 with the fastening means 5 it is simply pushed in the direction of the arrow P onto the visor, the shade, or the brim of the head covering 3 , as discernible from FIG. 1 h , and is here held by the fastening means 5 . A multimedia terminal 2 , held by the receiving and retaining means 6 , is then positioned in a pleasant distance in the middle of the field of view of the user so that he/she can relaxed observe the display device 2 a of the multimedia terminal 2 in a relaxed manner without using his/her hands.
[0104] The FIGS. 2 a through 2 h ( FIG. 2 for short) show certain further developments of another embodiment of the retaining device 1 according to the invention. In the present case, only the essential deviations from the above-described embodiment according to FIGS. 1 a through 1 h are discussed in greater detail.
[0105] As particularly discernible from the top view of FIG. 2 b the retaining device 1 according to FIG. 2 comprises two parallel retaining arms 4 . 1 and 4 . 2 , otherwise embodied identical to the retaining arms 4 according to FIG. 1 . For an adjustment to the usually slightly curved shape of the cap visor 3 a the two retaining arms 4 . 1 , 4 . 2 according to FIG. 2 c , for example, extend not in the same plane but at a certain (obtuse) angle α, see FIG. 2 c.
[0106] As discernible from FIG. 2 e , for example, the two retaining arms 4 . 1 , 4 . 2 are connected jointly to the receiving and retaining means 6 , which for this purpose exhibit a respective number of penetrations 6 e.
[0107] Otherwise the design and function of the retaining device 1 according to FIG. 2 is completely identical to the above-stated explanations concerning FIG. 1 so that no further description is necessary, here.
[0108] For the connection to the head covering 3 , accordingly both retaining arms 4 . 1 , 4 . 2 are pushed with the respective fastening means 5 . 1 , 5 . 2 onto the cap visor 3 a or the like of the head covering 3 (cf. FIG. 2 h ).
[0109] The embodiment according to FIG. 3 (comprising FIGS. 3 a through 3 h ) is largely identical to the above-described embodiment according to FIG. 2 . However, here some particulars shall be pointed out:
[0110] As discernible from FIG. 3 , for example the details 3 a and 3 b, the retaining arms 4 . 1 , 4 . 2 are not only curved downwards by 90° at the reference character 4 a but further in the direction towards the user (respectively at the left in the detailed illustrations of FIG. 3 ) twisted at the reference character 4 e by 90°. Except for this detail, the embodiment according to FIG. 3 is essentially equivalent to the one of FIG. 2 , with another essential exception that no fastening means per se are provided at the retaining arms 4 . 1 , 4 . 2 . As easily discernible from FIG. 3 h , in the present embodiment of the retaining device 1 the fastening means are a component of the head covering 3 , which as already mentioned therefore becomes a component of the retaining device 1 . According to the illustration in FIG. 3 h the fastening means, with only one being explicitly shown in 5 . 2 due to the selected illustration, are each embodied laterally as a pocket or tunnel arranged in the temple area of the head covering 3 , in which the retaining arms 4 . 1 , 4 . 2 are (detachably) inserted or sewn in. This way, the retaining arms 4 . 1 , 4 . 2 are held in the present embodiment of the retaining device 1 laterally at and/or in the head covering 3 , which provides the fastening means. The other embodiments of the retaining device 1 are otherwise equivalent to the ones in FIG. 1 and/or FIG. 2 , particularly with regards to the receiving and retaining means 6 and the adjustment possibilities of the retaining arms 4 . 1 , 4 . 2 .
[0111] In the embodiment according to FIG. 3 the retaining arms 4 . 1 , 4 . 2 are preferably embodied from an at least partially flexible material, in order to allow in the lateral area of the head covering 3 an at least partial adjustment to the shape of the head of the user (wearing the cap).
[0112] The embodiment according to FIG. 4 (comprising the details FIG. 4 a through 4 h ) is largely identical to the ones in FIG. 3 . The only essential difference here comprises that the head covering 3 is not embodied as a baseball cap or the like but as a headband without a visor. The reference character 3 ′ marks (idealized) the upper head area of the user.
[0113] In order to fasten the retaining arms 4 . 1 , 4 . 2 at the head covering 3 , i.e. the headband, the latter once more comprises at least a pocket or a tunnel 5 . 2 , into which the retaining arms 4 . 1 , 4 . 2 are inserted or sewn in to hold them laterally at the head of the user.
[0114] FIG. 5 (comprising the details 5 a through 5 e ) shows a particularly simple embodiment of the retaining device 1 according to the invention in which the retaining arms 4 . 1 , 4 . 2 are embodied from a preferably metallic tubular or wire material. The retaining arms 4 . 1 , 4 . 2 can here be formed in one piece from a single wire element.
[0115] In the following, some particulars of the embodiment according to FIG. 5 are explained in greater detail.
[0116] As particularly discernible from the side view in the (partial) FIG. 5 a the retaining arms 4 . 1 , 4 . 2 , starting from their end facing away from the receiving and retaining means, exhibit first a straight progression. Subsequently, at the reference character 4 f, first a bend downwards follows by approximately 45° and then, at the reference character 4 g, another bend again by approximately 45° upwards so that the progression of the retaining arms 4 . 1 , 4 . 2 is subsequently once more parallel in reference to the originally straight progression. Furthermore, the retaining arms 4 . 1 , 4 . 2 are embodied like a flange in one piece or, at the reference character 4 i, in a mountable fashion, and merge in the area of the receiving and retaining means 6 such that overall a U-shaped, flange-like progression develops in the top view (cf. FIG. 5 b ).
[0117] The receiving and retaining means 6 are provided in the area of the central U-legs 4 h , which may occur in an particularly simple fashion, for example, such that the retaining arms 4 . 1 , 4 . 2 each are laterally inserted in a respective recess of the receiving and retaining means 6 , as indicated in FIG. 5 d . Due to the preferably round cross-section of the retaining arms 4 . 1 , 4 . 2 , this way an easy pivoting of the receiving and retaining means 6 can be realized in the direction of the dual arrow in FIG. 5 d.
[0118] The fastening means to connect the retaining arms 4 . 1 , 4 . 2 with the head covering 3 according to FIG. 5 e are once more embodied as a part of the head covering 3 , which therefore represents a component of the retaining device. Preferably, in this context once more at least a lateral tunnel or a lateral pocket 5 . 2 is provided in the temple area of the head covering 3 . Within the scope of an embodiment as simple as possible in the retaining device 1 , in the above-mentioned area simply a series of loops or eyelets may be provided, into which the retaining arms 4 . 1 , 4 . 2 are respectively inserted. Here, a VELCRO connection is also possible.
[0119] As indicated in FIGS. 5 a and 5 b by a separating line T, the retaining device 1 may also be embodied shortened in the area of the retaining arms 4 . 1 , 4 . 2 . Such an embodiment is suitable for the fastening directly at the cap visor 3 a , particularly by way of sewing, riveting, adhering, or also via a VELCRO connection. In the following, the latter fastening variant is described in greater detail with reference to FIG. 7 . FIG. 8 also shows a shortened variant of the retaining device 1 , which is generally equivalent to the above-discussed variant when separated along the separation line T.
[0120] FIG. 6 (comprising the partial FIGS. 6 a through 6 g ) shows a particular embodiment of the retaining device 1 according to the invention, which is provided for an “over the head assembly”.
[0121] In the following, the particular features of this embodiment are discussed in greater detail, which in the area of the receiving and retaining means 6 as well as their connection to the retaining arms 4 . 1 , 4 . 2 are essentially equivalent to the embodiment according to FIG. 2 .
[0122] Contrary to FIG. 2 , the retaining arms 4 . 1 , 4 . 2 embodied shortened in the direction towards the head of the user are not equipped themselves with the fastening means 5 . 1 , 5 . 2 , but are connected to teach other via lateral connection parts 4 . 3 , 4 . 4 with the lateral connection parts 4 . 3 , 4 . 4 each exhibiting a penetration in the area between the retaining arms 4 . 1 , 4 . 2 , into which another retaining arm 4 . 5 can be inserted centrally into the area between the retaining arms 4 . 1 , 4 . 2 and is here held in an adjustable fashion. The additional retaining arm 4 . 5 comprises at one end, by which it is inserted into the above-mentioned lateral connection parts 4 . 3 , 4 . 4 , an essentially straight, flat progression. Towards its other, free end it is curved approximately semi-circularly and ends at its free end in a hook-shaped 180° bend 4 . 5 a.
[0123] The use of the retaining device according to FIG. 6 is here as follows:
[0124] Using the bend 4 . 5 a the retaining arm 4 . 5 is fastened and/or engaged in the area of the back of the head at the head covering 3 (cf. FIG. 6 h ), which for this purpose shows a suitable fastening structure in the areas mentioned, which preferably is formed by the adjustment tape of a conventional baseball cap or the like. Of course, in an arbitrary type of head covering a dedicated fastening structure may be provided in this area, e.g., in the form of a ring, an eyelet, or a flap, which the retaining arm 4 . 5 can engage with the bend 4 . 5 a.
[0125] Subsequently the retaining arm 4 . 5 with its curved area is guided over the head and/or the head covering 3 of the user and then contacts the head covering 3 preferably in the area of the lateral connection part 4 . 3 , 4 . 4 and/or the parallel retaining arm 4 . 1 , 4 . 2 at the reference character 4 . 5 b, for example at the visor 3 a of a baseball cap.
[0126] As discernible for one trained in the art it is generally also possible, instead of the retaining arms 4 . 1 , 4 . 2 and the lateral connection elements 4 . 3 , 4 . 4 , to provide a single retaining arm 4 . 5 , extended towards the front, which otherwise may be embodied in the frontal area essentially like the embodiment in FIG. 1 .
[0127] Furthermore, of course the object of FIG. 6 may also use an embodiment of the retaining arm 4 . 5 and/or the retaining arms 4 . 1 , 4 . 2 with joint(s) 4 d according to the FIGS. 1 d through 4 d.
[0128] In other areas one trained in the art also may freely combine individual features of the above-described embodiments according to the FIGS. 1 through 8 without any inventive activity.
[0129] FIG. 7 (comprising the partial FIGS. 7 a through 7 i ) shows another embodiment of the retaining device 1 according to the invention, which largely is equivalent to the embodiment shown in FIG. 2 , so that here only a few particulars need to be described in greater detail.
[0130] They relate to the fastening means 5 . 1 , 5 . 2 for fastening a retaining device 1 and/or the retaining arms 4 . 1 , 4 . 2 at the head covering 3 with a visor 3 a , shown exemplary in FIG. 7 i.
[0131] In the embodiment according to FIG. 7 the fastening means 5 . 1 , 5 . 2 are embodied in the form of VELCRO connections. They respectively comprise one hook element 5 e, which cooperates with a loop element 5 f. Preferably the hook elements 5 e are each arranged at the bottom of the retaining arms 4 . 1 , 4 . 2 , while the loop elements 5 f being located on the top of the visor of the cap (cf. FIG. 7 i ). However, the opposite arrangement is also possible. Furthermore, hook and/or loop elements may also be provided at the bottom of the visor of the cap. Instead of two separate hook and/or loop elements a single, continuous element may also be used on the visor of the cap.
[0132] Of course, such a connection between the retaining device 1 and the head covering 3 is generally also suitable for the use in the other embodiments of the present invention shown, particularly for the lateral mounting of the retaining arm according to FIG. 5 or instead of and/or in addition to engaging in the area of the back of the head in the embodiment according to FIG. 6 . Here, the hook or loop element may extend centrally over the entire head covering 3 .
[0133] For the intended use of the retaining device according to FIG. 7 it is connected via its retaining arms 4 . 1 , 4 . 2 simply in the direction of the arrow P 4 shown in FIG. 7 a and FIG. 7 i via the described VELCRO connection to the head covering 3 , i.e. the hook elements 5 e and the loop elements 5 f are made to contact each other.
[0134] Finally, FIG. 8 (comprising partial FIGS. 8 a through 8 f ) shows an embodiment of the present invention, which is based on those described above in detail based on FIG. 5 . In this context it has already been discussed that the embodiment according to FIG. 5 may be embodied shortened by separation at the separation line T and in this context is particularly suitable for fastening at a visor of a cap or a sun shade. This is shown in detail in FIG. 8 .
[0135] According to FIGS. 8 a through 8 c the retaining arms 4 . 1 , 4 . 2 are produced from the same material as in the embodiment according to FIG. 5 , however they otherwise extend similar to the embodiment according to FIG. 2 . In other words, the retaining arms 4 . 1 , 4 . 2 extend downwards after the bend at the reference character 4 a and inwardly towards a common point at which they are connected via the receiving and retaining means 6 . Here, too, the retaining arms 4 . 1 , 4 . 2 may be embodied in one piece. At the common point, a thickening (not explicitly shown) or even a U-shaped bend may be provided which serves to accept a screwing means for fastening the receiving and retaining means 6 .
[0136] The receiving and retaining means 6 according to the illustration in FIG. 8 e are formed by an X or cross-shaped part, which at its free bar end in turn shows slightly inwardly curved retaining projections 6 c, already mentioned repeatedly. The central penetration 6 e serves to the (detachable) connection to the ends of the retaining arms 4 . 1 , 4 . 2 , preferably via a screw connection.
[0137] The receiving and retaining part according to FIG. 6 in FIG. 8 e can particularly be embodied as a light-metal punched part, preferably comprising aluminum.
[0138] FIG. 8 f shows the fastening of the above-described retaining device 1 in the area of the visor of the baseball cap 3 a with an otherwise commercial baseball cap 3 . The fastening may occur by way of sewing, rivets, screws, adhesion, insertion, or by a VELCRO connection.
[0139] Here, it shall once more be pointed out that the head covering 3 shown in FIGS. 1 through 8 , particularly in FIGS. 1 h through 4 h, 5 e, 6 g, 7 i, and 8 f not necessarily needs to be a part of the retaining device according to the invention. The latter can also exist without any head covering 3 , acting independently. However, it is beneficial to provide a head covering as a part of the retaining device according to the invention when the head covering, in order to cooperate with the remaining retaining device must be adjusted in its design in a certain fashion, as is the case for example according to FIGS. 3 h through 5 h.
[0140] The sound system 7 , as already mentioned, is only an optional component of the present invention. In particular in the embodiments according to FIG. 3 and FIG. 4 the optional sound system 7 may be fastened at the retaining arms 4 . 1 , 4 . 2 extending lateral along the head.
[0141] The retaining device 1 and here particularly the retaining arm 4 and/or the retaining arms 4 . 1 , 4 . 2 , 4 . 5 with their parts as well as the receiving and retaining means 6 may be provided as separate parts for storage, transportation, and packaging purposes, which advantageously are combined only by the end user in order to form the finished retaining device.
[0142] For reasons of stability the retaining arms 4 . 1 , 4 . 2 may extend in the two-arm variants shown also crossing each other.
[0143] FIGS. 9 a through 9 c show views of another embodiment of the retaining device 1 according to the invention. FIG. 9 a shows a top view, FIG. 9 b shows a side view, and FIG. 9 c shows a front view displaying the side of the retaining arm 4 facing away from the wearer. The entire arrangement of retaining arm 4 , fastening means 5 , as well as receiving and retaining means 6 may be embodied in a particularly light-weight plastic construction, with particularly the V-shaped clamping means 5 . 1 , 5 . 2 , extending away from each other, and the retaining arm 4 being embodied integrally in one piece. The retaining arm 4 also splits sectionally into two parallel extending, curved retaining arms 4 . 1 , 4 . 2 , which define an approximately elliptic free space 8 between each other, which particularly contributes to save weight. However, it is also possible in the area of the free space 8 to provide an additional, appropriately shaped (plastic) part (not shown), which for example may be provided with printed advertisement. The fastening means 5 (in FIGS. 9 a - 3 also differently called fastening means 5 . 1 , 5 . 2 ) are equivalent in their function essentially to the fastening means according to, for example, FIG. 2 so that there is no need for further explanation, here.
[0144] The receiving and retaining means 6 differ from the ones in FIG. 2 essentially by their overall Y-shaped embodiment, which also requires no detailed discussion.
[0145] FIG. 10 (comprising the partial FIGS. 10 a through 10 c ) discloses however another essential aspect of the present invention, with the retaining device here being marked with the reference character 1 ′ and embodied as a retaining device for fastening at an air-conditioning register of a motor vehicle, which shall be explained in greater detail in the following. Here, FIG. 10 a shows a front view displaying the dashboard and/or the center console of a motor vehicle, FIG. 10 b a cross-section approximately along the line B-B in FIG. 10 a , and FIG. 10 c a schematic illustration to explain the function, which is essentially equivalent to the view along the line C-C in FIG. 10 a.
[0146] In FIG. 10 a the reference character 9 marks the dashboard and/or the center console of a typical motor vehicle. Here, a ventilation or air-conditioning duct 10 is arranged, which usually comprises an adjustable air-conditioning register 11 with horizontal bars 11 a and vertical bars 11 b, which are typically arranged like a rectangular grid. The retaining device 1 ′ according to the invention serves to fasten a multimedia terminal, not shown in FIG. 10 , in the area of the air-conditioning duct 10 and/or at the air-conditioning register 11 .
[0147] For this purpose, the retaining device 1 ′, as already discernible in FIG. 10 a , comprises a support part 12 , which in the present case shows four support arms 12 . 1 - 12 . 4 , arranged like the letter X. Here, the support arms 12 . 1 and 12 . 3 and/or 12 . 2 and 12 . 4 are each connected to each other in one piece, resulting in the above-mentioned X-arrangement. The support arms 12 . 1 - 12 . 4 are linked to a central retaining structure 13 and pivotal in reference to each other according to the dual arrow in FIG. 10 a , allowing an adjustment to various air-conditioning geometries. The other arrows E, for reasons of clarity drawn only in the area of the support arms 12 . 1 and 12 . 4 , symbolize the adjustability of the support arms 12 . 1 - 12 . 4 in the direction of their respective longitudinal extension, which allows an additional adjustment to the geometry of the air-conditioning duct.
[0148] Furthermore, a retaining arm 4 is discernible from FIG. 10 a , which in the present case extends starting at the central fastening structure 13 first forwardly and then parallel in reference to the dashboard 9 (upwardly) and which shows connection means 14 , drawn only schematically, for a detachable connection to the receiving and retaining means for a multimedia terminal to be fastened. Both the receiving as well as the fastening means, and the multimedia terminal are not shown in FIG. 10 for reasons of clarity. For example, they can generally be equivalent to the embodiment according to FIG. 1 or FIG. 2 without the present invention being restricted to such an embodiment, though.
[0149] The connection means 14 preferably represent a part of a ball-and-socket joint with the receiving and retaining means (not shown) then accordingly comprising another joint part. The present invention is not limited at all to the above-mentioned exemplary type of joints so that here all other types of joints and connections known to one trained in the art may be used, which may not only be mechanical in nature but also may be of a magnetic or adhesive nature.
[0150] The cross-section according to FIG. 10 b illustrates additional essential features of the retaining device 1 ′ according to the invention: As discernible from FIG. 10 b , an oblong anchoring part 15 with a hooked end 15 a is provided in a mechanically active connection with the retaining arm 4 (cf. also FIG. 1 c ), which can be guided between the bars 11 a, 11 b of the air-conditioning register 11 . In order to ensure this, a respective dimension of the hooked end 15 a may not be greater than the distance between two neighboring horizontal or vertical bars 11 a, 11 b . Advantageously, in this context the oblong anchoring part 15 is rotational about its longitudinal axis in order to this way allowing to thread the hooked end 15 between the bars 11 a, 11 b of the air-conditioning register 11 when required. The hooked end 15 a is embodied to engage behind a bar, in the present case a vertical bar 11 b of the air-conditioning register 11 , and this way appropriately anchoring the anchoring part 15 . As shown in FIG. 10 c , the hooked end 15 a may also be bent backwards in the direction of the remaining anchoring part 15 in order to engage this way the rear narrow side of the bar 11 b in an essentially form-fitting fashion. As already mentioned, due to the rotary embodiment of the anchoring part 15 the anchoring function according to the invention is not limited to engaging a vertical bar 11 b (cf. FIG. 10 c ). In this context it is particularly advantageous when the retaining arm 4 and the anchoring part 15 according to a preferred embodiment of the present invention are embodied in two parts, for example by providing a suitable screw-connection with an internal thread and an external thread (not shown). This way, it is ensured on the one hand that the retaining arm 4 and with it the connection means 14 , regardless of the orientation of the connection part and/or the connection part 15 and/or the hooked end 15 a, always exhibit the desired orientation with regards to the connection to the receiving and retaining means (not shown) for the multimedia terminal. Additionally this way an effective longitudinal extension of the unit comprising retaining arm 4 and anchoring part 15 can be adjusted to different geometries of the air-conditioning register.
[0151] In order to ensure a secure anchoring of the described retaining device 1 ′ at the air-conditioning register 11 the support part 12 with its support arms 12 . 1 - 12 . 4 is arranged thereon displaceable in reference to the hooked end 15 a of the anchoring part 15 and/or the retaining arm 4 , which is symbolized in FIG. 10 c by the dual arrow V. This way, the distance A between the support part 12 and the hooked end 15 a can be adjusted until it essentially matches a distance A between the front area of the dashboard and/or the center console 9 and the rear narrow side of the bars 11 a, 11 b . In reference to the retaining device 1 ′ the respective distance A′ between the base of the hooked end 15 a and the support elements 12 ′ of the support part 12 is defined, with the support elements 12 being arranged at the free ends of the support arms 12 . 1 - 12 . 4 . The support elements 12 ′ are preferably embodied from a soft, oscillation damping material, such as foamed rubber or the like. By pulling the retaining arm 4 and/or the anchoring part 15 in the direction of the arrow Z in FIG. 10 c and/or by pressing in the direction of the arrow D upon the support part 12 this way a tightening of the retaining device 1 ′ can be achieved between the air-conditioning register 11 and the dashboard and/or the center console 9 . The curved or bent embodiment of the support arms 12 . 1 - 12 . 4 shown increases the tightening force by the spring effect connected thereto.
[0152] In order to permanently fixate the relative arrangement of the anchoring part 15 , 15 a and the support 12 achieved this way in a detachable manner, a fixation means 16 is provided according to the schematically displayed illustration in FIGS. 10 b and 10 c , which acts in a suitable fashion upon the retaining arm-anchoring part arrangement 4 , 15 particularly mechanically or magnetically, in order to prevent that the support part 12 moves away from the dashboard and/or the center console 9 on the above-mentioned arrangement which would coincide with a loss of clamping force. In the schematic illustration according to FIG. 10 c the fixation means is embodied as spring-loaded clamping or latching means, which can be unlocked by pressing upon the operating element 16 a shown in order to tighten and/or to loosen the retaining device 1 ′ and to remove it from the air-conditioning register 11 .
[0153] However, the present invention is not limited to the above-described exemplary embodiment of the fixation means 16 . A simple alternative embodiment provides in this context for the operating element 16 a to be embodied in the form of a simple latching pin or screw, which can be inserted or screwed into suitable penetrations (not shown) in the retaining arm 4 and/or the anchoring part 15 .
[0154] At the reference character 17 the anchoring part 15 may exhibit in the area of the hooked end 15 a a predetermined breaking point with for example lower material thickness so that in case of excessive tightening force no damage of the respective bar 11 a, 11 b can occur but “only” the hooked end 15 a being torn off. In this context it is advantageous for the anchoring part 15 to be embodied as a separate exchangeable part in order to allow exchanging it independent from the retaining arm 4 .
[0155] In particular the support part 12 with the above-mentioned support arms 12 . 1 - 12 . 4 is embodied from a plastic material within the scope of the present invention, with the use of non-fiberglass reinforced polyamide (PA) proved to be particularly advantageous, without being restricted thereto.
[0156] FIG. 11 (comprising partial FIGS. 11 a through 11 c ) shows a particular embodiment of the receiving and retaining means 6 as a separately traded unit, which generally may be used in all retaining devices 1 , 1 ′ shown in connection with the respective retaining arm 4 .
[0157] FIG. 11 a shows schematically the receiving and retaining means 6 , which generally may be equivalent to the above-described embodiments. They serve to receive and retain a multimedia terminal 2 , also shown only schematically. In the following, as well as generally according to the wording of the present description, the side of the receiving and retaining means 6 mutually engaging the multimedia terminal 2 is called the “front”. According to this wording, at the rear of the receiving and retaining means 6 connection means 14 ′ are arranged, which beneficially are embodied complementary in reference to the two already discussed connection means 14 (cf. FIG. 10 ) at the retaining arm 4 in order to this way allowing a detachable connection between the retaining arm 4 and the receiving and retaining means 6 . According to the schematic illustration in FIG. 11 a the above-mentioned connection is here realized in the form of a pivotal joint, and for this purpose a first joint part 14 a is provided at the retaining arm 4 with a penetration 14 b and a second joint part 14 a ′ with a penetration 14 b ′ at the receiving and retaining means 6 . The above-mentioned joint parts 14 a, 14 a ′ can also be mechanically interacting, with the above-mentioned penetrations 14 b, 14 b ′ being aligned to each other such that via an inserted rod-shaped connection part 18 the desired (pivotal) connection develops between the retaining arm 4 , on the one side, and the receiving and retaining means 6 , on the other side. This is indicated in FIG. 11 via a dot-dash line. Accordingly, the receiving and retaining means 6 can be separated from each other after the removal of the connection part 18 . This status is shown in FIG. 11 b.
[0158] As furthermore discernible, at their rear the receiving and retaining means 6 exhibits a recess in the form of a blind hole 19 , embodied for partially accepting the connection part 18 by a simple plug-in connection. Here, the recess 19 is embodied such that it extends the connection part 18 after insertion at an angle ε, with ε preferably being below 90°. This way, without any major construction expense a table fastening can be realized for the mobile multimedia terminal 2 , based on the receiving and retaining means 6 . The connection part 18 may be embodied at its end not inserted in a suitable fashion such that it ensures secure placement, for example by a suitable slip-resistant coating, an enlarged embodiment, or the like.
[0159] FIG. 11 c shows a variant of the embodiment of the receiving and retaining means 6 described above based on FIG. 11 b . In addition to the connection part 18 shown in FIG. 11 a and FIG. 11 b and/or instead thereof, in the embodiment according to FIG. 11 c a pivotal support 18 ′ is provided, which is linked at the reference character 18 ″ at the rear of the receiving and retaining means 6 and pivotal in the direction of the dual arrow according to FIG. 11 c . The pivotal support 18 ′ may be provided, as already mentioned, in addition to the inserted support according to FIG. 11 b in order to ensure a secure stand of the receiving and retaining means 6 . Furthermore, there is the chance to provide the recess 19 shown in FIG. 11 b in the area of the pivotal link 18 ″ according to FIG. 11 c so that then the pivotal support 18 ′ could be realized by the inserted connection part 18 according to FIG. 11 b.
[0160] In a suitable embodiment of the retaining arm 4 (cf. FIG. 11 a ) the receiving and retaining means 6 according to FIG. 11 can be used both within the scope of the (cap) fastening device 1 as well as the (air-conditioning register) fastening device 1 ′. This once more illustrates the uniform, modular character of the present invention, which provides system components adjusted to each other for the flexible use of mobile multimedia terminals. | A retaining device ( 1′ ) for a mobile multimedia terminal ( 2 ), such as a pocket PC, smart phone, navigation device, or the like, including: at least one retaining arm ( 4 ); a fastening device ( 5′ ), arranged at a first end of the retaining arm and which is designed to fasten the retaining arm to an air-conditioning duct cover ( 11 ) in the area of the dashboard or the center console ( 9 ) of a motor vehicle; a connecting device ( 14 ) arranged at the other, second end of the retaining arm for connecting to a receiving and retaining element ( 6 ) for the multimedia terminal. The retaining device ( 1′ ) is characterized in that the fastening device ( 5′ ) includes at least the following elements: at least one elongated anchoring part ( 15 ) having at least one hook end ( 15 a ), which can be inserted between bars ( 11 a , 11 b ) of the air-conditioning cover ( 11 ), the hook end ( 15 a ) being designed to encompass the rear narrow side of at least one bar in a substantially form-closed manner; at least one support part ( 12 ) having at least one support element ( 12′ ) for being supported outside the air-conditioning cover ( 11 ) on the dashboard or the center console, which can be moved (V) relative to the hook end ( 15 a ) of the anchoring part ( 15 ); a locking device ( 16 ) for detachably fixing the relative arrangement of the hook end ( 15 a ) and the support part ( 12 ). The retaining device is part of a modular component system for the flexible use of modern multimedia terminals. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
The invention in the present application is related to the subject matter in U.S. patent application Ser. No. 08/537,569, filed Oct. 2, 1995, which is a continuation of Ser. No. 08/290,4351, filed Aug. 15, 1994, now abandoned, which is a continuation of Ser. No. 07/807,007, filed Dec. 13, 1991, now abandoned; Ser. No. 08/173,738, filed Dec. 23, 1993, now allowed; U.S. Pat. No. 5,526,472; and U.S. Pat. No. 5,525,982.
CROSS-REFERENCE TO RELATED APPLICATIONS
The invention in the present application is related to the subject matter in U.S. patent application Ser. No. 08/537,569, filed Oct. 2, 1995, which is a continuation of Ser. No. 08/290,451, filed Aug. 15, 1994, now abandoned, which is a continuation of Ser. No. 07/807,007, filed Dec. 13, 1991, now abandoned; Ser. No. 08/173,738, filed Dec. 23, 1993, now allowed; U.S. Pat. No. 5,526,472; and U.S. Pat. No. 5,525,982.
FIELD OF THE INVENTION
The present invention relates generally to systems and methods for compressing data. More particularly, the invention is directed to systems and methods for implementing a sliding window type Lempel-Ziv data compression algorithm.
BACKGROUND OF THE INVENTION
Digital data compression is a technology experiencing accentuated interest in the recent years. In part, this is a consequence of the broad use of personal computers and workstations having high resolution graphic display systems. The volume of the digital data used to represent the video information, as well as the speed with which it must be compressed and decompressed, in the course of storage or transmission has motivated significant investigation in the technologies related to data compression.
A data compression algorithm which has proven to be quite popular was first described in an article entitled "A Universal Algorithm for Sequential Data Compression" by authors Lempel and Ziv, as appeared in the IEEE Transactions on Information Theory, Vol. IT-23, No. 3, pp. 337-343, 1977, generally referred to as the LZ-1 data compression algorithm. The LZ-1 algorithm has been refined in various respects by subsequent investigators, examples being the variance described in U.S. Pat. Nos. 5,003,307 and 5,146,221, the subject matter of which is incorporated by reference herein.
The fundamental concepts which characterize these and other versions of the basic LZ-1 algorithm involve the use of a buffer to store new data and to identify new strings of data which match previously received and processed data. Thereby, new strings of data, typically alphanumeric characters, which match existing strings can be identified by merely referring to an offset and length in an earlier point in the string sequence. The LZ-1 algorithm is dynamic in that new data is entered into the buffer which stores the earlier data after the comparison and encoding of new data is completed. The size of the buffer is analogous to a sliding window over a data stream in which the new data characters are always compared to previously received characters within the length of the window. The encoded output is either a raw/literal character, indicating no compression, or a compressed/string character, providing a length and offset identifying the matching previously existing character string within the window. As would be expected, the algorithm is increasingly effective as the size of the window increases and repetition of the patterns in the data characters within the window increases.
However, the classical LZ-1 algorithm suffers from the need for extensive comparison between the data characters within the window and various combinations of new data characters. As a consequence, implementations involving large sliding window buffers seldom complete exhaustive searches of the window data for data character matches.
The aforementioned U.S. patent application Ser. No. 08/537,569 relates to a high speed hardware implementation of the LZ-1 algorithm, the subject matter which is incorporated by reference herein. U.S. Pat. No. 5,526,472 relates to a toroidally implemented circular bit shift register which is characterized by its high speed of accomplishing linear shift operations in a conventional processor environment. U.S. patent application Ser. No. 08/173,738 relates to a new way of practicing the LZ-1 algorithm, involving the use of a data character addressed history buffer with shifting entries and various registers for comparing, tracking and counting markers associated with the presence and order of data characters.
The data compression implementation according to U.S. patent application Ser. No. 08/173,738 involves extensive shifting of bits in unison within the history table, or individually with selective update, and is therefore not particularly adapted to execution by a conventional processor. Though barrel shifters can be used to shift the markers in the history buffer, the operational widths of barrel shifters typically conform to the processor operand size. In contemporary designs this is 32 bits. In contrast, the length of the bit string of markers in a typical row of the history buffer is at least 512 bits, requiring 16 operations by a 32-bit barrel shifter to complete processing.
Therefore, there remains a need for systems and method which provide exhaustive sliding window data compression while reducing the number of shift operations and minimizing the number of such shift operations to the extent that they do exist.
SUMMARY OF THE INVENTION
The present invention defines a lossless data compression system, comprising a means for receiving successive data of different characters, means for marking a memory to indicate the receipt of a first data character and its order of occurrence, means for marking the memory to indicate the receipt of a second data character and its order of occurrence, means for detecting a string match between an order of successive new data characters and the first and second data characters by copying, shifting and comparing marked position from the memory, and means for encoding new data responsive to the means for detecting a string match. In another form, the invention relates to methods for performing the operations characterized by the aforementioned apparatus.
In one form, the present invention defines a refined combination of the teachings in aforementioned U.S. patent application Ser. No. 08/173,738 and U.S. Pat. No. 5,526,472, where the history buffer is managed by a pointer and the comparison data in registers is shifted using a circular bit shift register of toroidal form. The use of a pointer avoids the need for shifting the numerous marker bit strings in the history buffer, but necessitates the shifting of comparison data in a related register. In view of the earlier noted limitations of barrel shifters, and the absence of barrel shifters in many processors, the long bit string is optimally shifted using the preferred toroidal bit shift register.
A preferred implementation of the invention involves the use of a large character history bit pattern memory of matrix form in which the row addresses uniquely correspond to different data characters and the column address is specified by an indexed or incremented pointer. Together the addresses uniquely identify a memory cell storing a marker bit. The pointer is incremented with the receipt of each successive data character subject to comparison. The onset and continuity of data character string matches is accomplished with registers which are used to copy marker patterns from the memory, which provide information identifying continuing matches, which store logical AND combinations of marker data, and which are bit serially rotated in relative synchronism with the pointer as new data characters are evaluated. The sliding window data compressions so accomplished are exhaustive as to the memory content. The output of the compression is a succession of raw/literal or compressed/string tokens which represent the data in a lossless format.
The use of the toroidal bit shift register architecture to accomplish the bit wise shift of marker related to data in a register permits the shift to be accomplished with minimum operations in a generic processor. The linear pattern of the marker bits in the register are translated into a matrix and efficiently manipulated in that format to accomplish the shift.
The present invention lends itself to high speed lossless exhaustive sliding window data compression which can be efficiently accomplished with conventional data processors.
These and other features of the invention will be more fully understood and appreciated upon considering the description of the detailed embodiment set forth hereinafter.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 depicts a personal computer or workstation system.
FIG. 2 schematically depicts by block diagram the relation of the processor to the various other elements in a personal computer or workstation system.
FIG. 3 depicts by schematic block diagram the functional elements which comprise one embodiment of the present system.
FIGS. 4A and 4B schematically depict the status of markers in the memory and registers as relates to the encoding of the data characters "ABABC".
FIGS. 5A and 5B provide by flow chart the operations characterizing FIGS. 3, 4A and 4B.
FIG. 6 schematically depicts the operation of a toroidal shift register.
FIGS. 7A, 7B and 7C provide by flow chart descriptions of the matrix formation and manipulation to accomplish a toroidal bit shift operation.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The fundamental concepts of Lempel-Ziv data compression have been well known for years, as evidenced by the date of the initial technical publication and ensuing refinements thereof. The present invention is directed to systems and processes which refine and extend the basic principles in the Lempel-Ziv data compression algorithm variant generally known as LZ-1.
In general, the LZ-1 algorithm achieves compression by creating and maintaining a data structure, generally called a history buffer, which represents the succession of previously received data characters. New data characters are compared individually and in successively longer strings to the data character patterns in the history buffer for matches. When such matches are detected, the output from the data compressor is a compressed/string token which references the length and position of the existing data character string rather than explicitly coding that string. Data characters not within the history buffer are issued as raw/literal tokens. The larger the history buffer and more repetitive the data character patterns, the greater the effective data compression that can be accomplished.
The LZ-1 data compression algorithm is lossless in that each incoming character is represented in the compressed form as either a raw/literal token or a part of a compressed/string token.
In the context of such prior art practice an input data character not subject to compression is issued as a raw/literal token, composed of a binary "0" followed by 8 bits representing the character. A compressed/string token is composed of a binary "1" followed by two strings of bits, the first string representing the length of the corresponding previously existing data character string and the second string representing the position or relative position of the prior character string in the history buffer.
During decompression, the raw/literal and compressed/string tokens are translated in a complementary fashion, whereby the raw/literal tokens are translated directly into the corresponding characters and compressed/string tokens are translated by reference to previously translated tokens in a decompression buffer.
Implementations of the LZ-1 data compression algorithm through software manipulation are subject to the constraints characterizing conventional processors. For example, the refined implementation in U.S. patent application Ser. No. 08/173,738 defines an arrangement for exhaustively searching a large sliding window but requires shifting of numerous extensive bit strings. Unfortunately, general purpose processors are not efficient at shifting extremely long strings of data bits. Though barrel shifters are available in some processors, the barrel shifters still manage data shifting typically only by the operand width of the processor.
A refined system and method for circularly shifting by one bit position long strings of bits is described in U.S. Pat. No. 5,526,472. The system and method define the management of a single string of bits to accomplish a circular shift. Unfortunately, the refined history buffer architecture described in U.S. patent application Ser. No. 08/173,738 involves the shifting of multiple bit strings, each of a bit width equal to the sliding window size in bytes.
The invention as embodied herein defines a system and method for efficiently compressing data characters, in a format suitable for a conventional decompression, using a general purpose personal computer or workstation, such as the one depicted in FIG. 1. Workstation system 1 includes cabinet 2 which houses the volatile and non-volatile memory, the processor, and the input/output (I/O) system. The I/O system provides access to external communications resources as well as communication between workstation resident tape drives, floppy disc drives, hard disc drives and CD disc drives. FIG. 1 shows that the preferred system includes a video display 3 with screen 4, a keyboard system 6 and a mouse controller 7. All such devices are well known in the industry.
FIG. 2 depicts by block diagram the functional interconnection of the elements from FIG. 1. Though system 8 as depicted in FIG. 2 is generic, it represents the operating environment within which the present invention may be practiced. Namely, it indicates that data compression of the form and in the manner now described does not require specialized hardware or system configurations.
FIG. 3 depicts by functional blocks the elements and operations needed to accomplish data compression in the manner characterizing the present invention. The functions are preferably accomplished within the processor. The memory is preferably the cache or main memory of the processor. Although the registers can be the processor registers, they will more likely be uniquely defined sections of the cache or main memory.
The input data 9 in FIG. 3 provides a serial succession of data characters, such as the classic alpha numeric characters represented, by the 8-bit (byte) ascii character string. As each character is received, state machine 11, programmed within the processor, undertakes specified operations within the system by generating control signals or sending data to the related functional elements. Character history bit pattern memory 12 stores marker bits at locations in the matrix coincident with new data characters (specifying a row address), and the order of occurrence of that character as defined by circular pointer 13 indexed or incremented with the processing of new characters. The pointer identifies the column position of the marker corresponding to a new character. Addressing of the markers in memory 12 is responsive to update and read signals generated by state machine 11, as implemented through the read/update select section 14 of memory 12.
The rows of marker bits for each character within memory 12 are selectively conveyed to AND block and COPY block 17. AND block 17 is selectively enabled by state machine 11 to perform a bit wise AND operation on a row from memory 12 with a corresponding string of bits in OLD register 18, and to provide the outcome by bit to lower portion 19 of the NEW register. COPY block 17 is selectively enabled by state machine 11 to convey a row of marker data bits to register 19. The NEW register also includes functional block 21, block 21 having resources to provide a toroidal type circular bit shift and a COPY upon enablement by state machine 11. The shifted and copied marker bits are selectively transferred from the NEW register to OLD register 18. An efficient way to accomplish the shift between registers 21 and 18 is to ping-pong the two registers during operation.
As state machine 11 cycles with the receipt of new input data characters, matches to the strings of previously received data characters, as represented by the pattern of markers in character history bit pattern memory 12, are counted in match length block 23. Encoder 24 generates encoded output data tokens representing the input data characters received from block 9. If an input data character is to remain in the raw/literal form, state machine 11 enables encoder 24 accordingly. In contrast, when the encoder output is to be a compressed/string token, the issuance is delayed until the maximum length input data character string can be represented by a single token. The length of the compressed/string token is provided by block 23, while the location of the matching character string is derived from the set bit index provided by OLD register 18.
What makes the present invention particularly valuable is the combined use of an entry pointer to distribute new data characters into history buffer array locations in a circular fashion, together with the use of a circular bit shift register, such as the preferred toroidal bit shift register, to shift occurrence bit patterns in synchronism with the pointer.
FIGS. 4A and 4B illustrate by example the use of the invention to compress a sequence of input data characters, the sequence being the character string "ABABC". The character string "ABABC" is compressed in the succession of operational cycles 0-4, with cycle 5 performing an end of termination or initialization operation. For purposes of this illustration, character history bit pattern memory 12 (FIG. 3) is eight positions in length, has a matching circular column pointer, and is composed of three rows individually ascribed to characters A, B and C. The operations and effects associated with each cycle and input data character are described and depicted at the right.
The compression of the input data character sequence commences with an initialization, wherein the memory registers are all zeroed. At cycle zero, the input data character is "A". Reference to the OLD register indicates there is no continuing match status. Reference to the "A" character row indicates the presence of no markers, establishing no previous occurrences of "A" Therefore, "A" is encoded immediately as a raw/literal token r(A) as shown in output sequence 26. Since no match was identified, the match length must be zero. After the raw/literal token is generated, a marker bit is placed in the leftmost location of the row corresponding to the "A" history. The location is designated by the pointer. A rotation of the marker pattern in the NEW register and a transfer into the OLD register concludes cycle zero.
Cycle 1 illustrate the processing of a subsequent input data character "B" An evaluation of the marker pattern in the OLD register again indicates the absence of a continuing match, by the lack of any 1s. The absence of any 1s in the "B" row of the memory indicates no previous occurrences of the "B" Therefore, raw/literal token r(B) is generated immediately for the input data character "B" The memory row for the "B" data characters is then updated with a marker, in this case situated in the next column as specified by the incremented pointer. The match length remains O. The marker data in the NEW register is again rotated by the toroidal bit shift register, by one bit position, and entered into the OLD register.
Cycle 2 represents the evaluation of the next input data character "A" Again, an examination of the OLD register indicates the absence of a continuing match. However, an examination of the "A" character row indicates a non-zero marker location, signaling the beginning of a match. Accordingly, the COPY function is initiated to copy the row of marker data corresponding to the "A" character into the NEW register, and the match length function is correspondingly incremented by one. Thereafter, the "A" row in memory is updated by the addition of a marker in the column designated by the indexed pointer. Note that no tokens are issued by the encoder.
Cycle 3, the processing of next successive character, begins as shown in FIG. 4B with an examination of the bits in the OLD register. The presence of a nonzero bit represents a continuing match status. In such case, a bit wise AND is performed between the bits in the OLD register and marker bits in the "B" row of the memory. The outcome of the AND operation is provided as a string to the NEW register. Since the outcome in the NEW register is non-zero, a continuing match condition is indicated and the match length is indexed or incremented by one from its prior value. The "B" data character row in memory is then updated with a marker coinciding with the shifted pointer, in this case adding a one to the fourth position from the left. Note again that no token is issued.
Cycle 4, the receipt of the "C" input data character, commences with an examination of the OLD register and a responsive conclusion that a continuation of a match is still in progress. A bit wise AND of the OLD register with the markers in the "C" register produces an outcome which is entered into the NEW register. An examination of the bits in the NEW register indicates that the match with a prior character string was terminated with the "C" character. Since the match length, namely the character string "AB" is greater than one, a compressed/string token is issued. The token C(len=2, disp=0) indicates a match length of two and a displacement of zero, the latter location defined by the onset of the match. An examination of the markers in this "C" data character row indicates no prior occurrence of "C", resulting in the generation of a raw/literal "C" token. The "C" row in the memory is then updated with a marker as indicated by the indexed pointer. Note that during cycle 4 two tokens were issued, the first being a compressed/string token and the second being a raw/literal token. The issuance of the first token is motivated by the end of a string match while that of the second token is attributable to an absence of any markers in this "C" row during the preceding four cycles.
Cycle five is a termination cycle to reset the example system.
The embodiment described with reference to FIGS. 4A and 4B utilizes a pointer which is successively indexed or incremented through the column addresses of the character history bit pattern memory in an endless circular loop. The rotate one bit operation performed in anticipation of a transfer from the NEW register to the OLD register, before the commencement of a new cycle, involves a circular bit shift preferably performed by a toroidal bit shift register.
It should be apparent that increasing the number of characters subject to encoding increases the number of rows in the memory array, while increasing the size of the history through which the match is undertaken increases the number of columns in the memory array. The example also illustrates that the system and method of the present invention completes an exhaustive search of the history in memory for all incoming character strings, to identifying the longest matching sequence. Foremost, note that the rows of the memory are not shifted with each cycle as characterized by prior practices, but rather rely upon a pointer. The rotation of the bit pattern by one bit position per incoming character is performed in a highly efficient manner for very lengthy bit strings without resort to barrel shift registers and within the framework of conventionally architected processors. The unique efficiency of the toroidal bit shift register will be described hereinafter.
FIGS. 5A and 5B depict by generic flow diagram the operations performed to process input data characters, as exemplified in FIGS. 4A and 4B. Elements 26, 27, 28, 29, 31 and 32 describe the management of the initialization and conclusion, as well as the selection of the characters from the character history bit pattern in the memory. Element 33 relates to the evaluation of the match for continuity. Elements 34 and 36 relate to the generation of a token upon the finding of a full length match. Element 37 relates to the bit wise AND operation of the OLD register data with the markers in the character history bit pattern. Element 38 involves the determination of whether a token can be generated in element 41, or whether the match length should be incremented as indicated in element 39. Element 41 relates to a copying of the character history bit pattern responsive to an outcome of element 33, indicating all zeros in the OLD register. Element 42 involves an evaluation of the bits in the NEW register, which results in either a token generation according to element 43 or a setting of the match counter back to one according to element 44. The operation defined in element 46 is accomplished in succession after the completion of element 39, the completion of element 43 or the completion of element 44. The rotation of the new register by one bit position is defined in element 47, which upon conclusion returns the operating sequence back to element 27.
Referring briefly back to the functional block diagram in FIG. 3, recall that the key distinctions which characterize and make valuable this invention over the teachings in U.S. patent application Ser. No. 08/173,738 involve the use of a pointer to avoid the need for shifting markers within character history bit pattern memory 12, and the use of a circular bit shift register, the preferred toroidal bit shift register, to accomplish the circular bit shift ascribed to block 21 of the NEW register. The goal is to allow a general processor to rapidly compress data, thereby requiring that the number of circular bit shift registers be minimized and that such remaining circular shift function be accomplished with minimum complexity and time delay. The present invention reduces the circular bit shift register count down to a single unit and optimizes that unit through the use of the toroidal bit shift register architecture and method of operation.
The toroidal bit shift register is described in U.S. Pat. No. 5,526,472. The particulars of the toroidal bit shift register are schematically depicted in FIG. 6, where a 16-bit position pattern (0-15) is shown undergoing a circular shift by one position. The goal is to progress from the linear string at 48 to the one bit circular shifted string at 49 with minimum expenditures of processor resources and time. This is accomplished according to the toroidal bit shift register by first transforming the linear pattern at 48 into the matrix pattern at 51. Next, a single bit circular shift of one row from within matrix 51 is followed by an indexing of the row pointer by one position. These operations are schematically depicted within the matrix at 52. The end result is the matrix at 53. The matrix at 53 is then transformed back to the linear format at 49. Note that only one row of the matrix required a single bit circular shift, in the example involving the shift of 4 bit positions in contrast to the original need for shifting 16 bit positions.
FIG. 7A depicts by a flow chart the operations performed to arrange a linear bit string, such as 48 in FIG. 6, into the matrix format 51 in FIG. 6. The flow chart in FIG. 7B indicates the operations undertaken by a processor to perform the functions schematically depicted in the matrix at 52 in FIG. 6, namely the circular shift of a row and indexing of the row pointer. FIG. 7C depicts the flow chart for a processor executing the regeneration of the linear format at 49.
Decompression of the tokens generated by the system depicted in FIG. 3 involves nothing more than conventional decompression practices. In general, the tokens are parsed into the raw/literal and compressed/string elements. The literal elements are nothing more than the direct representations of the data character conveyed. In contrast, the compressed/string tokens are decoded to identify the locations and lengths of preceding strings of characters as stored within a conventional linear decompression buffer. The data character string so identified is then inserted in the appropriate location within the sequence entered into the buffer. Movement within the linear buffer is readily accomplished using a pointer.
The present invention significantly improves the speed of exhaustive sliding window data compression over large windows using conventional processors.
Program code suitable to tuning the character history bit pattern for increased performance during compression is set forth below.
__________________________________________________________________________hmaint(c,pc) /* maintain history bit patterns once per input byte */int c,pc:register unsigned row,col; /* temp variables to map bit pos in tsr todisp */register unsigned colbit, rowbit;col = (bin >> 4) & 31;row = bin & 15;colbit = 1 << col;rowbit = 1 << row;#if SMALL.sub.-- PAGESif( hind[c] & rowbit)history[c][row] |= colbit;elsehistory[c][row] = colbit;#elsehistory[c][row] |= colbit;#endifhind[c] |= rowbit;if( bin >= HIST LEN){if(!(history[pc][row] &= .sup.˜ colbit))hind[pc &= .sup.˜ rowbit;}}__________________________________________________________________________
A subroutine for rapidly performing the AND operations between bit patterns ascribed to block 16 in FIG. 3 is set forth below.
__________________________________________________________________________c.sub.-- pat.sub.-- X.sub.-- hist(possible, hist, pattern )unsigned register possible; /* value in this is really type short (16bits)*/unsigned int hist[ ];unsigned int pattern[ ];unsigned register newhits;register int f;unsigned register b,r,np;unsigned int pi,pl;newhits = 0;pl = pat.sub.-- len;do {f = smart.sub.-- first.sub.-- set.sub.-- bit(possible );b = 1 << f;pi = (f - pl) & 15;r = pattern[pi];if( np = r & hist[f] ){ /* it is very important NOT to store a zeroresultback to the pattern, because if the overall result is zero, we need togoback and find a set bit from the previous pattern to generate thedisplacement.This avoids all the data movement in having an old and new copy of thestringocurrence history bit pattern, i.e. an alternating buffer. We can dothisbecause in this code a history word is never referenced if its index bitisclear. *//* if(np !=r) */pattern[pi] = np;/* technically we dont have to do the store if the value has notchanged, however the compare and branch may be more costly than thestore, since this location is now in the cache and the eff addresshas already been computed above. This is why the np != r test iscommented out. */newhits |= b;/* set the bit in result index that indicates the indexed word in newoccurrence pat contains ones. */} }while( possible &= .sup.˜ b);return hewhits;}__________________________________________________________________________
Though the invention has been described and illustrated by way of a specific embodiment, the systems and methods encompassed by the invention should be interpreted to be in keeping with the breadth of the claims set forth hereinafter. | Systems and methods for compressing data. Lempel-Ziv data compression is applied in the context of an exhaustive sliding window implementation using a large character history bit pattern memory. Shifted updating of the character history bit pattern memory is accomplished through a pointer system. Linear patterns of bits, derived by COPY function from the character history bit pattern memory or by bit wise AND logic combination of selected bit patterns, are circularly shifted in synchronism with new data characters using a toroidal bit shift register. The relatively long bit strings subject to shifting are converted to a matrix format, shifted with fewer affected bits and returned to a linear format. The systems and methods materially improve the speed of exhaustive sliding window data compression as accomplished by general purpose processors. | 7 |
FIELD OF THE INVENTION
[0001] This invention relates to the protection of power transistors, and, more precisely, to a thermal protection device for an integrated power MOSFET that generates an over temperature flag signal for turning off the overheated power transistor.
BACKGROUND OF THE INVENTION
[0002] During operation, power MOS transistors warm up and accidentally may reach temperatures high enough to cause their failure. For this reason, it is important to know the so-called Safe Operating Area (SOA) of MOS transistors, for ensuring that they function in safe operating conditions.
[0003] FIG. 1 illustrates a SOA. A Safe Operating Area of a transistor corresponds to a set of the working points of the transistor bordered by certain curves. These curves are calculated for a certain drain-source voltage and a certain working temperature of the transistor. Typically, they indicate limit functioning conditions for safe operations of a power transistor at a certain working temperature when a square drain-source voltage pulse is applied.
[0004] The typical approach to prevent failures of power transistors includes integrating together with the power MOS a protection device that monitors the current flowing in the transistor and the voltage across it (Vds). If the working point identified by these two values approaches a border of the SOA, the protection device intervenes to keep the working point inside the SOA.
[0005] An important parameter to be considered for determining the SOA of a power MOSFET is its working temperature. It is a well known fact that the SOA of a transistor shrinks when the working temperature increases. Therefore, a certain driving voltage appropriate for driving a power transistor at a certain temperature, may damage it if the working temperature of the power transistor is higher.
[0006] Indeed, a protection device capable of considering all variables that may influence the SOA of a transistor is practically impossible to implement. For this reason, certain protection devices overprotect the power MOS transistor, thus strongly limiting it functioning, while other protection devices though allowing a full exploitation of the capabilities of the transistor, may be unable to prevent failure by overheating under any condition.
[0007] To prevent power transistors from heating up to a temperature potentially dangerous for its integrity, a temperature sensor may be realized near the power MOS or inside it, for sensing its working temperature. The protection device of the power MOS may thus limit power dissipation when the working temperature exceeds a pre-established threshold.
[0008] Commonly, a suitable temperature sensor is realized in the form of a bipolar transistor, as disclosed in U.S. Pat. No. 5,396,119 assigned to the assignee of the present invention.
[0009] A drawback of this approach may be that the sensor is generally integrated on the chip at a certain distance from the power MOS, and it may not sense exactly the real working temperature of the MOS transistor. Moreover, parasitic activations of this sensor, caused by below ground voltages of the drain of the power MOS (in case of an N-channel MOS) are likely to occur.
SUMMARY OF THE INVENTION
[0010] It has been found a thermal protection device for an integrated power MOS transistor that overcomes the above mentioned drawbacks.
[0011] Basically, the temperature in the well diffusion containing the interdigitated power MOS structure is sensed by forcing a certain current through a small number of the interdigitated source regions of the power MOS, purposely connected separately from the others.
[0012] Of course, the voltage of these separately connected source regions through which a certain current is forced will depend on their temperature, thus an over temperature flag may be generated by comparing the voltage of these separately connected source regions with a threshold voltage.
[0013] The thermal protection device of this invention benefits from the outstandingly precise manner in which the temperature of the power MOS is monitored because the temperature sensor is essentially a portion of the integrated power MOS itself.
[0014] More precisely, this invention provides a thermal protection device for an integrated power MOSFET transistor including interdigitated array of source regions and drain regions defined in a well region of the monocrystalline silicon substrate, and gate structures overhanging channel regions defined between adjacent source and drain regions, having a temperature sensor and a comparator for generating an over temperature flag signal usable for turning off the overheated power transistor.
[0015] The thermal protection device senses in a very accurate manner the temperature of the power MOS because it includes: means or a circuit for forcing a fixed current through a small number of source regions of the interdigitated array separately connected from the other source region selectrically connected in common of the power transistor; and a comparator, integrated on the substrate outside the well region, comparing the source voltage present on the small number of separately connected source regions with a threshold voltage for producing on an output the over temperature flag signal.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] The features and advantages of this invention will become even more evident through the following detailed description of an embodiment and by referring to the attached drawings, wherein:
[0017] FIG. 1 shows as already discussed a typical Safe Operating Area of a power MOS as in the prior art;
[0018] FIG. 2 shows a first embodiment of the thermal protection device of this invention;
[0019] FIG. 3 shows an alternative embodiment of the thermal protection device of this invention;
[0020] FIG. 4 shows a sample layout positioning of the components of the device of FIG. 3 ;
[0021] FIG. 5 shows a preferred circuit embodiment of the comparator of the device of FIG. 3 ;
[0022] FIG. 6 shows the circuit of a generator of the current If(t, Rv) for the comparator of FIG. 5 ;
[0023] FIG. 7 is a diagram showing the loci of pair of temperatures of the well region (Thot) and of the substrate outside the well region (Tcold) for which the comparator of FIG. 5 generates an over temperature flag; and
[0024] FIG. 8 shows a third embodiment of the thermal protection device of this invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0025] In the ensuing description, the invention will be described for the case of a N-channel power MOS, but any skilled person would immediately recognize that the protection device that will be illustrated may be easily adapted to the case of a P-channel MOS by reversing polarities and type of conductivity of transistors.
[0026] A first embodiment of the thermal protection device of this invention is depicted in FIG. 2 , together with the power transistor Dw to be protected.
[0027] The protection device includes a transistor Dw/n for sensing the temperature that is provided by a small portion of the integrated structure of the power transistor, and a comparator of the gate-source voltage on the temperature sensing transistor Dw/n with a certain threshold, corresponding to a maximum allowed temperature.
[0028] Commonly, an integrated power transistor is includes an interdigitated array of source regions and drain regions, all defined within a diffused well region of the semiconductor chip, and of gate structures overhanging the channel regions defined between adjacent source and drain fingers.
[0029] An aspect of the device is that the temperature sensor, besides being intimately located in the well region of the power transistor structure, has the same identical characteristics of the power transistor structure because it is provided by a small number n of separately connected source regions of the same power transistor to be controlled. Because of the separate connection of the n source regions, a pre-established source current Is 1 may be forced through the temperature sensor Dw/n.
[0030] Being known the characteristic curve of the relationship between the gate-source voltage and the functioning temperature, it is possible to determine the threshold value of the gate-source voltage, VgsRef, that corresponds to the maximum allowed temperature for the integrated structure of the power MOS. The comparator Comp compares the gate-source voltage of the temperature sensor with the threshold VgsRef for generating an over temperature flag signal when it is exceeded.
[0031] The temperature sensor is located in the same well of the power transistor, therefore the distance between the sensor and the power MOSFET is minimized (few microns). Moreover, the sensor usually has the same structure as the host power transistor. Therefore, the protection device has an enhanced precision compared to similar devices of the prior art and it is substantially not influenced by below ground voltages or parasitic activations.
[0032] The thermal protection device of FIG. 2 may still be affected by variability of parameters of the sensor with temperature, such as the threshold voltage of the transistor Dw/n, carrier mobility and the like, that may limit its precision. To obviate these residual causes of imprecision because of possible drifts of the gate-source voltage of the transistor Dw/n due to other causes, the thermal device may be optionally provided with a second temperature sensor Dw/m, as shown in FIG. 3 .
[0033] This optional second sensor is a MOS transistor having the same structure of the integrated power transistor, in practice including a second number m of source finger regions like those of the integrated power transistor, but purposely integrated outside the well region containing the power transistor structure and the first temperature sensing transistor Dw/n, and in a location as close as possible to the comparator, where a lower temperature than that in the well region normally exists.
[0034] Moreover, the protection device of this alternative embodiment depicted in FIG. 3 , includes means or a circuit for generating a voltage Vcomp that in general depends on the temperatures T“hot” and T“cold” as sensed by the first sensor Dw/n and second sensor Dw/m, respectively. Preferably, the voltage Vcomp is generated so as to decrease when the temperature T“cold” increases.
[0035] The gate of the MOSFET Dw/m, defining the second integrated temperature sensor, is in common with the gate of the power transistor, while its drain may be connected either to the drain of the power MOSFET or even to a voltage Vd(cold), close to but not identical to the drain voltage of the power MOSFET.
[0036] A current Is 1 *m/n, a scaled replica of the current Is 1 by the ratio between the integer numbers m and n, is forced through the sensor Dw/m so that when the two sensors Dw/n and Dw/m are at the same temperature, their gate-source voltages are perfectly equal to each other.
[0037] The protection device of the embodiment of FIG. 3 may be insensitive to any cause (different from temperature) that could modify the threshold voltages of the sensors Dw/n and Dw/m or the mobility of carriers, because in such an event it would affect both sensors in the same way. Moreover, the protection device is not affected by temperature variations of the second sensor Dw/m because the voltage drop Vcomp compensates eventual variations of its source voltage Vc.
[0038] In the circuit of FIG. 3 , when the output voltage is close to the source voltage of the power MOSFET, the sensors tend to enter the ohmic region of their functioning characteristic. Tests carried out by the applicants have shown that when functioning in the ohmic region whereat the laws that tie the Vgs to the temperature are no longer those on which the protection is designed and this phenomenon may jeopardize reliability.
[0039] Even when the drain-source voltage of the MOSFET is relatively low, the power dissipated in the MOSFET may still increase dangerously the temperature thereof. A further embodiment shown in FIG. 8 overcomes the above mentioned possible effect. According to this embodiment, the gate electrodes of the temperature sensors and of the power MOSFET are not shorted to each other, as in the embodiment of FIG. 3 , but biased to a certain minimum voltage V GateSens .
[0040] Being Vgs Max the maximum gate-source voltage of the sensors when the current Is 1 flows through them, and being V Is1min the minimum voltage drop on the current generators Is 1 , the minimum bias voltage V GateSens applied to the gates of the temperature sensors will be:
V GateSens =Vgs Max +V Is1min
[0041] By applying such a minimum gate-source voltage, the sensor is prevented from entering into its ohmic region even if the drain-source voltage of the MOSFET becomes relatively low. Of course, the embodiment of FIG. 8 requires two distinct gate electrode corrections instead of a single one.
[0042] FIG. 4 is a sample illustration of the layout positioning of the sensors of the device of FIG. 3 . FIG. 5 shows a possible circuital embodiment of the comparator of FIG. 3 .
[0043] Supposing the comparator of FIG. 5 to be fully balanced (M 1 =M 2 , M 3 =M 4 etc.), the threshold voltage of the comparator is the voltage drop on the resistor R, when the current flowing in the two transistors of the differential pair M 1 and M 2 equal each other.
[0044] When the currents If(Rf)i and If(Rf)o equal each other
If( Rf ) i= If( Rf ) o =If( Rf )
the voltage drop Vcomp is given by the following equation:
Vcomp=R *If( t, Rv )/2 −R *If( Rf )
[0045] Therefore, the threshold voltage Vcomp depends linearly on the currents If(t, Rv) and If(Rf).
[0046] By adjusting these currents, it is possible to establish the temperatures T“hot” and T“cold” on the basis of which the comparator eventually generates the over temperature signal.
[0047] To have a voltage drop Vcomp that decreases when the temperature T“cold” increases, it is desired that the current If(t, Rv) decreases when T“cold” increases. A suitable circuit for generating the currents If(t, Rv) and If(Rf)i and If(Rf)o is shown in FIG. 6 .
[0048] The operational amplifier imposes a certain constant voltage Vref on the source node of the MOSFET Mfb, thus the current flowing through it is inversely proportional to the resistance Rfb. Both MOSFETs Mfa and Mfb are kept in a conduction state by the operational amplifier, thus a current inversely proportional to the source degeneration resistance Rfa circulates through the transistor Mfa.
[0049] In practice, the MOSFETs Mfa and Mfb are the two current generators that generate the currents If(Rf)o and If(Rf)i, respectively, for the comparator of FIG. 5 , as a function of the resistances Rfa and Rfb.
[0050] The transistor B 1 is turned on by forcing through it a bias current delivered by the current generator I. Therefore, the resistor Rv takes the base-emitter voltage of the transistor B 1 . Given that B 1 is in a conduction state, the MOSFET M 1 is activated and thus the current If(t, Rv) is the current flowing through the resistor Rv, that is
If( t, Rv )= Vbe B1 /Rv
wherein Vbe B1 is the base-emitter voltage of the transistor B 1 .
[0051] It is worth noticing that the base-emitter voltage Vbe B1 of the transistor B 1 decreases with the working temperature of B 1 . Therefore, the current If(t, Rv) varies with temperature and may be adjusted by varying the resistance Rv.
[0052] By properly dimensioning the transistors Msa-Msb of the current mirror that generates If(Rf)i, the transistors Mfa and Mfb and the source degeneration resistors Rfa and Rfb, it is possible to make
If( Rf ) i= If( Rf ) o =If( Rf )
[0053] A possible dimensioning for obtaining this condition is the following:
Msa=Msb; Mfb=Mfa; Rfa=Rfb.
[0054] Therefore, with the circuit of FIG. 6 it is possible to adjust the currents If(Rf) and If(t, Rv) by varying the resistances Rv, Rfa and Rfb, and thus to adjust the threshold voltage Vcomp of the comparator. This feature allows choosing the pair of temperatures T“cold” and T“hot” for which the comparator generates the over temperature flag.
[0055] FIG. 7 shows a sample diagram of possible loci, that are substantially straight lines, of pairs T“hot”, T“cold” values for which the over temperature flag is generated. Hereinbelow, these straight lines will be referred as the “lines of intervention” of the comparator.
[0056] In the example shown, the vertical lines indicate that the flag is generated when the temperature T“hot” reaches 220° C. or 180° C. whichever the temperature T“cold” is, while the inclined lines indicate that the temperature T“hot”, at which the over temperature flag is generated, depends on the temperature T“cold”.
[0057] As suggested by the arrows, by adjusting the ratio R/Rf it is possible to translate horizontally the line of intervention, while by adjusting the ratio R/Rv it is possible to modify the slope of the line of intervention of the comparator.
[0058] By summarizing, the protection device according to the first embodiment of FIG. 2 senses only the temperature of the power DMOS T“hot”, while the device according to the second embodiment of FIG. 3 generates the over temperature flag by considering also the temperature T“cold” of the substrate outside the well region of the power MOS. Of course, in both cases, the maximum allowable temperature T“hot” may be fixed as desired.
[0059] With the device of FIG. 3 and the circuit of FIG. 7 , it is also possible to vary the maximum allowable temperature T“hot”, as a function of the temperature T“cold”, for obtaining a certain line of intervention of the comparator. Moreover, the functioning of the device made according to the embodiment depicted in FIG. 3 is substantially insensitive to eventual variations of parameters of the device, such as carrier mobility, threshold voltage of the temperature sensing transistor Dw/n that could be induced by causes other than temperature. | A thermal protection device is for an integrated power MOSFET transistor including an interdigitated array of source regions and drain regions defined in a well region of the monocrystalline silicon substrate, and gate structures overhanging channel regions defined between adjacent source and drain regions. The thermal protection device may include a temperature sensor and a comparator for generating an over temperature flag signal usable for turning off the overheated power transistor. The thermal protection device may sense, in a very accurate manner, the temperature of the power MOS and may include a circuit for forcing a fixed current through a small number of source regions of the interdigitated array separately connected from the other source regions electrically connected in common of the power transistor; and a comparator, integrated on the substrate outside the well region, comparing the source voltage present on the small number of separately connected source regions with a threshold voltage for producing on an output the over temperature flag signal. | 7 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to foreign French patent application No. FR 1100550, filed on Feb. 24, 2011, the disclosure of which is incorporated by reference in its entirety.
FIELD OF THE INVENTION
[0002] The domain of the invention is that of telescopes and more particularly observation telescopes aboard satellites. More precisely, the domain of the invention relates to wide angle catoptric systems, allowing terrestrial or space observation in a broad spectral band.
BACKGROUND
[0003] Generally, these telescopes have a large angular field in a first direction and an angular field of lesser magnitude in the perpendicular direction. This arrangement makes it possible to produce optical architectures comprising solely off-axis mirrors without central occlusion. This type of architecture makes it possible to produce compact telescopes, having very good transmission and free of chromatic aberrations. However, these optical architectures are often complex in so far as the image quality must be excellent in a large field.
[0004] Currently, a first type of optical architecture of anastigmatic telescopes comprises three mirrors. These telescopes are also called “TMA telescopes” according to the terminology signifying “Three Mirrors Anastigmat”. TMA telescopes offer angular fields of generally between 25° and 30° while correcting the so-called third-order geometric aberrations. But beyond this field, the degradations of the image become significant. Thus, U.S. Pat. No. 5,379,157 from the Hugues Aircraft company describes a combination of this type. This field limitation is not suited to the trends in earth observation missions which require, ever more, wide linear fields so as to increase the instantaneous field covered by the instrument during rotation about the earth. The importance of these missions is to photograph a wide field at regular intervals. In this context, the telescopes of TMA type are no longer sufficient to cope with the missions requiring the photographing of large fields.
[0005] A solution making it possible to increase the field is the use of a second type of architecture of anastigmatic telescopes comprising four mirrors, also called in the technical terminology “FMA” for “Four Mirrors Anastigmat”. Application EP 0 601 871 from the Hugues Aircraft company describes such a combination. Patent FR 2 764 081 from the Sagem company details a telescope comprising four mirrors whose field possesses a maximum angular width of 70°. Finally, application EP 2 073 049 from the Thales company and from the same inventor also describes an optical architecture with four mirrors where the large field is raised to 85°.
[0006] However, conventional “TMA” or “FMA” telescopes have a convex primary mirror and a virtual entrance pupil. This absence of real pupil presents several drawbacks. In the absence of a real entrance pupil, it is impossible or very difficult to accommodate a diffuser, a depolarizing window or a removable cowl at the instrument input and thus to calibrate it or to protect it very effectively. A real entrance pupil facilitates the interface between the telescope and other instruments.
SUMMARY OF THE INVENTION
[0007] Hence, one of the aims of the invention is to remedy these drawbacks by producing an optical architecture with real entrance pupil. This new type of architecture presents, moreover, the advantage of exceeding the current field width limitations for observation telescopes.
[0008] More precisely, the subject of the invention is a wide angle catoptric telescope, characterized in that:
the telescope comprises five successive off-axis mirrors denoted respectively and in the order of succession first, second, third, fourth and fifth mirror; the first mirror or entrance mirror of the said five mirrors is concave; the entrance pupil of the telescope is real and situated in front of this said first mirror.
[0012] Advantageously, the first mirror is spherical.
[0013] Advantageously, the exit pupil, that is to say the image of the entrance pupil through the five mirrors, is at infinity, the telescope thus being telecentric.
[0014] Advantageously, the second mirror is convex and aspherical.
[0015] Advantageously, the third mirror is concave, the fourth mirror is convex and the fifth mirror is concave.
[0016] Advantageously, at least the third or the fourth or the fifth mirror is conical.
[0017] Advantageously, if R1 is the radius of curvature at the vertex of the first mirror, the radius of curvature at the vertex of the second mirror R2 equals substantially 0.5.R1, the radius of curvature at the vertex of the third mirror R3 equals substantially 1.2.R1, the radius of curvature at the vertex of the fourth mirror R4 equals substantially 0.8.R1, the radius of curvature at the vertex of the fifth mirror R5 equals substantially 0.9.R1, the focal length of the telescope being equal to 0.25.R1.
[0018] Advantageously, the object field of the telescope is substantially rectangular, the width of the rectangle being at least 1 degree and its length at least 100 degrees.
[0019] Finally, the image field is substantially plane.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] The invention will be better understood and other advantages will become apparent on reading the nonlimiting description which follows and by virtue of the appended figures among which:
[0021] FIG. 1 represents an exemplary optical architecture of a telescope according to the invention in the symmetry plane of the telescope;
[0022] FIG. 2 represents the optical architecture of FIG. 1 in a plane perpendicular to the symmetry plane, three light rays of the central field being represented;
[0023] FIG. 3 represents the optical architecture of FIG. 1 in a plane perpendicular to the symmetry plane, three light rays of the extreme field being represented;
[0024] Finally, FIG. 4 represents the optical architecture of FIG. 1 in a plane perpendicular to the symmetry plane, two symmetric light rays of the extreme fields being represented.
DETAILED DESCRIPTION
[0025] The particular feature of the telescopes according to the invention is to work with object fields that are very significant in one direction and small in the perpendicular direction. This particular arrangement makes it possible to construct optical architectures comprising only mirrors without central occlusions, the mirrors being sufficiently off-axis to reflect the light rays of one mirror towards the next mirror without occluding same.
[0026] Whereas the optical architectures of the prior art possess three or four mirrors, the telescope according to the invention is a combination with five mirrors, the first mirror being concave. The addition of this fifth mirror presents numerous advantages over the previous solutions. This arrangement makes it possible to obtain:
a very large field, of the order of 100 degrees; very good image quality, limited by diffraction over the whole of the field; low distortion along the field, not exceeding +/−1.25 degrees, whereas the best solutions of “TMA” and “FMA” type have twice as much distortion; a real entrance pupil; an architecture of telecentric type at output, ideal for accommodating an entrance slit of a spectrometer; a plane image field.
[0033] By way of example, FIGS. 1 to 4 represent a telescope optical architecture according to the invention in two different sectional planes, the first (O, x, z) is situated in the symmetry plane of the telescope, the second (O, x, y) is situated in a perpendicular plane. The optical architecture comprises five mirrors denoted M 1 , M 2 , M 3 , M 4 and M 5 . In these various figures, the mirrors are represented by thick lines. The focal plane PF is also represented by thick lines. The light rays RL are represented by thin lines, the pupils P and P′ by double lines and the intermediate focusing zone ZF by dashed lines.
[0034] The first mirror M 1 is a spherical concave mirror. The entrance pupil P of the telescope is situated in the vicinity of the centre of curvature of this first mirror M 1 . This mirror gives from the object field at infinity a curved intermediate real image situated in the intermediate focusing zone ZF situated between the first mirror M 1 and the second mirror M 2 .
[0035] The set of four mirrors M 2 , M 3 , M 4 and M 5 gives from this intermediate real image a real image devoid of geometric aberrations in the focal plane PF.
[0036] The mirrors M 2 and M 3 form, from the image of the pupil P, an intermediate image P′ situated between the mirror M 2 and the mirror M 3 . The image of this pupil P′ is collimated at infinity by the mirrors M 4 and M 5 . Thus, the optical combination is telecentric, signifying that, whatever the object field, the light rays passing through the centre of the entrance pupil are all parallel to one another in the vicinity of the focusing plane. This arrangement greatly facilitates the adaptation of measurement instruments such as spectroscopes arranged in the focal plane PF. Moreover, the image field is plane, thereby further facilitating the placement of the photosensitive surface of a detector or the entrance slit of a spectrometer.
[0037] In FIGS. 1 and 2 , three rays RL represent the path of the light rays arising from the central field through the telescope, the central ray passes through the centre of the pupil P, the other two rays pass through the edges of the pupil.
[0038] In front of the telescope, these three rays are mutually parallel. They are focused a first time at the level of the intermediate focusing zone ZF and then a second time at the level of the focal plane PF. The off-axis offset of the mirrors is calculated so as not to cause vignetting of these rays.
[0039] In FIG. 3 , three rays RL represent the path of the light rays arising from an extreme field through the telescope, the central ray passes through the centre of the pupil P, the other two rays pass through the edges of the pupil.
[0040] In front of the telescope, these three rays are mutually parallel. They are focused a first time at the level of the intermediate focusing zone ZF and then a second time at the level of the focal plane PF. The central ray is perpendicular to the focusing plane.
[0041] FIG. 4 represents the two rays arising from the two ends of the field.
[0042] The mirrors M 2 and M 4 are convex and the mirrors M 3 and M 5 are concave. The four mirrors M 2 , M 3 , M 4 and M 5 are aspherical or conical. More precisely, the profile Z of the representative surface of these mirrors as a function of the distance h from the vertex to a point P of the surface satisfies:
[0000]
Z
=
h
2
R
1
+
1
-
(
1
+
k
)
·
h
2
R
2
+
Ah
4
+
Bh
6
+
Ch
8
+
Dh
10
[0043] with:
[0044] R: radius of curvature at the vertex of the surface;
[0045] k: conicity constant of the surface;
[0046] A: profile constant of order 4;
[0047] B: profile constant of order 6;
[0048] C: profile constant of order 8;
[0049] D: profile constant of order 10.
[0050] More precisely, the mirror M 2 is convex aspherical of order 6, the mirror M 3 is concave conical, the mirror M 4 is convex conical and the mirror M 5 is concave conical.
[0051] The tables hereinbelow give the main geometric characteristics of an optical architecture according to the invention. Table I gives the geometric parameters of the mirrors and table II the main distances separating these mirrors.
[0000]
TABLE I
Radius of
curvature
A
B
Shape
mm
k
mm −3
mm −5
M1
Concave Spherical
26.2
—
—
—
M2
Convex aspherical
15.5
0.85
0
−0.18 × 10 −7
M3
concave conical
32.16
0.08
—
—
M4
convex conical
21.8
2.09
—
—
M5
concave conical
23.8
0.51
—
—
[0000]
TABLE II
Distance
mm
M1-M2
24.5
M2-M3
20.1
M3-M4
24.7
M4-M5
7.7
M5-Focal plane
18.2
[0052] Under these conditions, the entrance pupil is situated 21 mm in front of the mirror M 1 , the exit pupil is at infinity, the resulting focal length of the telescope equals 6.8 mm. The object field θ in the plane (O, x, y) is of the order of 100 degrees and in the plane (O, x, z) of the order of a degree.
[0053] The overall proportions of this optical combination are as follows:
[0054] Length L: 67 mm
[0055] Height H: 25 mm
[0056] Depth Pr: 44 mm
[0057] The quality of the image throughout the fields is limited by diffraction. | A wide angle catoptric telescope comprises five successive off-axis mirrors. The first mirror or entrance mirror of the five mirrors is concave. The entrance pupil of the telescope is real and situated in front of this said first mirror. The second and the fourth mirror are convex. The third and the fifth mirror are concave. The optical combination is telecentric, and the image field is plane. | 6 |
FIELD OF THE INVENTION
[0001] The present invention relates generally to chemical mechanical polishing and, more particularly, to polishing pad cleaner for in-situ cleaning.
BACKGROUND OF THE INVENTION
[0002] CMP is a process for improving the surface planarity of a semiconductor wafer and involves the use of mechanical pad polishing systems usually with a silica-based slurry. CMP offers a practical approach for achieving the important advantage of overall wafer planarity.
[0003] CMP systems place a semiconductor wafer in contact with a polishing pad that rotates relative to the semiconductor wafer. The semiconductor wafer may be stationary, or it may also rotate on a carrier that holds the wafer. Problems of conventional methods of performing a chemical mechanical polish is that they produce nonuniform wafers and produce larger than desirable edge exclusion areas. Both of these problems impair operation of resulting electronic components formed from the semiconductor devices. Semiconductor wafer non-uniformity may cause undesirable layers not to be removed at some places and desirable layers to be removed at other places on the wafer surface. This causes various areas on the wafer surface to be unusable for forming semiconductor devices. Process uniformity from wafer to wafer is also important in CMP processing. Known CMP systems, however, suffer from significant wafer-to-wafer non-uniformities. This can also adversely affect the throughput and yield of the CMP process. To achieve a low defect rate, each successive substrate should be polished under similar conditions.
[0004] Another limitation of existing CMP systems relates to a part of the system known as the CMP polish pad. The silica-based slurry is applied to the CMP polish pad to lubricate the interface between the wafer and the CMP polish pad. The slurry also serves the function, because of its silica content, of mildly abrading or affecting the surface of the semiconductor wafer. Relative motion of the polishing pad with respect to the wafer effectuates polishing of the wafer through mechanical abrasion and chemical etching. The amount of mechanical abrasion is determined in part by the size of the abrasive particles in the slurry. Often, during the polishing process, the particles conglomerate forming larger particles which can scratch or otherwise effect the polishing. Changes in the slurry solution properties, such as the particle sizes, have a profound effect on the polishing chemistry and relative removal rates of dielectric films if not properly removed from the pad.
[0005] One of the factors that is accounted for in returning the polishing pad to its condition prior to the polishing of another wafer is the removal from the polishing pad of the debris, such as conglomerated slurry, created during the polishing period. These debris may be on the surface of the polishing pad or trapped within grooves of the polishing pad. If the debris are left on and within the pad, the polishing conditions for the next wafer to be polished will be different from the previous wafer that was just polished.
[0006] A typical method of removing the debris from the polishing pad after a wafer has been polished is to employ a spray rinse over a portion of the surface of the polishing pad. The spray rinse provides a de-ionized water to the pad in hopes of washing away all the debris from the polishing pad following a wafer polishing phase. In another approach, described in U.S. Pat. No. 6,224,470, a pad cleaning brush is used in conjunction with spray rinse water. Although conventional spray rinse approaches and the above-mentioned cleaning brush apparatus provide some measure of cleaning to the polishing pad, some debris can remain behind within the center area of the polishing pad.
SUMMARY
[0007] The present invention achieves technical advantages as an apparatus and system used in conjunction with rinse water to thoroughly clean a polishing pad of a chemical-mechanical polishing apparatus after a wafer has been polished. A sprayer or sprayer extension is strategically positioned and securely retained on a portion of the dispensing arm and adapted for applying a rinse water spray directly to the center portion of the pad preventing conglomerated slurry from accumulating.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] For a more complete understanding of the present invention, reference is made to the following detailed description taken in conjunction with the accompanying drawings wherein:
[0009] FIG. 1 illustrates a conventional chemical-mechanical polishing system 100 ; and
[0010] FIGS. 2A-2C illustrate spray extensions in accordance with exemplary embodiments of the present invention.
DETAILED DESCRIPTION
[0011] The numerous innovative teachings of the present application will be described with particular reference to the presently preferred exemplary embodiments. However, it should be understood that this class of embodiments provides only a few examples of the many advantageous uses and innovative teachings herein. In general, statements made in the specification of the present application do not necessarily delimit any of the various claimed inventions. Moreover, some statements may apply to some inventive features, but not to others. Throughout the drawings, it is noted that the same reference numerals or letters will be used to designate like or equivalent elements having the same function. Detailed descriptions of known functions and constructions unnecessarily obscuring the subject matter of the present invention have been omitted for clarity.
[0012] Referring now to FIG. 1 there is shown a conventional chemical-mechanical polishing system 100 that employs a polishing pad cleaning device. The cleaning device 100 includes a rotatable (rotation direction is shown by the arrow) platen on which a polishing pad 110 is disposed. A drive device is adapted for and used to bring a wafer 120 into mechanical contact with the pad 110 and rotate the wafer 120 in the opposite direction. During a polishing operation, the device may also move the wafer 120 in a linear motion across the surface of the polishing pad 110 in which a portion of the wafer 120 is in mechanical contact with the center most portion of the pad 110 . The wafer 120 is pressed against the pad 110 at a predetermined pressure. During polishing, a slurry is dispensed in droplets onto the surface of the pad 110 to effectuated the chemical mechanical removal of materials from the wafer 120 surface.
[0013] The slurry composition and the pressure applied between the wafer surface and the polishing pad 110 determine the rate of polishing or material removal from the wafer surface. A slurry composition typically includes a colloidal suspension of oxide particles suspended in an alkali solution. Other abrasive components such as ceria suspensions may also be used. During a CMP process, a large volume of a slurry composition is delivered by a dispensing arm 130 positioned over the surface of the polishing pad 110 as the pad 110 is rotated.
[0014] After the wafer 120 has been polished and moved to the next station or from the CMP apparatus 100 , the polishing pad 110 is cleaned by a spray of de-ionized water. Typically the dispensing arm 130 is also used to deliver the spray. Conventionally, the spray is delivered by several nozzles forming a typical spray pattern shown as item 140 . The centrifugal force from the rotation and the de-ionized water are cooperable for carrying away the debris from the polishing pad 110 . Although the typical spray pattern 140 of de-ionized water is adequate to clean most of the debris from a polishing pad, a slurry build-up occurs at the center most portion of the pad 110 of conventional wash approaches. This build-up often includes a conglomeration of the slurry material which is problematic for subsequent polishing of wafers 120 in a sequence process.
[0015] In order to overcome the above-stated concern of cleaning debris more thoroughly from the polishing pad, the present invention provides a spray extension advantageously positioned to thoroughly spray the entire center portion 150 of the pad 110 while the pad is being rotated acting to more thoroughly clean the debris from the polishing pad 110 , wherein the extension further does not interference with other hardware during the process.
[0016] A cross-sectional side view of spray extensions in accordance with exemplary embodiments of the present invention is provided in FIGS. 2A-2C . Referring now to FIG. 2A there is shown a spray extension 210 coupled to a conventional dispensing arm 130 and shown in relation with the center portion 150 of the pad 110 . In this embodiment, the spray extension 210 is adapted to have a profile such that no part of the extension extends over the end of the dispensing arm 130 . Further, the extension is provided with a directional spray nozzle which enables water to be sprayed directly on the pad center 150 .
[0017] Referring now to FIG. 2B there is shown another spray extension 220 . In FIG. 2B , this spray extension 220 extends the nozzle beyond the dispense arm 130 and points the de-ionized water spray directly over the center 150 of the pad. This maximizes the spray force from the fluid velocity in dislodging the slurry conglomerates and cleaning the pad 110 . The water spray angle should be at 90 degrees relative to the pad surface. System 230 allows adjustments to be made on the extension for adequate pad coverage.
[0018] Referring now to FIG. 2C there is shown another spray extension 250 . In FIG. 2C , the extension is another form that allows easy installation by using ‘off the shelf’, currently available components for high purity plumbing. The extension 250 includes a conventional plumbing collar 240 coupling two pieces of pipe such that adjustments can be made on the extension for adequate pad coverage from the water spray. This design also allows optimal cleaning in that the de-ionized water spray from the extension 250 is positioned directly over the pad center 150 to maximize fluid energy.
[0019] Although exemplary embodiments of the invention are described above in detail, this does not limit the scope of the invention, which can be practiced in a variety of embodiments. | A pad cleaning device ( 210, 220, 250 ) is used in conjunction with spray rinse water to thoroughly clean a polishing pad ( 110 ) of a chemical-mechanical polishing system ( 100 ) after a wafer ( 120 ) has been polished. A sprayer or sprayer extension ( 210, 220, 250 ) is strategically positioned and securely retained on a portion of the dispensing arm ( 130 ) and adapted for applying a rinse water spray directly to the center portion ( 150 ) of the pad preventing conglomerated slurry from accumulating. | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to the field of fluid sampling, and more specifically, to a mobile sampling system for taking samples from a natural gas well that is at low pressure (less than 5 psig) or under vacuum and analyzing those samples in the field.
2. Description of the Related Art
In most cases, after years of production, the amount of natural gas available for production from a given well will decrease. The rate and quantity of the decrease will vary from well to well, but for many wells, it eventually becomes necessary to lower the pressure (to less than 5 psig) or place the well under vacuum in order to cause the natural gas to flow out of the well. In order to lower the pressure or place the well under vacuum, compressors, pumps and/or blowers are added to the pipeline system downstream of the wellhead electronic flow meter. Typically, the well operator can take a sample from the natural gas stream and analyze it in the field as long as the stream is under enough positive pressure to drive the fluid through the sampling and analysis equipment, but when the stream is at low pressure (less than 5 psig) or under vacuum, there has historically been no way to take the sample and analyze it. The reason it is important to have contemporaneous chemical compositional analysis of a natural gas sample is because it affects both economics and safety, as explained more fully below.
In terms of economics, it is customary in the natural gas industry for producers of natural gas to be paid based on the BTU (British Thermal Unit) corrected volume of the natural gas stream. The BTU content of a natural gas stream is calculated based on chemical compositional analysis of a natural gas sample. For example, the relative amounts of nitrogen, oxygen, carbon dioxide, methane, ethane and propane components of a coal bed natural gas sample all affect its BTU content. Producers generally pay taxes and royalties based on the wellhead quantities of natural gas, and such taxes and royalties are based on the BTU corrected volume of the natural gas, also known as MMBTU (million BTUs). If the BTU content is over-estimated (for example, because it is not based on current data), the producer will overpay taxes and royalties. For this reason, it is highly desirable to ascertain the BTU content of the natural gas in the field so that the producer has real-time data for the natural gas that is produced at the wellhead.
As fields age, the concentration of non-combustible gases (nitrogen and carbon dioxide) in the natural gas generally increases, and toward the end of the production life of a coal bed natural gas well, the concentration of non-combustible gases in the natural gas emanating from the well usually spikes. As the concentration of non-combustible components increases, the concentration of hydrocarbon components (which typically include, but are not limited to, paraffins like methane, ethane and propane) decreases, thereby decreasing the BTU value. For each well, there is a point at which it no longer makes economic sense to produce from that well because of the increased non-combustible components and decreased hydrocarbon content of the natural gas. Having access to this information in the field allows operators to make timely decisions concerning the allocation of production resources.
Contemporaneous access to the results of chemical compositional analysis in the field is highly beneficial not only for economic reasons but also because it affects safety. Information about the chemical composition of the natural gas stream may let the operator know if there are leaks in the system that require immediate attention. For example, high levels of nitrogen in the sample might signify to the operator that there are leaks drawing air into the system. The presence of oxygen (presumably from the atmosphere) in the sample means there could be a risk of fire when the natural gas is compressed. If the operator becomes aware of increased nitrogen levels or the presence of oxygen in the system, he or she can take immediate steps to remedy the situation to prevent catastrophic loss or injury. Downstream pipelines that receive the produced natural gas may have compositional quality specifications that limit the amount of non-hydrocarbon gases (carbon dioxide, hydrogen sulfide, other sulfur species, and oxygen) allowed into their system to maintain the system integrity.
As noted above, mechanisms currently exist for taking natural gas samples and analyzing them in the field as long as the well is under enough positive pressure so that the natural natural will flow through the sampling and analysis equipment. Aside from the present invention, however, no mechanism exists for taking natural gas samples and analyzing them in the field when the well is at low pressure (less than 5 psig) or under vacuum. This creates problems for the well operators because they must extract a sample from the natural gas stream under vacuum conditions, deliver the sample to an offsite laboratory, and wait—usually several days and oftentimes up to two weeks—for the results of the chemical compositional analysis. This procedure lacks the immediate results that are obtainable when the chemical compositional analysis is conducted in the field. Furthermore, it is generally more cost-effective to analyze a sample in the field than to send it out to a laboratory since the lag time requires multiple visits to the well to input the updated chemical compositional analysis into the electronic flow computer, and if there was a problem with the initial sample, the process would have to be repeated until accurate data was obtained.
Accordingly, it is an object of the present invention to provide a natural gas sampling system that will allow samples to be taken and chemically analyzed to determine the composition of the fluid flowing from wells that are at low pressure (less than 5 psig) or under vacuum. It is a further object of the present invention to provide a means for such chemical compositional analysis to occur in the field. Yet another object of the present invention is to provide a low pressure and vacuum sampling system that is mobile and can be taken from field to field.
BRIEF SUMMARY OF THE INVENTION
The present invention is a mobile vacuum sampling system comprising: an inlet; a first filter; a gas sample vacuum pump; a solenoid valve; a sample tube; a pressure gauge; a first block valve; a second filter; a micro filter; a gasifier; a gas analyzer; and a computational, recording and/or analysis display device; wherein the first filter is a membrane filter situated between the inlet and the gas sample vacuum pump; wherein a natural gas stream enters the gas sample vacuum pump via the inlet and is compressed to between 3 and 5 psig; wherein the solenoid valve is situated directly adjacent to the gas sample vacuum pump; wherein the solenoid valve and gas sample vacuum pump are controlled by an electrical switch; wherein when the solenoid valve is only open when the gas sample vacuum pump is on and pumping gas through the system; wherein when the vacuum pump is turned off, the solenoid valve is closed and prevents natural gas from flowing back through the compressor; wherein the sample tube is located downstream of the solenoid valve; wherein the sample tube collects natural gas to be analyzed; wherein the pressure gauge is situated downstream of the sample tube and gauges the pressure in the sample tube; wherein the purpose of the first block valve is to allow pressure to build in the sample tube prior to analysis of a natural gas sample; wherein the system comprises a highest physical point; wherein the second filter is a membrane filter situated downstream of the sample tube and at the highest physical point in the system; wherein the micro filter is located downstream of the second filter and upstream of the gasifier; wherein the micro filter remove solid particles from the natural gas stream prior to the stream entering the gas analyzer; wherein the gasifier is situated downstream of the micro filter and ensures that any natural gas entering the gas analyzer is in gaseous phase; wherein the gas analyzer is situated downstream of the gasifier; wherein the gas analyzer is portable; wherein the gas analyzer analyzes gas samples from the sample tube; and wherein the entire system is contained within a truck or other mobile unit.
In a preferred embodiment, the invention further comprises a drain, wherein the drain is located directly underneath the first filter. Preferably, the gas sample vacuum pump is oil-free, explosion-proof and portable; the gas sample vacuum pump is manufactured of stainless steel or polytetrafluoroethylene; and the gas sample vacuum pump has a Class 1, Division 1 electrical rating. The vacuum pump preferably compresses 0.6 cubic feet of gas per minute, has the ability to overcome 26.9 inches of Hg on the inlet side of the pump, and is run on 120-volt or 220-volt AC power.
In a preferred embodiment, the present invention further comprises a flow meter, wherein the flow meter is located between the pressure gauge and the second filter. Preferably, the present invention further comprises a second block valve and first vent located between the first block valve and flow meter and a third block valve and second vent located directly underneath the second filter. The micro filter is preferably a 5-micron filter.
In a preferred embodiment, the present invention further comprises a micro needle valve and third vent, wherein the micro needle valve and third vent are located on the gasifier and are used to purge the system in between natural gas samples.
In an alternate embodiment, the present invention is a mobile vacuum sampling system comprising: an inlet; a first filter; a gas sample vacuum pump; a solenoid valve; a sample tube; a pressure gauge; a first block valve; a second filter; a micro filter; a gasifier; a gas analyzer; and a computational, recording and/or analysis display device; wherein the first filter is a membrane filter situated between the inlet and the gas sample vacuum pump; wherein a gas stream enters the gas sample vacuum pump via the inlet and is compressed to between 3 and 5 psig; wherein the solenoid valve is situated directly adjacent to the gas sample vacuum pump; wherein the solenoid valve and gas sample vacuum pump are controlled by an electrical switch; wherein when the solenoid valve is only open when the gas sample vacuum pump is on and pumping gas through the system; wherein when the vacuum pump is turned off, the solenoid valve is closed and prevents gas from flowing back through the compressor; wherein the sample tube is located downstream of the solenoid valve; wherein the sample tube collects gas to be analyzed; wherein the pressure gauge is situated downstream of the sample tube and gauges the pressure in the sample tube; wherein the purpose of the first block valve is to allow pressure to build in the sample tube prior to analysis of a gas sample; wherein the system comprises a highest physical point; wherein the second filter is a membrane filter situated downstream of the sample tube and at the highest physical point in the system; wherein the micro filter is located downstream of the second filter and upstream of the gasifier; wherein the micro filter remove solid particles from the gas stream prior to the stream entering the gas analyzer; wherein the gasifier is situated downstream of the micro filter and ensures that any gas entering the gas analyzer is in gaseous phase; wherein the gas analyzer is situated downstream of the gasifier; wherein the gas analyzer is portable; wherein the gas analyzer analyzes gas samples from the sample tube; and wherein the entire system is contained within a truck or other mobile unit.
In a preferred embodiment, the invention further comprises a drain, wherein the drain is located directly underneath the first filter. Preferably, the gas sample vacuum pump is oil-free, explosion-proof and portable; the gas sample vacuum pump is manufactured of stainless steel or polytetrafluoroethylene; and the gas sample vacuum pump has a Class 1, Division 1 electrical rating. The vacuum pump preferably compresses 0.6 cubic feet of gas per minute, has the ability to overcome 26.9 inches of Hg on the inlet side of the pump, and is run on 120-volt or 220-volt AC power.
In a preferred embodiment, the present invention further comprises a flow meter, wherein the flow meter is located between the pressure gauge and the second filter. Preferably, the present invention further comprises a second block valve and first vent located between the first block valve and flow meter and a third block valve and second vent located directly underneath the second filter. The micro filter is preferably a 5-micron filter.
In a preferred embodiment, the present invention further comprises a micro needle valve and third vent, wherein the micro needle valve and third vent are located on the gasifier and are used to purge the system in between gas samples.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagram that shows the relation of the present invention to the wellhead.
FIG. 2 is a schematic drawing that shows the various components of the present invention.
REFERENCE NUMBERS
1 Wellhead
2 Tertiary flow element (electronic flow computer)
2 a Secondary flow element (sensing lines and transmitters)
3 Primary flow element (direct or inferential flow meter)
4 Stream sample probe
5 Manifold
6 Compressor/pump/blower
7 Truck/mobile unit
8 Inlet
9 First filter
10 Drain
11 Gas sample vacuum pump
12 Solenoid valve
13 Electrical switch
14 Sample tube
15 Pressure gauge
16 First block valve
17 Second block valve
18 First vent
19 Gas sample flow meter
20 Second filter
21 Third block valve
22 Second vent
23 Micro filter
24 Gasifier
25 Micro needle valve
26 Third vent
27 Gas analyzer
28 Computer
DETAILED DESCRIPTION OF INVENTION
The present invention is a system and method specifically designed for dealing with natural gas at low pressure (less than 5 psig) or under vacuum. The invention compresses the natural gas to sufficient levels to work in a sample system, such as a gas analyzer (for example, a gas chromatograph). As explained more fully below, the invention incorporates a number of filters to segregate liquids (including water) from the natural gas stream and also to prevent undesired particles from entering the gas analyzer.
FIG. 1 is a diagram that shows the relation of the present invention to the wellhead. In this figure, an electronic flow computer 2 is shown downstream of the wellhead 1 . A primary flow element 3 is typically situated directly underneath the secondary flow element 2 a and tertiary flow element (or electronic flow computer) 2 . The manifold 5 is used to isolate the primary flow element 3 and the secondary flow element 2 a when calibrating the measurement system. In the context of the present invention, the natural gas sample can be taken from a stream sample probe 4 , which is typically located downstream of the electronic flow computer 2 , or it can be taken directly from a vent on the manifold 5 . The former method is preferable, but not all lines have a stream sample probe 4 , in which case the sample could be taken directly from the electronic flow computer 2 . The stream sample probe is not always installed or required, but it provides for a more representative sample if placed in the middle third of the pipe. The location of the sampling point is not critical to the operation of the present invention.
A compressor 6 (or, alternately, a pump or blower) is located downstream of the electronic flow computer 2 and stream sample probe 4 . This compressor 6 reduces the wellhead pressure to enable higher production rates and higher recovery of oil and gas reserves. (Remember that the present invention is used in those cases where the oil and gas reservoir is so depleted that it will not economically flow unless the wellhead pressure is reduced to a low pressure (less than 5 psig) or placed under vacuum.) The sample that is taken from the stream sample probe 4 (or the vent in the manifold 5 , whichever the case may be) is the sample that enters the present invention.
FIG. 2 is a schematic drawing that shows the various components of the present invention. In order to be mobile, the invention is preferably contained within a truck or other mobile unit 7 that can travel from well to well and from field to field and that has access to a supply of electrical power. The sample from the stream sample probe 4 (or from the vent in the manifold 5 ) enters the invention through an inlet 8 . Immediately downstream of the inlet 8 is a first filter 9 . In a preferred embodiment, the first filter 9 is a GENIE Supreme Model 120 filter manufactured by A+ Corporation, LLC of Gonzales, La. The first filter 9 is a membrane filter, and its primary purpose is to allow gas molecules to pass through the filter while preventing liquid molecules (such as water, amines, glycols, frac fluids, corrosion inhibitors, other production chemicals, lube oils, production fluids, etc.) from passing through the filter.
Directly underneath the first filter 9 is a drain 10 . The purpose of the drain 10 is to allow liquid to be drained from the system after the system has been shut down. After passing through the inlet 8 and first filter 9 , the sample enters a gas sample vacuum pump 11 . In a preferred embodiment, the gas sample vacuum pump 11 is a model UN026STI (EX) vacuum pump manufactured by KNF Neuberger, Inc. of Trenton, N.J. Any oil-free, explosion-proof vacuum pump with a Class 1, Division 1, electrical rating may be used as long as it is manufactured from a material that can withstand contamination, such as stainless steel or polytetrafluoroethylene, and of a suitable size for use in this particular application (i.e., small enough to be portable).
When the natural gas sample enters the gas sample vacuum pump, it is at low pressure (less than 5 psig) or under vacuum. When it exits the gas sample vacuum pump, it is under positive pressure, typically between 3 and 5 pounds per square inch gauge (psig). In a preferred embodiment, the gas sample vacuum pump 11 is able to compress 0.6 cubic feet of gas per minute and can be run on 120-volt or 220-volt AC power. The preferred gas sample vacuum pump must have sufficient head, that is, the differential pressure of (i) the lower pressure or the vacuum suction that is experienced by the well and (ii) the required discharge pressure needed to force the gas through the sampling and analysis equipment. In a preferred embodiment, the gas sample vacuum pump is able to overcome 26.9 inches of Hg on the suction side and compress the gas to a maximum of 6 psig discharge pressure.
A solenoid valve 12 lies directly adjacent to the gas sample vacuum pump 11 . Note that both the solenoid valve 12 and gas sample vacuum pump 11 are controlled by the same electrical switch 13 . This is key to the design of the present invention because it prevents the natural gas from flowing back through the gas sample vacuum pump. In other words, the valve is only open when the gas sample vacuum pump is on and pumping gas through the system. When the pump is turned off, the valve is also closed, thereby preventing backflow through the gas sample vacuum pump (which would otherwise occur because the gas in the wellhead system is at low pressure (less than 5 psig) under vacuum on the inlet side of the compressor, pump or blower).
Next, the natural gas sample travels to a sample tube 14 , where the natural gas to be analyzed is collected. A pressure gauge 15 immediately downstream of the sample tube 14 is used to gauge the pressure in the sample tube 14 . A first block valve 16 is preferably located downstream of the pressure gauge 15 . The purpose of this valve 16 is to allow the operator to build pressure/volume in the sample tube 14 during the final phase of the pump/purge cycle (discussed below). The first block valve 16 is closed and the pressure is allowed to build up in the sample tube 14 to between 3 and 5 psig, at which point the solenoid valve 12 is closed and the gas sample vacuum pump 11 is shut off. The first block valve 16 is then opened and a sample is analyzed by the gas analyzer (e.g., gas chromatography 27 and the computer 28 . A second block valve 17 and first vent 18 are optionally located between the first block valve 16 and gas sample flow meter 19 in case it becomes necessary to vent the system at this point.
A gas sample flow meter 19 located downstream of the first block valve 16 tells the operator whether natural gas is flowing through the system. After the sample passes through the gas sample flow meter 19 , it passes through a second filter 20 . The second filter 20 is preferably the same kind of filter as the first filter 9 . The invention incorporates a second filter because compression causes much of the water and potentially some hydrocarbon in the vapor phase to condense into liquid phase; therefore, the second filter 20 will separate the liquid phase that forms after the sample exits the gas sample vacuum pump 11 from the gas sample. The sample tube 14 provides gas volume storage for the gas analyzer, and it also acts as a catch point for any liquid that may be present in the sample after compression. The second filter 20 will stop the migration of any liquid that is able to travel past the sample tube 14 . The second filter 20 is preferably positioned at the highest point in the system so that any liquid that may be in the system will have difficulty passing through the gas sample flow meter 19 to the second filter 20 . A third block valve 21 and second vent 22 are preferably located directly underneath the second filter 20 so that the system can be purged with natural gas prior to the natural gas entering the gas analyzer, as explained more fully below.
After the second filter 20 , the sample passes through a micro filter 23 before entering the gasifier 24 . The micro filter 23 is preferably a CP736729 manufactured by Varian, Inc. of Palo Alto, Calif., although any suitable 5-micron filter may be used. The purpose of the micro filter 23 is to remove grit, dirt, dust and other solid particles from the stream prior to entering the gas analyzer. The invention intentionally incorporates redundant filters to ensure that the sample entering the gas analyzer is free of liquids and entirely in gaseous phase (i.e., does not contain any solids or liquids).
The gasifier 24 is preferably a CP740431 also manufactured by Varian, Inc. of Palo Alto, Calif., although any suitable gasifier may be used. The gasifier 24 maintains the sample at a constant temperature and pressure and ensures that the entirety of the sample entering the gas analyzer is in a gaseous phase. If there were any liquid in the system at this point, the gasifier 24 would vaporize it. (The inclusion of water in liquid phase in the sample would damage the gas analyzer if it were to enter the gas analyzer, which is the reason for the gasifier. However, it is preferable to eliminate liquid even in gaseous phase from the sample because if present in anything other than miniscule quantities, it will dilute the natural gas sample and skew the results of the chemical compositional analysis. The first filter 9 , together with the gas sample vacuum pump 11 and second filter 20 , are the primary mechanisms for removing liquid from the sample.) A micro needle valve 25 and third vent 26 from the gasifier allows the system to be purged in between samples. Once the sample enters the gas analyzer 27 , the gas analyzer analyzes the sample and transmits the results to a computer 28 .
In a preferred embodiment, the gas analyzer 27 is a Varian CP 4900 Micro manufactured by Varian, Inc. of Palo Alto, Calif. The gas analyzer must be small enough to be portable, which typically means it will use a fused silica capillary column for sample separation. Other gas analysis technologies may be used in connection with the present invention.
To operate the present invention, the drain 10 must be closed, and the first block valve 16 open. The second block valve 17 and first vent 18 should be closed. The third block valve 21 and second vent 22 , as well as the micro needle valve 25 and third vent 26 , should also be closed. Next, the third block valve 21 and second vent 22 are opened slightly and the switch 13 turned on. With the switch 13 turned on, the solenoid valve 12 opens, and the gas sample vacuum pump 11 pulls natural gas from the inlet 8 into the sample tube 14 . The pressure gauge 15 is used to monitor the pressure in the sample tube 14 , and the third block valve 21 can be opened or closed slightly to maintain the pressure at a more or less constant three (3) to five (5) psig. This is continued for several minutes to purge the system (between the inlet 8 and the second vent 22 ) of any non-representative sample components.
Next, the micro needle valve 25 and third vent 26 are opened, and the third block valve 21 and second vent 22 are closed. With the gas sample vacuum pump 11 still on, the system is being purged through the gasifier 24 .
After several minutes, the switch 13 is shut off, and the natural gas is allowed to flow out to atmosphere through the third vent 26 until the pressure decreases to three (3) psig. The switch 13 is then turned back on, and the gas sample vacuum pump 11 draws more natural gas into the system. This on-and-off cycle is continued for anywhere from a few to several iterations, with the operator watching the pressure gauge 15 to make sure that the pressure stays roughly within the range of three (3) to five (5) psig. (The sample must be between three (3) and five (5) psig in order for it to flow through the gas analysis equipment. When the operator is satisfied that the system has been adequately purged, the micro needle valve 25 and third vent 26 are closed. The first block valve 16 is also closed, allowing the pressure in the sample tube 14 to build to 3 to 5 psig, at which point the gas sample vacuum pump 11 is turned off and the first block valve 16 opened.
At this stage, the sample tube 14 is holding sufficient volume for at least four samples to be analyzed in the gas analyzer. Approximately 200 nanoliters are needed for each gas analyzer sample. Preferably, the sample tube 14 holds approximately 0.5 liters. The operator utilizes the computer 28 to generate and display the gas analyzer results. Typically, four samples are analyzed and the first one disregarded. Once the samples have been analyzed, the third block valve 21 and second vent 22 are opened, and the natural gas is allowed to flow out to atmosphere. The stream sample probe 4 is shut off, or if the sample is being drawn from the vent in the manifold 5 , the vent line is disconnected. Lastly, the drain 10 is opened to allow any liquid that was collected during the process to drain out of the system. The drain 10 is preferably located at a relatively low point in the system to allow the liquid to drain out more easily.
Although the above examples deal primarily with coal natural gas wells, the present invention can be used with any natural gas well that is at low pressure (less than 5 psig) or under vacuum or that is experiencing a pressure sufficiently low as to not allow for a representative sample to be taken from the production stream in a timely and efficient manner. In addition to production analysis (i.e., from the wellhead 1 to the compressor 6 ), the invention may be used in other parts of the oil and gas collection and condition systems including pipelines, compression, storage, separation, treating and processing (collectively, midstream operations), and delivery systems (downstream operations) in which the streams are at a low pressure (less than 5 psig) or vacuum condition where there is not enough pressure for the gas to flow through the sampling and analysis apparatus. Examples of where this invention may be used in midstream operations include compressor station suction, vapor recovery units, flare systems, flash gas systems, amine regeneration, tri-ethylene glycol regeneration, oil stock tank vents, fuel gas systems, blanket gas systems, etc.
Furthermore, the present invention may be used to gather sample data on any low-pressure system (not necessarily a well) where there is positive pressure, but the pressure is intermittent or too low for a conventional system to be used. For example, the present invention could be used to analyze samples from fluid storage tanks, where the hydrocarbon fluid naturally vaporizes or flashes to a gas phase due to temperature changes.
Although the preferred embodiment of the present invention has been shown and described, it will be apparent to those skilled in the art that many changes and modifications may be made without departing from the invention in its broader aspects. The appended claims are therefore intended to cover all such changes and modifications as fall within the true spirit and scope of the invention. | A mobile vacuum sampling system comprising: an inlet; a first filter; a gas sample vacuum pump; a solenoid valve; a sample tube; a pressure gauge; a first block valve; a second filter; a micro filter; a gasifier; a gas analyzer; and a computational, recording and/or analysis display device; wherein a natural gas stream enters the gas sample vacuum pump via the inlet and is compressed to between 3 and 5 psig; wherein the sample tube collects natural gas to be analyzed; wherein the gas analyzer is portable; wherein the gas analyzer analyzes gas samples from the sample tube; and wherein the entire system is contained within a truck or other mobile unit. | 4 |
BACKGROUND OF THE INVENTION
The present invention relates to an improvement in a marine vessel such as a cantilever jack-up drilling barge or the like for use in underwater operations. More particularly, the present invention relates to an improved offshore drilling rig assembly.
In relatively shallow offshore oil drilling operations of the type conducted from an offshore platform or a jack-up type barge it is conventional for the external drive pipe, or conductor, to be free standing from the ocean floor to a point above the surface of the water and just below the drilling rig. The drive pipe is driven into the ocean floor with a pile driver to a depth of 200 or 300 feet and is cemented to the ocean floor at the mudline.
The drive pipe encloses a concentric arrangement of one or more drill pipe casings and a drill string. The drive pipe provides lateral support for the casings and drill strings from the drilling rig to the well bore and also typically provides support for the pressure control equipment normally referred to as "blow out preventers". Alternatively, the drill pipe casings may be supported at the level of the ocean floor. In either arrangement, the drive pipe provides fluid communication to the drill hole as well as support for the blow out preventers and drill pipe casings.
The drive pipe and drill pipe casings terminate just before the pipe column reaches the drilling platform. The drill string continues through the pressure control equipment affixed to the end of the pipe column.
The action of the ocean waves on the free standing pipe column comprising the drive pipe and drill pipe casings causes the column to sway. Such wave-induced lateral displacement of the pipe interferes with normal drilling and producing operations.
The magnitude of the pipe column's lateral displacement can be reduced if the pipe column is provided with lateral support from the barge. This may be accomplished by connecting to the barge a restricting assembly that hangs beneath the barge and grips the outer pipe of the pipe column. Such lateral support stabilizes the pipe column against the laterally dislocating forces of the ocean waves.
Some special problems must be overcome to attach a restricting assembly to a cantilever type jack-up drilling barge. The cantilever beams which extend outboard over the ocean during drilling and production operations must be retracted when the barge is to be moved to a new location. If the restricting assembly that hangs beneath the drilling platform to stabilize the pipe column is permanently affixed below the level of the cantilever beams, then the restricting assembly would interfere with the retraction of the cantilever beams. Since the deck of the barge under the cantilever beams is used for storage of drill pipe, and since that area must remain free of obstruction, a restricting assembly permanently affixed above the level of the cantilever beams is also not practical.
OBJECTS OF THE INVENTION
It is an object of this invention to provide a simple, efficient and economic means for restricting the lateral motion of a pipe column extending upward from the bottom of a body of water to a point above the surface of the water, said restricting means adaptable to be mounted on a marine vessel such as an offshore drilling barge or the like.
Another object of this invention is to provide pipe column restricting means that may be easily stowed when not in use and that may be easily moved to and from stowed position so that a pipe column may be stabilized without interfering with normal drilling or servicing operations.
These and other objects and features of advantage of this invention will be apparent from the drawings, the detailed description, and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings in which is shown a preferred embodiment the invention may assume, and in which like numerals indicate like parts,
FIG. 1 is a side view of a jack-up cantilever type drilling barge showing the barge and the present invention in drilling or operating position;
FIG. 2 is an enlarged, detailed side view of the cantilevered portion of the apparatus of FIG. 1, showing the attachment of the present invention to the barge in operating position (solid lines) and in stowed position (dotted lines);
FIG. 3 is an enlarged, detailed end view of the barge showing the attachment of the present invention to the barge in operating position (solid lines) and stowed position (dotted lines);
FIG. 4 is a plan view of the movement restricting apparatus of the present invention including the pipe column restricting frame and its supporting means;
FIG. 5 is an enlarged detail view taken on the line 5--5 of FIG. 4 showing the construction and attachment of a portion of the pipe column restricting means;
FIG. 6A is a somewhat diagrammatic end view of the apparatus of the invention illustrating the initial movements of the restricting assembly when the restricting assembly is being stowed;
FIG. 6B is a view similar to FIG. 6A illustrating the movements of the restricting assembly at an intermediate point in the stowing process;
FIG. 6C is a view similar to FIGS. 6A and 6B illustrating the movements of the restricting assembly during the final stages of the stowing process.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to the drawings, 10 indicates a marine vessel such as a floating barge or the like which can be anchored to the ocean bottom and raised above the level of the water by means of supporting columns 12. The barge 10 may be provided with a drilling platform 14, which may be slidably connected to the barge so that the platform may be extended outboard over the surface of the water in cantilever fashion. A derrick 15 on the cantilevered portion 14 may be used for drilling operations when the cantilevered portion is in its outboard position.
With the cantilever section 14 of the barge extended, a pipe column 18 is extended to the floor of the ocean and is driven by pipe driving means (not shown) into the ocean floor to a depth of 200 to 300 feet. With the pipe column 18 (i.e., the drive pipe) anchored in the ocean floor, one or more drill pipe casings 16 may be concentrically inserted into the pipe column 18 for drilling and producing operations.
When more than one drill pipe casing 16 is used, the outermost casing is cemented to the pipe column 18 at the mudline by extruding cement 20 into the annular space between the pipe column 18 and the drill pipe casing 16. Of course, if only one drill pipe casing 16 is used, then it is the outermost casing so cemented. For simplicity and clarity, only one drill pipe casing 16 will be depicted in the present description.
A rotary drill string 17 is disposed within the bore of the drill pipe casing 16 for rotating the drill bit in the well and for supplying drilling mud for lifting well cuttings up the annulus between the drill string 17 and the drill pipe casing 16.
The section of drill pipe casing 16 that is covered by the pipe column 18 is that section which extends from a point 200 or 300 feet below the floor of the ocean to some point above the surface of the water where the drill pipe casing 16 and pipe column 18 are connected to the pressure control equipment (not shown). The drill string 17 continues through the pressure control equipment to the drilling platform 14.
The pipe column 18 which encloses the drill pipe casing 16 and the drill string 17 is free standing and has no external point of support other than that indirectly imparted by the drill pipe casing 16 and the drill string 17.
The present invention is designed to give lateral support to the pipe column 18 against forces generated by the action of the ocean waves. The preferred embodiment of the invention accomplishes this aim by providing lateral support via a restricting assembly comprising a restricting frame 22 fitted with pipe engaging bumpers 24 and suspended from the cantilever section 14 of the barge by rigid elongate metal rods 26.
Referring to FIG. 4, the restricting frame 22 comprises two parallel elongate frame members 28 rigidly connected by cross beam frame members 30 so that the elongate frame members 28 remain essentially parallel to each other at a fixed distance. The length of the cross beam frame members 30 is chosen so that the distance of separation between the elongate frame members 28 is slightly greater than the outer diameter of the pipe column 18 that passes between the two parallel elongate frame members 28.
That means carried by the restricting frame 22 for restricting the lateral motion of the pipe column 18 comprise two cross braces 32, described below, and a plurality of pipe engaging bumpers 24 attached to the elongate frame members 28 and to the cross braces 32. One end of each cross brace 32 is connected to one of the elongate frame members 28 and the other end of each cross brace 32 is connected to the other elongate frame member 28. Thus, the cross braces 32 are affixed to the restricting frame so that they are both relatively parallel to each other and relatively perpendicular to the elongate frame members 28. The cross braces 32 are affixed to the restricting frame so that they are separated by a distance slightly greater than the outer diameter of the pipe column 18. The cross braces 28 together with the elongate frame members 28 form a generally rectangular enclosure through which the pipe column 18 narrowly passes. The pipe column 18 is prevented from rubbing against said pipe restricting enclosure by attaching pipe engaging bumpers 24 to the elongate frame members 28 and the cross braces 32. During normal operations such bumpers touch or nearly touch the pipe column 18, thus entirely preventing or narrowly limiting lateral movement of the upper end of pipe column 18.
Referring to FIG. 5, each cross brace 32 comprises an "I" shaped metal beam which is laid across and affixed to the two elongate frame members 28. The cross braces 32 are affixed by placing a flat rectangular-shaped metal flange plate 34a over the cross brace 32 and a similar flange plate 34b under an elongate frame member 28 at a point of connection and clamping the cross brace 32 to the elongate frame member 28, said clamping being accomplished by securing elongated bolts 36 through flange plate 34a, around cross brace 32, around elongate frame members 28, and through flange plate 34b.
The cross braces 32 are clamped to the elongate frame members 28 rather than being permanently affixed to them in order that the cross braces 32 can be moved to different positions on the restricting frame 22 to accommodate the pipe column 18 in a plurality of drilling positions. FIG. 3 indicates the extent of lateral placement of the cross braces 32 on the restricting frame 22 by showing in dotted outline the position that pipe column 18 would occupy at each end of the restricting frame. FIG. 4 shows wire mesh flooring 38 covering the portions of the restricting frame 22 outside the rectangle formed by the cross braces 32 and the elongate frame members 28. Also shown is an accommodation ladder 40 which allows access to the area of the restricting frame 22 covered by the wire mesh flooring 38.
The restricting frame 22 is attached to the cantilever section 14 of the barge by four elongate metal rods 26. Each elongate metal rod 26 is pivotally attached to a corner of the restricting frame 22 and is pivotally attached to the cantilever section 14 of the barge by metal pivot joint assemblies 42. The pivot in each metal pivot joint assembly 42 is generally parallel to the cross beam frame members 30 of the restricting frame 22. This arrangement permits the restricting frame 22 and the four elongate metal rods 26 pivotally attached to it to have considerable flexibility and freedom of motion in a plane perpendicular to the direction of the cross beam frame members 30. The restricting frame 22 and the pivotally attached elongate metal rods 26 have relatively little freedom of motion in the direction of the cross beam frame members 30.
When the restricting assembly is in position to restrict the motion of the pipe column 18, the flexibility provided by the pivotal attachment of the elongate metal rods 26 must be reduced in order to give the restricting assembly sufficient rigidity with respect to the cantilever section 14 of the barge to restrict the lateral motion of the pipe column 18. The restricting assembly is made rigid via mechanically detachable bracing means in the form of rigid struts 44 which connect the restricting frame 22 with the elongate metal rods 26. The end of each strut 44 is forked and is adapted to receive a pin through the furcations of said forked end in order to attach the strut 44 to the restricting frame 22 and each of the elongated metal rods 26. When all four of the struts 44 are attached the restricting assembly is suitably rigid. The struts 33 are removed during the stowing process described below.
The flexibility of the restricting assembly described above permits the restricting frame 22 and the pivotally attached elongate metal rods 26 to be easily maneuvered into a stowed position while the elongate metal rods 26 remain pivotally attached to the cantilever section 14 of the barge. Referring to FIG. 6A, the dotted outline diagrammatically represents the position of the restricting assembly when it is in position to restrict the motion of the pipe column 18. The solid lines diagrammatically represent the initial movements of the restricting assembly when the restricting assembly is being stowed. After the assembly has been disengaged from the pipe column 18 and drill pipe casing 16, the restricting assembly is pulled to one side of the center line of the cantilever section 14 of the barge until the pivotally elongate metal rods 26 on the other side of the restricting frame 22 come into planar alignment with the restricting frame 22.
Referring to FIG. 6B which illustrates the movements of the restricting assembly during an intermediate point in the stowing process, the restricting assembly is moved back toward the center line of the cantilever section 14 of the barge causing the pivotally attached metal rods 26 on the far side of the restricting frame 22 to move upward out of planar alignment with the restricting frame 22.
Referring to FIG. 6C which illustrates the movements of the restricting assembly during the final stages of the stowing process, the upward movement of the restricting frame 22 is continued. The restricting frame 22 comes into planar alignment with the second set of pivotally attached elongate metal rods 26. At this point, the direction of motion of the restricting frame 22 is reversed, and the restricting frame 22 is once again moved back toward the center line of the cantilever section 14 of the barge in such a manner that the restricting frame 22 moves upward out of planar alignment with the second set of pivotally attached elongate metal rods 26.
The restricting assembly comes to rest and may be secured in the stowed position diagrammatically indicated by the dotted outline in FIG. 6C. In the stowed position as shown, the restricting assembly does not hang down below the level of the cantilever section 14 of the barge and does not, therefore, interfere with the retraction of said cantilever section. Further, the restricting assembly in stowed position is well above the deck area of the barge 10 used for the storage of drill pipe. When the cantilever section 14 of the barge is retracted, the restricting assembly in stowed position freely clears obstructions on the storage deck of the barge 10.
From the foregoing, it may be seen that the objects of this invention have been obtained. There has been provided simple and efficient means for restricting the lateral motion of a pipe column in offshore drilling or producing operations. The invention may be easily stowed when not in use and may easily be moved to and from stowed position. The invention may be stowed so that it does not interfere with any drilling or producing operations.
The foregoing disclosure and description of the invention are illustrative and explanatory thereof, and various changes in the size, shape and materials, as well as in the details of the illustrated construction, may be made within the scope of the appended claims without departing from the spirit of the invention. | An apparatus for restricting the lateral motion of a pipe column extending upward from the bottom of a body of water to a point above the surface of the water. The apparatus finds its preferred use as a drive pipe stabilizer for a cantilever-type offshore drilling barge or the like. | 4 |
FIELD OF THE INVENTION
This invention relates generally to a process and apparatus for feeding weft inlay threads to a warp knitting machine in which the weft threads are initially fed to rakes positioned adjacent the longitudinal weft thread conveyors and with the rakes being movable between a starting position and a racking position with the weft threads being transferred from the rakes onto the longitudinal conveyors when the rakes are in the racking position, and more particularly to such a process and apparatus in which the rakes are temporarily coupled to the longitudinal conveyors to move the rakes from the racking position to the starting position.
BACKGROUND OF THE INVENTION
It is generally known to utilize longitudinal conveyors and rakes for feeding weft inlay threads to the knitting instrumentalities of a warp knitting machine in parallel relationship and at a consistent distance relative to each other, as disclosed in U.S. Pat. No. 3,564,872. A weft carriage feeds an array of weft threads with each transverse movement across the machine so that individual consecutive arrays consist of equally spaced weft threads. The desired equal distance between all threads is obtained by the rake taking over the array of weft threads at the end of each transversal movement of the weft carriage outside of the longitudinal conveyors by imparting a racking movement to the rake in the opposite direction of the direction of travel of the longitudinal conveyors at the end of each transversal movement of the weft carriage. The array of weft threads is transferred from the rake to the longitudinal conveyor when the rake moves to the racking position. The movement of the weft carriage and the rack is coordinated with the movement of the longitudinal conveyor so that the stroke and speed of movement of the rake accurately matches the corresponding movement of the longitudinal conveyor. In the aforesaid U.S. patent this coordination of movement is accomplished with the aid of a cam which rotates in synchronism with the continuously running longitudinal conveyor.
This type of timing cam is expensive to manufacture. Also, the timing cam must be changed when the width of the array of weft threads is altered. In particular situations where several weft carriers are used, as disclosed in DE-OS No. 3 343 048, the timing cam must have its own drive. In these instances where two cams are required for each weft carriage, each timing cam must be provided with its own drive so that this arrangement necessitates a very expensive construction.
SUMMARY OF THE INVENTION
It is an object of the present invention to simplify the drive of the rake by temporarily coupling the rake to the respective longitudinal conveyor so that the rake and the longitudinal conveyor can be easily adapted to varying widths of arrays of weft threads, and so that a high degree of accuracy is assured in regard to the synchronous movement of the rake and the longitudinal conveyor.
In accordance with the present invention, the movement of the rake from the racking position to the starting position is carried out by temporarily drivingly connecting the rake with the longitudinal conveyor and then breaking or disconnecting this temporary coupling upon movement of the rake back to the starting position.
By coupling the rake to the respective longitudinal conveyor, the movement of the rake and the longitudinal conveyor will be synchronous as long as this coupling connection is maintained. Since the position of the rake and the longitudinal conveyor does not change relative to each other, it is possible to transfer one array of weft threads from the rake to the longitudinal conveyor at any time during this movement. Under these circumstances, it is possible to perform this transfer at a time at which the weft yarn guide carriage is on its way to the other associated longitudinal conveyor. In this position of the weft carriage, the weft threads which it is laying extend relatively flat across the area between the two longitudinal conveyors which substantially simplifies the transfer. This transfer essentially consists in the weft threads gliding off of the teeth of the rack at an angle depending upon the angle of the weft threads so that the thus moved weft threads are captured by the respective hooks of the longitudinal conveyor.
This gliding off and capturing of the weft threads does not take place at an accurately definable point in time since it is dependent upon thread tension, current thread friction, and, of course, possible minor inaccuracies in the position of the teeth of the rake. Because of these variables, the gliding off of individual warp threads of an array of threads will not take place at exactly the same time but occurs during the period of time in which the weft carriage is moving across the area between the two longitudinal conveyors. For this reason, it is especially important to maintain accurate synchronization between the movement of the rake and the longitudinal conveyor and, in the present instance, is achieved by the temporary coupled driving connection between the rake and the longitudinal conveyor so that the teeth of the rake and the hooks of the longitudinal conveyor remain in the same position relative to each other to insure that the individual weft threads which glide off of the teeth of the rake are accurately positioned on the hooks of the longitudinal conveyor.
Adoption to different widths of the arrays of weft threads poses no problem when the rake is coupled to the respective longitudinal conveyor in accordance with the present invention. From the starting position, in which the weft threads are placed both into the longitudinal conveyor and into the rake by the weft carriage, the rake is moved into the racking position, which may be effected in the known manner by one quick step by means of random mechanical means. Thus, the racking position may be defined by an adjustable mechanical stop or an adjustable proximity switch or stroke limiter. The driving coupling between the rake and the respective longitudinal conveyor is achieved at this racking position when the stop or the proximity switch is reached so that the rake then moves in synchronism with the longitudinal conveyor. This optional setting of the racking position permits the mechanism to be adapted to the currently required width of the array of threads.
The mechanism for performing the process according to the present invention is conveniently provided by a coupling link on the rake which engages the respective longitudinal conveyor and may be coupled or uncoupled, depending upon the position of the rake. The arrangement of the coupling link of the rake facilitates compact construction, and because of the proximity of the rake and the longitudinal conveyor, engagement of the coupling link to the longitudinal conveyor is accomplished by a very short route.
In the illustrated embodiment of the invention, the coupling link includes a sprocket wheel having its teeth in driving engagement with the longitudinal conveyor and the sprocket wheel is selectively rotatable on or lockable to a shaft attached to the rake. Thus, drivingly engaging the rake to the longitudinal conveyor is accomplished by mean of the sprocket wheel acting as a coupling link. When the sprocket wheel is supported for rotation on the shaft, the rake and the longitudinal conveyor are not drivingly coupled to each other because the sprocket wheel is free to idle along the longitudinal moving conveyor. When, however, the sprocket wheel is locked on the shaft and coupled to the rake, the longitudinally moving conveyor moves the nonrotatable sprocket wheel and thus the rake.
The coupling link for permitting the sprocket wheel to rotate on or be lockingly engaged with the shaft attached to the rake comprises a magnetic clutch between the sprocket wheel and the fixed or nonrotating shaft. A magnetic clutch has the advantage of being controllable in a simple and effective manner so that the driving connection between the rake and the longitudinal conveyor is easily controlled in a simple manner.
The engagement and disengagement of the coupling link may be controlled by providing a stop for the starting position of the rake and an adjustable stroke limiter for the racking position of the rake. With this arrangement, the racking movement is completed when the stroke limiter is reached and the racking movement is completed, thereby establishing the coupling link between the longitudinal conveyor and the rake. A limit switch is provided on the stop which cancels or disengages the coupling connection when the rake engages the stop, at the starting position.
Disengagement of the coupling link at the end of the racking movement of the rake is conveniently effected by means of a contact switch. This contact switch is actuated by the weft thread carriage when the weft threads are placed in position thereby.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects and advantages will appear as the description proceeds when taken in connection with the accompanying drawings, in which
FIG. 1 is a fragmentary plan view of a longitudinal conveyor with a rake associated therewith in accordance with the present invention;
FIG. 2 is a side elevational view of FIG. 1 looking inwardly at the right-hand side thereof; and
FIG. 3 is an enlarged vertical sectional view through the longitudinal conveyor of FIG. 1 and illustrating the weft thread carriage associated therewith.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows the longitudinal conveyor, broadly indicated at 1, and the associated rake 2 supported on one side of the frame of a warp knitting machine. A mirror image of the longitudinal conveyor 1 and the rake 2 is provided on the opposite side of the warp knitting machine, not shown. The weft inlay threads extend across the area between the two longitudinal conveyors in the manner illustrated in the aforesaid U.S. Pat. No. 3,564,872 and the DE-OS No. 3 343 048. The longitudinal conveyor 1 includes a triple roller chain 3 (FIG. 3) provided with rows of chain rollers 4, 5 and 6. Individual hook sockets 7 are attached in succession onto roller chain 3 by screws 9 and carry hooks 8 of the longitudinal conveyor 1. The roller chain 3 is carried and guided by a chain guide track 10 which is secured to a carrier frame member 12. In order to accommodate tee tension exerted upon the hooks 8 by the weft threads, the roller chain 3 is provided with support rollers 13 which roll against the side face 14 of the roller chain guide track 10. The support rollers 13 are supported and connected to the chain 3 by angle brackets 15. The roller chain 3 is driven by the main drive of the warp knitting machine in a conventional manner.
The rake 2 is supported for longitudinal forward and rearward movement adjacent to the longitudinal conveyor 1 and includes outwardly extending rake teeth 16 positioned opposite the hooks 8 of the longitudinal conveyor 1. The rake 2 is supported for movement on and along upper and lower guide rods 17 fixed at their opposite ends to the machine frame 11 by means of spaced-apart bearing blocks 19.
The rake 2 is fixed on a carrier bracket 20 by means of screws 21 and the carrier bracket 20 is supported for longitudinal movement along the guide rods 17 by bearings 18 (FIG. 3). A bearing block 22 is supported on the upper surface of the carrier block 20 by screws 23 which extend through elongated holes or slots 24 to facilitate longitudinal adjustability of the bearing block 22 along the carrier block 20. One end of a stub shaft 25 is clamped in the bearing block 22 and is, therefore, nonrotatable in relation to the bearing block 22, in the embodiment shown. A magnetic clutch 26 and associated coupling collar 27 are supported on the stub shaft 25 and are connected to the sprocket wheel 28 mounted on the stub shaft 25. The sprocket wheel 28 is freely rotatable on the stub shaft 25 when the magnetic clutch 26 is not energized. When the magnetic clutch 26 is energized, the magnetic clutch 26 prevents rotation of the sprocket wheel 28 on the stub shaft 25.
When the magnetic clutch 26 is not energized, rollers 4 of the roller chain 3 move forwardly and rotate the sprocket wheel 28 without imparting movement to the carrier bracket 20 and rake 2. On the other hand, when the magnetic clutch 26 is energized, the sprocket wheel 28 is maintained in a fixed and nonrotating position so that the rollers 4 of the chain 3 move the rake 2 forwardly in a synchronous manner with the forward movement of the longitudinal conveyor 1.
FIG. 2 illustrates the manner in which the carrier bracket 20 and the rake 2 carried thereby may be moved to and fro relative to the conveyor 1 and the machine frame 11 when the magnetic clutch 26 is not energized so that the sprocket wheel 28 is freely rotatable. For this purpose, an air or oil operated cylinder 29 of a piston cylinder unit is secured to the machine frame 11 by means of a bearing block 30 with the outer free end of a piston rod 31 being fixed to a medial transverse member 32 of the carrier bracket 20. The piston cylinder unit is provided with the usual inlet and outlet openings 33 to accommodate the pressure medium used in operating the piston cylinder unit.
The reciprocal movement of the rake 2, along with the necessary control of the magnetic clutch 26, will now be explained in connection with FIGS. 2 and 3. In FIG. 2, the rake 2 is shown in the solid line racking position indicated by the dash-dot line B, in which position the weft threads held by the teeth 16 on the rake 2 are transferred to the hooks 8 of the longitudinal conveyor 1. In racking position B, the rearward movement of the rake 2 has been stopped by a stroke limiter 36 which is illustrated in the form of a conventional electrical proximity switch having a front face 44 which detects the approach of a transverse rear end member 39 of the carrier bracket 20. The proximity switch 36 operates when the front face 44 of the stroke limiter 36 is at a certain position relative to the corresponding face of the transverse member 39 so that the proximity switch 36 emits a signal which stops the movement of rake 2 in the rearward direction toward the stroke limiter 36, in a manner to be presently described. The signal from the stroke limiter 36 energizes the magnetic clutch 26 so that the sprocket wheel 28 is locked in a nonrotating position on the stub shaft 25. The longitudinal conveyor 1, advancing in the forward direction of the arrow, then moves the bearing block 22, the carrier bracket 20 and the rake 2 supported thereon by means of the nonrotating sprocket wheel 28 at exactly the same speed as that of the longitudinal conveyor 1. While the rake 2 is moving forwardly, the weft threads held by the teeth 16 of the rake 2 are transferred to the hooks 8 of the longitudinal conveyor 1.
A switch operator 37 (FIG. 3) is carried by the carrier bracket 20 and cooperates with a proximity limit switch 38. When the switch operator 37 is moved along opposite the proximity limit switch 38, an electrical signal is emitted to deenergize the magnetic clutch 26. At this time the sprocket wheel 28 is free to rotate on the stub shaft 25, thereby cancelling the coupling link between the longitudinal conveyor 1 and the rake 2 so that forward movement of the rake 2 is discontinued. The signal emitted by limit switch 38 35 simultaneously controls the cylinder 29 so that the piston rod 31 is retracted until the inner face of the transverse end member 39 of the carrier bracket 20 contacts an adjustable stop 40. Stop 40 finally arrests forward motion of the rake 2. In FIG. 2, this forward stopped position of the carrier bracket 20 is illustrated by the dotted line position of the transverse member 39 and this position is denoted as the starting position, represented by the dash-dot line A. From the starting position A, rake 2 is moved rearwardly to the racking position B by means of a signal triggered by a weft thread guide carriage 35 (FIG. 3). The weft thread guide carriage 35 is moved back and forth across the width of the warp knitting machine in a conventional manner along traversing rail 41 (FIG. 3). The conventional back-and-forth movement of the weft carriage 35 is illustrated in detail in the patents referred to heretofore.
The weft carriage 35 is moved to the right along the traversing rail 41 beyond the area of the hooks 8 and teeth 16 so that the weft threads carried by the weft thread carriage 35 extend between the hooks 8 and teeth 16 in a conventional manner. As the weft thread carriage 35 reaches the right-hand end of the stroke, a magnet 43 attached to the weft thread carriage 35 moves into position below a proximity switch 42 attached to the machine frame 11. In FIG. 3, this position of magnet 43 is shown in dotted lines. In this position, the proximity switch 42 emits a signal which triggers the racking movement of the rake 2 by connecting the piston cylinder unit so that the piston rod 31 moves the carrier bracket 20 in a rearward position from the starting position A to the racking position B. This rearward racking movement is relatively short and continues over only a very short period of time, less than a second. When the rear transverse member 39 of the carrier block 20 approaches the face 44 of the stroke limiter 36, movement in the rearward direction is stopped, as heretofore described.
The proximity switches heretofore described, the stroke limiter 36, limit switch 38, stop 40 and proximity switch 42 are supported for adjustment to be locked in the adjusted position by providing either conventional elongated slot arrangements or threads with lock nuts. This adjustment provides that the proximity switch 42 will emit a signal at the exact moment when the hooks 8 and teeth 16 are in alignment with each other so that the magnetic clutch 26 is energized at the proper time. With this arrangement, it is possible to insure that the movement of the longitudinal conveyor 1 and movement of the weft thread carriage 35 are maintained in rigid synchronization with the central machine drive. The axial adjustment of the stroke limiter 36 thus determines the exact length of the racking movement and thereby permits adjustment of the width of the array of weft threads. The adjustability of the limit switch 38 and the stop 40 determines the exact starting position of the rake 2.
The reason for continuing to move the rake 2 by means of the cylinder 29 after reaching the limit switch 38 until it hits the stop 40 is that it is not possible to exactly define the starting position by means of the magnetic clutch 26 discontinuing rotation of the sprocket wheel by means of the limit switch 38. However, a definite starting position is accurately defined when the carriage bracket 20 engages the stop 40. For this reason, rake 2 is moved a relatively short distance by means of the cylinder 29 after the limit switch 38 has disengaged the magnetic clutch 26 so that the rake 2 is then moved to an accurately defined starting position A.
In the drawings and specification there has been set forth the best mode presently contemplated for the practice of the present invention, and although specific terms are employed, they are used in a generic and descriptive sense only and not for purposes of limitation, the scope of the invention being defined in the claims. | A process and apparatus is disclosed for feeding weft threads to a warp knitting machine including longitudinal conveyors traveling towards the knitting instrumentalities. Weft thread rakes are arranged outside of the longitudinal conveyors and are movable between a starting position in which the weft threads are placed into the longitudinal conveyors and the rakes, and a racking position against the traveling direction of movement of the longitudinal conveyors. After reaching the racking position, the weft threads are transferred onto the longitudinal conveyors and the rakes are then returned to the starting position in the direction of travel of the longitudinal conveyors. The move of the rakes from the racking position to the starting position is effected by a temporary coupling connection of the rakes with the longitudinal conveyors. After transfer of the weft threads, this coupling connection is cancelled as the rakes reach the starting position. | 3 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a thermal transfer printer for color printing and, in particular, to a thermal transfer printer for color printing on a recording paper by using an ink sheet having sequential segments of ink of three primary colors or four colors including black.
2. Description of the Prior Art
A thermal transfer printer used as an output printer in the computer system, word-processor, and the like is readily capable of color printing the application of ink of several different colors to the same page of the same printing medium. Thus, such a printer can be used for outputting such data as displayed by the so-called computer graphics or to produce multi-color images.
A thermal transfer printer capable of color printing as described above has been disclosed in, for example, the Japanese Patent, Laid-open No. 58-140266 (1983).
In the thermal transfer printer such as above, generally, an ink sheet having sequential segments of ink in four colors including three primary colors (yellow, magenta, and cyan) and black and a recording paper are put one upon another and carried to a contact position between a thermal transfer head and the platen so that all colors of ink are thermally transferred to the recording paper in succession. Each time that printing in one color is completed, the recording paper is reversed, then brought forward and again printed in the succeeding color on the same page as that previously printed, the repeat of such process providing multi-color printing.
However, with a thermal transfer printer of this type, it is necessary to press a thermal transfer head to a platen or release the thermal transfer head from the platen very frequently in comparison with a usual printer. In such prior art printers, the head is pressed to the platen when a recording paper is first set on the printer to carry out the initial position setting of the recording paper relative to the thermal transfer head and then a predetermined color of an ink sheet is set to a printing position or when the recording paper is carried in the backward direction after completing the printing with an ink of one color.
However, with the above described conventional example, the mechanism comprises a first lever for pressing the thermal transfer head to the platen by a biasing force of a spring and a second lever for releasing the thermal transfer head from the platen by the action of an electro-magnetic solenoid. Accordingly, with such the conventional construction, the construction itself is complicated and the size and weight of each lever and the like is large, so that it is difficult to reduce the size of the printer as a whole and the printer has problems with respect to reliability and durability.
In addition, since the positional relation between the thermal transfer head and the platen is unstable directly after the printer is switched on, various kinds of problem occur in the subsequent controls. Accordingly, it is desired to instantly control the positional relation between the thermal transfer head and the platen to the predetermined initial condition when the printer is initially powered and carry out the subsequent controls with this initial condition as a basic state for control.
This is accomplished by the provision of mechanisms for pressing the thermal transfer head to the platen and releasing the thermal transfer head from the platen with a very simple structure of reduced size and weight, being more economical to produce and of a high reliability and durability.
SUMMARY OF THE INVENTION
The present invention is intended to overcome the problem described above and it is a primary object of the present invention to provide a thermal transfer printer with a mechanism for pressing a thermal transfer head to a platen and separating the thermal transfer head from the platen which can reliably operate with a simple structure and a reduced size and which has desired duability. This is achieved by the provision of a mechanism whereby the thermal transfer head is pressed to the platen and released from the platen by the rotation of an eccentric cam.
It is another object of the present invention to provide a thermal transfer printer capable of reliably carrying out the subsequent controls by importing the control function of initially setting the positional relation between the thermal transfer head and the platen directly after being powered to the predetermined relation without delay.
The thermal transfer printer of the invention is provided with a thermal transfer head on which a series of heating elements arranged in parallel to an axial direction of a platen, supported so as to be brought into contact with said platen or released from said platen, and a biasing member for biasing said thermal transfer head to be pressed to said platen, characterized by comprising an eccentric cam rotationally controlled so as to be positioned at either a first position, at which said thermal transfer head is pressed to said platen, or a second position, at which said thermal transfer head is released from said platen; and a cam follower being mounted on and rotating together with said thermal transfer head, which is released from a cam surface to press said thermal transfer head to said platen by the biasing force of said biasing member when said eccentric cam is positioned at the first position and pressed by the cam surface to release said thermal transfer head from said platen when said eccentric cam is position at the second position.
The above and further objects and features of the invention will more fully be apparent from the following detailed description with accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view showing the appearance of a thermal transfer printer of this invention;
FIGS. 2 and 3 are sectional side views showing the mechanical structure thereof;
FIG. 4 is a fragmentary perspective of a structure of carrying system for the ink sheet;
FIG. 5 is an plan view thereof;
FIG. 6 is a fragmentary perspective view of a structure of a thermal transfer head and nearby parts, the major part being an eccentric cam for pressing and releasing the thermal transfer head to and from the platen;
FIGS. 7 and 8 are side views thereof;
FIG. 9 is a block diagram showing a structure of a control system of the thermal transfer printer of this invention;
FIG. 10 is a flow chart showing the sequence for initialization of positioning of cam by a control unit;
FIGS. 11a-c is a model view showing a position of cam for explanation of the above sequence;
FIG. 12 is a flow chart showing the control sequence in pressing the thermal transfer head of the platen by means of the control unit;
FIG. 13 is a flow chart showing the control sequence in releasing the thermal transfer head from the platen by means of the control unit;
FIG. 14 is a flow chart showing the control sequence for initialization of position of the recording paper by means of the control unit;
FIG. 15 is a flow chart showing the control sequence for adjustment of position of the ink sheet by means of the control unit; and
FIG. 16 is a flow chart showing the control sequence for backward carrying of the recording paper by means of the control unit after completing the printing with one color.
DESCRIPTION OF THE PREFERRED EMBODIMENT
A description of this invention will be made with reference to the drawings showing the preferred embodiment of this invention.
FIG. 1 is a perspective view showing the appearance of a thermal transfer printer of this invention. Mechanical structural elements of the thermal transfer printer of this invention are contained in a roughly box-like casing 120. The printer is provided with a main switch 122 disposed on the upper rear end of the casing 120, an indication part 123 having various indicators, a key board 92 having various instruction keys disposed on the front right side, and a cover 121 for covering the central portions of the upper front sides throughout. An outlet 125 for the printed recording paper is provided in the upper surface of cover 121.
FIGS. 2 and 3 are sectional side views of a mechanical structure of the thermal transfer printer of this invention, showing a condition in which the thermal transfer head 5 and the platen 6 are pressed to each other and the other condition in which an upper part including the platen 6 is opened.
The main component members of this thermal transfer printer are fixed to a pair of stationary side plates 80 and 80 suitably fixed to the interior of the casing 120 upright on the right and left sides to be parallel with each other and also to a pair of movable side plates 82 and 82 lying above the stationary side plates 80 and 80 to be parallel with each other along the front-to-back direction (the direction of carrying the ink sheet 2 and the recording paper 13 as will be described later), being pivotally fixed to the stationary side plates 80 and 80.
Between the stationary side walls 80 and 80 and near the rear ends thereof (the right side on every drawings), is provided a supply roll 1 having the ink sheet 2 wound therearound; at the central parts of the stationary plates 80 and 80, a bracket 60 having the thermal transfer head 5 fixed thereto; at the front upper parts (the left side on every drawing), a take-up roll 11 for the ink sheet 2; in a position between the bracket 60 and the take-up roll 11, an ink sheet carrier roller 8 for carrying the ink sheet 2; and at the lower central parts of the stationary plates 80 and 80, a cam supporting shaft 70 being fixed an eccentric cam 68 whose rotational center lies on a pivot of a segment. Further provided are: a guide shaft 3 for the ink sheet 2 and a first head guide shaft 4 between the ink sheet supply roll 1 and the platen 6; a second head guide shaft 7 between the platen 6 and the ink sheet carrier roller 8; and a guide shaft 10 between the ink sheet carrier roller 8 and the take-up roll 11.
The ink sheet carrier 8 is driven by an electric driving motor 30 as will be described later (see FIGS. 4 and 5). The rotational speed of roller 8 for carrying ink sheet 2 is synchronized with the carrying speed for the recording paper 13 as will be described later.
The movable side plates 82 and 82 are pivotally supported at one end thereof at an axis 81 of rotation provided on the front upper parts of the aforesaid stationary side plates 80 and 80. This permits the platen 6 and the thermal transfer head 5 to be pressed to each other with the other ends thereof turned backward in the normal state of operation. In other words, the movable side plates 82 and 82, when put into a state of use, are provided with: a recording paper roll 12 having the recording paper 13 wound therearound, disposed near the rear ends of the side plates (near the other ends of the casing 120); a slit-like sheet-inserting passage 15 formed by guide plates 105 and 106 depending almost vertically from the guide shaft 14 in the middle portion of a space interposed between the movable side plates 82 and 82; an upwardly directed recording paper discharging passage 20 formed by the second paper carrier roller 18 and the second pressing roller 19 facing each other so that the discharge passage is roughly parallel with the recording paper inserting passage 15; a platen 6 in the form of a roller further serving as a first recording paper carrier roller disposed between the lower end parts of the inserting passage 15 and of the discharging passage 20, as well as a first pressing roller 17; and another pressing roller 9 disposed slighly behind the axis of rotation 81 lying on the front side.
A pressing position of the first pressing roller 17 against the platen 6, serving as the first carrier roller, lies on the upstream side along the carrying direction for the recording paper above a contact position produced when the thermal transfer head 5 is pressed to the platen 6 (also a position of a line of heating elements of the thermal transfer head 5). Therefore, an acting position of carrying force exerted by the platen 6 as the first recording paper carrier roller upon the recording paper lies on the upstream side along the carrying direction for the recording paper 13 above the pressing position of the thermal transfer head 5 to the platen 6.
The upper end of the inserting passage 15 and that of the discharging passage 20 lead to an inlet opening 15a for the recording paper 13 undergoing change of running direction thereof at the guide shaft 14 and to an outlet 20a for discharging the recording paper 13 toward a discharging opening 125 of the cover 121 of the casing 120, repectively.
A positional relation between parts to be arranged when the printer is in use (a state as shown in FIG. 2) is fixed so that the pressing roller 9 and the ink sheet carrier roller 8 on the side of the stationary side plates 80 and 80 are pressed to each other at the same time that the platen 6, as the first recording paper carrier roller, and the thermal transfer head 5 are pressed to each other.
A first sensor 100 is provided in a position relatively near the upper end (near insertion opening 15a) of the inserting passage 15; a third sensor 102, in a relatively lower position (near the platen 6) between the first sensor and the platen 6 in the insertion passage 15, and a second sensor 101, in a position relatively near the upper part (near discharging outlet 20a) of the discharging passage 20. The first and the second sensors 100 and 101 are photosensors for detecting whether the recording paper is present or not, and the third sensor 102 is a photosensor for detecting a mark indicating a printing start position impressed on the recording paper 13.
The printing start position mark is used as a basis for setting a position from which printing with each color of the ink sheet 2 on the recording paper 13 is started.
A color sensor 111 is fixed to the movable side plates 82 and 82 at a position to intermediate platen 6 and ink sheet supply roll 1. Further, a light source 110 for the color sensor 111 is fixed at the position of the plate brackets 60 and 60 opposite the color sensor 111 and interposed by the carrying passage for the ink sheet 2.
When the movable side plates 82 and 82 are turned counterclockwise around shaft 81 with the cover 121 removed as shown in FIG. 3 to be put into an open state, the ink sheet supply roll 1 and the ink sheet 2 are exposed to a wide open space above the casing 120 and the ink sheet supply roll 1 is readily inserted or replaced.
When the movable side plates 82 and 82 are turned as described above, the platen 6 is displaced from its position adjacent the thermal transfer head 5. However, clockwise rotation of the thermal transfer head 5 by the spring 67 around shaft 63 is prevented by the contact of lower branch parts 62 and 62 of the plate brackets 60 and 60 with cam supporting shaft 70. Accordingly, there is no possibility that the thermal transfer head 5 may obstruct the movenent of side plates 82 and 82.
FIGS. 4 and 5 are a fragmentary perspective view and a plan view, respectively, of a main parts composing a carrying system for the ink sheet 2.
The electric driving motor 30 used in this printer is a pulse motor capable of rotating in either direction and mounted with a spur gear 31 at the output shaft. The spur gear 31 meshes with another spur gear 32 fixed to a shaft 8S pivoted by the stationary side plates 80 and 80. The shaft 8S in mounted with spur gears 34 and 33 disposed in succession from a position near the spur gear 32 and a part thereof closer to the front end is formed of a larger diameter to work as an ink sheet carrier roller 8.
A cogged belt 37 having teeth corrugated on its inner periphery is extended between the spur gear 33 and an idler gear 35 idly mounted on a shaft 35S fixed to the side plate 80 and spaced from the shaft 8S at an appropriate distance. Another similar cogged belt 38 is extended between the spur gear 34 and an idler gear 36 idly mounted on a shaft 36S fixed to the side plate 80 and spaced from the shaft 8S at an appropriate distance. The idler gear 35 is connected to an idler gear 41 idly mounted on the shaft common thereto through a spring clutch 39. Another idler gear 36 is connected to an idler gear 42 idly mounted on the shaft common thereto through a spring clutch 40.
The spring clutch 39 transmits rotation of the idler gear 35 to the idler gear 41 only when the idler gear 35 turns counterclockwise on FIG. 4. The spring clutch 40 transmits rotation of the idler gear 36 to the idler gear 42 only when the idler gear 36 turns clockwise on FIG. 4.
The idler gears 41 and 42 mesh with idler gears 43 and 44 idly fitted onto shafts 49 and 50 fixed to stationary side plates 80 and spaced at appropriate distances from shafts 35S and 36S, respectively.
The idler gears 43 and 44 are provided with spring clutches 51 and 52 on the root sides of shafts 49 and 50, respectively. The spring clutch 51 operates for intercepting rotation of the idler gear 43 in the counterclockwise direction on FIG. 4 whereas another spring clutch 52 operates intercepting rotation of the idler gear 44 in the clockwise direction.
Friction rings 45 and 46 as well as holding reels 47 and 48 for the ink sheet take-up roll 11 and for the ink sheet supply roll 1, respectively, are idly fitted on the front end sides of the idler gears 43 and 44 on the end parts of the shafts 49 and 50, respectively. Both reels 47 and 48 press the friction rings 45 and 46 toward the idler gears 43 and 44 by means of coiled springs 47S and 48S provided for both reels, respectively.
Performance of the driving system thus constructed for the carrying of the ink sheet 2 is fully described in our co-pending Application Ser. No. 897,193, and will not be described here.
The structure around thermal transfer head 5 of the printer of this invention, particularly, a structure for adapting the printing head 5 to be pressed or to be released from the platen 6 will be described with reference to FIGS. 6, 7 and 8. FIG. 6 is a fragmentary perspective view of the structure around the thermal transfer head 5; FIG. 7 is a side view showing a state in which the platen 6 and the thermal transfer head 5 are tightly pressed together with an eccentric cam 68 set in a first position; and FIG. 8 is a side view showing a state in which th platen 6 is released from the thermal transfer head 5 with the eccentric cam 68 set in a second position.
A pair of plate brackets 60 and 60 disposed right and left for supporting the thermal transfer head 5 are each formed of an upper branch part 61 positioned above and a lower branch part 62 positioned below which extend so to be distant from each other at the front end and to provide a V-shape. Both plate brackets 60 and 60 are pivoted rotatably about a shaft 63 positioned near the stationary side plates 80 and 80 so as to be parallel with each other between the side plates 80 and 80. Further, both plate brackets 60 and 60 are made in one body with each other in order that the thermal transfer head 5, first head guide shaft 4, and second head guide shaft 7 are fixed to both upper branch parts 61 and 61 and a cam pressing shaft 65 provided with a cam pressing roller 64 as a cam follower is fixed to the lower branch parts 62 and 62.
Both plate brackets 60 and 60 are biased rearwardly upwardly (clockwise on the drawings) at the front end portion thereof to turn around the shaft 63 by tensions of the springs 67 and 67 as biasing members stretched between the front end of each of lower branch parts 62 and 62 and a shaft 66 fixed to both stationary side plates 80 and 80.
Positions of parts fixed between the plate brackets 60 and 60 are set in such manner that, when the platen 6 and the thermal transfer head 5 are pressed to each other, the first and the second head guide shafts 4, 7 are disposed before and behind the platen 6, respectively.
The position of pressing roller 64 on the cam pressing shaft 65 is set to face the cam surface of the eccentric cam 68 fixed to the aforesaid cam supporting shaft 70.
A sensor shutter 69 is also fixed to cam supporting shaft 70. A cam position sensor 71, which comprises a photo-interrupter being turning on and off by rotational position of the sensor shutter 69 when the eccentric cam 68 and the sensor shutter 69 rotate together with the rotation of the cam supporting shaft 70, is disposed on the sides of the stationary side plates 80 and 80. The cam position sensor 71 outputs: a signal "0" when the sensor shutter 69 is out of engagement with this sensor 71 on account of a positional relation that the eccentric cam 68 is in a second position where the cam surface thereof is directed downward to press the cam pressing roller 64 downward, that is, in the direction opposite to that of biasing force of the spring 67 (the thermal transfer head 5 is released from the platen 6) and is at a first position where the plate brackets 60 and 60 are urged upwardly by the springs 67 and 67 (the thermal transfer head 5 is in pressing to the platen 6) while the eccentric cam 68 is adapted to be out of contact with cam pressing roller 64 with the cam surface of the eccentric cam 68 turned upwardly; and a signal "1" when the sensor shutter 69 is in engagement with the cam position sensor 71 due to other positional relations than the above-described one.
Accordingly, as shown in, for example, FIG. 7, when a positional relation that the eccentric cam 68 is at the first position and the platen 6 is pressed to the thermal transfer head 5 is changed to a position where the cam surface of the eccentric cam 68 is brought into contact with the cam pressing roller 64 being turned on the cam supporting shaft 70 and the eccentric cam 68 reaches the second position with the cam pressing shaft 65 depressed lower, the plate brackets 60 and 60 are turned downward together at the front ends thereof in opposition to stretching force of the spring 67. Thus, as shown in FIG. 8, the thermal transfer head 5 is released from the platen 6.
The plate brackets 60 and 60 are also provided with a light source 110 for the color sensor 111 for sensing the colors of ink of the ink sheet 2.
FIG. 9 is a block diagram showing structure of a control circuit of the thermal transfer printer of this invention.
In the drawing, the reference numeral 90 designates a microcomputer system as a control unit including CPU as a control center, ROM containing programs for various kinds of control and RAM for memorizing various kinds of information. The control unit 90 receives various kinds of key signals from the key board 92. Further, the control unit 90, while receiving signals from the aforesaid first sensor 100, second sensor 101, third sensor 102, color sensor 111, and cam position sensor 71, provides control signals to a light source 110 for the color sensor 111, driving system 6D for the platen 6 as the first recording paper carrier roller, driving system 18D for the second recording paper carrier roller 18, driving motor 30 for the ink sheet driving system, and driving motor 93 for driving the eccentric cam through an interface 91.
Next, control operation conducted by the control unit 90, that is, a performance of the thermal transfer printer of this invention will be described.
In the thermal transfer printer of this invention, the eccentric cam 68 is initially set in the second position where the cam surface thereof presses the cam pressing roller 64 immediately after the power source is thrown in. In other words, in the printer of this invention, immediately after the power source is turned on, the platen 6 and the thermal transfer head 5 are always set in positions so as to be distant from each other. The sequence for initial position setting of the eccentric cam 68 by means of the control unit 90 will be described with reference to the flow chart in FIG. 10 and illustrative drawings in FIG. 11
First, with the power source turned on, the control unit 90 distinguishes signals outputted from the cam position sensor 71 (step S1). As a result, if the output from the cam position sensor 71 is "1", it informs that the cam surface of the eccentric cam 68 lies between the first and the second positions as shown by the black round mark () 68S in FIG. 11. In this case, the control unit 90 performs control to drive the eccentric cam driving motor 93 so as to move the cam surface of the eccentric cam 68 toward the second position (lower in the clockwise direction on the drawings) (step S7). When output from the cam position sensor 71 changes into "0" from "1", the control unit 90 moves the cam surface of the eccentric cam 68 from the previous position further toward the second position by a predetermined degree θ2 of angle (for example 30°) (steps S8 and S9). In this way, the eccentric cam 68 is set in the second position.
On the other hand, in the case when the output of the cam position sensor 71 is "0" when the power source is thrown in, it represents that the cam surface of the eccentric cam 68 is in or near the first position (FIG. 11(b)), or in or near the second position (FIG. 11(c)).
As shown by the round black mark 68S in FIG. 11(b), when the cam surface of the eccentric cam 68 is in or near the first position, the control unit 90 first performs control operation to drive the eccentric cam driving motor 93 so that the cam surface of the eccentric cam 68 may be turned clockwise on the drawings by a predetermined degree θ1 of angle (for example, 20°) (step S2). When output of the cam position sensor 71 turns into "1", the control unit 90 performs the steps S3 to aforesaid steps S7, S8, and S9 for setting a second position of the eccentric cam 68.
When the cam surface of the eccentric cam 68 is in or near the second position as shown by the black round mark 68S in FIG. 11(c), the control unit 90 performs the step S2 in the same way as above. In this case, however, since the eccentric cam 68 further turns clockwise from the second position, output of the cam position sensor 71 is not "1". Accordingly, the control unit 90 proceeds from the step S3 to that S4 so as to turn the eccentric cam 68 in the direction opposite to the previous one (counterclockwise on the drawings). As a result, when output of the cam position sensor 71 changes into "1", the control unit 90 distinguishes "1" from the other through the step S5 and stops the rotation of the eccentric cam 68, that is, stops driving the eccentric cam driving motor 93 (step S6). Afterward, with the successive operation of the steps S7, S8, and S9 in the same manner as before by means of the control unit 90, the eccentric cam 68 is set in the second position.
The control unit 90 always keeps the position of the eccentric cam 68 as above in the memory of RAM after initial setting of the position of the eccentric cam 68.
In the thermal transfer printer of this invention, initial setting is performed in a state that the platen 6 is released from the thermal transfer head 5 immediately after the power source is switched on and, in connection therewith, a control process for pressing the thermal transfer head 5 to the platen 6 after the initial setting will be described with reference to FIG. 12 which is a flow chart showing the process performed by the control unit 90.
The control unit 90 turns the eccentric cam 68 counterclockwise until output of the cam position sensor 71 becomes "1" (steps S11 and S12). When output of the cam position sensor 71 changes into "1", the control unit 90 further turns the eccentric cam 68 counterclockwise until output of the cam position sensor 71 changes into "0" (steps S13 and S14). Upon change of output of the cam position sensor 71 into "0", the control unit 90 further turns the eccentric cam 68 by a predetermined degree θ2 of angle (30°, the same as before) counterclockwise (step S15). Through the successive processes as above, the eccentric cam 68 is turned from the second position to the first position to be set, whereby the thermal transfer head 5 is pressed to the platen 6 by biasing force of the spring 67.
On the other hand, the control for setting the eccentric cam 68 from the first position into the second position, is performed as shown in FIG. 13.
The control unit 90 turns the eccentric cam 68 clockwise until output of the cam position sensor 71 changes "1" (steps S21 and S22). With change of output of the cam position sensor 71 into "1", the control unit 90 further turns the eccentric cam 68 clockwise until output of the position sensor 71 changes "0" (steps S23 and S24). With change of output of the cam position sensor 71 into "0", the control unit 90 further turns the eccentric cam 68 clockwise by a predetermined degree θ2 of angle (30°, the same as before). Through the above process, the position of the eccentric cam 68 is shifted from the first one to the second one to be set so as to release the thermal transfer head 5 from the platen 6 in opposition to biasing force of the spring 67.
Control for initial position setting of the recording paper 13 by means of the control unit 90 will be described with reference to a flow chart in FIG. 14.
When the eccentric cam 68 is not being set in the first position, the control unit 90 sets the eccentric cam 68 in the first position depending on the abovesaid control (step S31) to keep the thermal transfer head 5 pressed to the platen 6.
When the recording paper 13 is drawn from the recording paper roll 12 by the operator and the foremost end thereof is inserted into the printer through the insertion opening 15a and positioned on the contact part between the platen 6 as the first paper carrier roller and the first pressing roller 17, the first sensor 100 detects the recording paper 13 and outputs a predetermined signal "1" to the control unit 90 (step S32). In the case where the first sensor 100 detects absence of the recording paper 13, an indication as "paper out" is displayed on the indication part 123 of the casing 120 (step S38).
When a recording paper carrier switch placed on the key board 92 is turned on while only the first sensor detects the recording paper 13 (step S34), the platen 6 and the paper carrier roller 18 are driven clockwise respectively. Thus, the recording paper 13 is carried from the contact part between the platen 6 and the first pressing roller 17 to another contact part between the platen 6 and the thermal transfer head 5 and further to still another contact part between the paper carrier roller 18 and the second pressing roller 19 (step S35) until the second sensor 101 detects the recording paper 13 and outputs a signals "1" (step S33).
In this way, the recording paper 13 is further carried after the foremost end thereof is detected by the second sensor 101 (step S34). When the detection signal "1" is outputted to the control unit 90 (step S36) with detection of a printing start position mark impressed on the recording paper 13 by the third sensor 102, the control unit 90 further carries the recording paper 13 by a predetermined length (step S37) so as to bring the actual printing start position on the recording paper into adjustment with a printing position of the thermal transfer head 5.
Since initial position setting for the recording paper 13 as above is performed in a state that the thermal transfer head 5 is pressed to the platen 6, that is, the eccentric cam 68 is set in the first position, so the ink sheet 2 is also carried in the forward direction by the same length as that of the recording paper 13. Therefore, if the above state continues as it is, a length of the ink sheet 2 carried during initial position setting of the recording paper 13 is useless and, in view of this drawback, rewinding of the ink sheet 2 in the thermal transfer printer of this invention is so designed as to be performed at the time of position adjustment of the ink sheet 2.
FIG. 15 is a flow chart showing a sequence of the control unit 90 in position adjustment of the ink sheet 2.
Position adjustment of the ink sheet 2 is to bring the foremost end of each section of ink sheet 2 having four colors as yellow:Y, magenta:M, cyan:C, and black:B face sequentially into exact adjustment with respective printing positions (positions for line of heating elements of the thermal transfer head 5). Position adjustment of the ink sheet 2 is carried out in an initial state immediately after the power is switched on and prior to printing with a section in one color following the finish of printing with the preceding color.
Control of position adjustment of the ink sheet 2 is performed by the control unit 90 on the basis of a detection signal obtained from the color sensor 111 which detects light rays passing through the ink sheet 2 emitted from the light source 110 disposed to face the sensor 111 with the carrying passage for the ink sheet 2 interposed therebetween. As a color sensor for the use as above, for example, an amorphous integrated full color sensor as disclosed in the Japanese Patent, Laid-Open No. 58-125865 (1983) is suitable. The color sensor disclosed therein is so composed as to provide three bits of signals in response to the color of light received thereby.
For position adjustment of the ink sheet 2, the control unit, first, performs controls for setting the eccentric cam 68 in the second position to release the thermal transfer head 5 from the platen 6 (step S41). Since the ink sheet 2 is carried in the forward direction by a length equal to that of the recording paper carried at the time of initial position setting of the recording paper 13, the control unit 90 performs control to drive the driving motor 30 in the opposite direction and carries the ink sheet 2 in the opposite direction by a length as described above (step S42).
The control unit 90 then turns on the light source 110 (step S43). At this time, if the required color (yellow at the time of initial setting) is detected, the control unit 90 drives the driving motor 30 to carry the ink sheet 2 step by step in the forward direction until the color is not detected (steps S44 and S45). Afterward, the control unit 90 drives the driving motor 30 to carry the ink sheet 2 step by step in the forward direction until the required color is again detected (steps S46 and S47). When the required color is detected at step S45 as above, the detected position is not proved to be the foremost end position of a section having the required color, however, since the other color is detected afterward and the other section having the other color is carried in the forward direction until the required color is again detected, the foremost end position of the section having the required color is substantially detected.
Subsequently, the control unit 90 turns off the light source 110 (step S48) and completes the process of position adjustment of the ink sheet 2.
When the recording paper 13 and the ink sheet 2 are separately subjected to initial position adjustment as above, the control unit 90 performs control to set the eccentric cam 68 in the first position so that the thermal transfer head 5 presses to the platen 6, and carries the recording paper 13 and the ink sheet 2 while synchronizing carrying speeds for the ink sheet 2 and recording paper 13. In such a state as above, control over heat generation at a line of heating elements of the thermal transfer head 5 provides thermal transfer printing with one color, for example, yellow.
Subsequently to the completion of thermal transfer printing in yellow ink as a first-color ink, the recording paper 13 is rewound. FIG. 16 is a flow chart showing a sequence of control over rewinding of the recording paper 13 by means of the control unit 90.
The control unit 90 operates to release the thermal transfer head 5 from the platen 6 (to set the eccentric cam 68 in the second position) (step S51). The control unit 90 then rewinds the recording paper 13 step by step, that is, carries the recording paper 13 in the reverse direction (step S52, S53, and S54) until the foremost end of the recording paper 13 is detected by the second sensor 101, that is, the foremost end of the reocrding paper 13 is carried to the side of the platen 6 beyond the detecting position for the second sensor 101, or the printing start position mark on the recording paper 13 is detected by the third sensor 102. Usually, the printing start position mark on the recording paper 13 is first detected by the third sensor 102 through the abovesaid process and, therefore, initial position setting of the recording paper 13 is possible after the abovesaid detection.
In the result that the printing start position mark cannot be detected by the third sensor 102 for some reasons during the carrying of the recording paper 13 in the reverse direction, detection of the foremost end of the recording paper 13 by the second sensor 101 prevents the foremost end of the recording paper 13 from being carried in the reverse direction beyond the contact part between the paper carrier roller 18 and the second pressing roller 19. Accordingly, excessive rewinding of the recording paper 13 to slip off the contact part between the paper carrier roller 18 and the second pressing roller 19 is prevented. Even in such a case as excessive rewinding of the recording paper 13, intial position setting as described above can be performed accurately.
As this invention may be embodied in several forms without departing from the spirit of essential characteristics thereof, the present embodiment is therefore illustrative and not restrictive, since the scope of the invention is defined by the appended claims rather than by the description preceding them, and all changes that fall within metes and bounds of the claims, or equivalents of such metes and bounds thereof are therefore intended to be embraced by the claims. | The thermal transfer printer of the present invention is provided with a cam follower mounted on a thermal transfer head in one body and an eccentric cam, which is controlled within a semicircle so as to be positioned at either a first position for releasing it from the cam follower to press the thermal transfer head to a platen or a second position for pressing it to release the thermal transfer head from the platen, as a construction for pressing the thermal transfer head to the platen and releasing the thermal transfer head from the platen, whereby the mechanism for pressing the thermal transfer head to the platen and releasing the thermal transfer head from the platen itself can be remarkably small-sized and is simple in action due to its remarkably small working quantity, the printer can be small-sized as a whole and improved in reliability of operation as well as durability. Furthermore, the thermal transfer printer can be stably carried out the subsequent controls after initial powering, since the positional relation between the thermal transfer head and the platen is controlled so as to be initially set to the predetermined relation without delay when it is initially powered. | 1 |
FIELD OF THE INVENTION
This invention relates to exhaust gas after-treatment systems and more particularly relates to apparatus, systems and methods for defining a regeneration availability profile.
DESCRIPTION OF THE RELATED ART
Environmental concerns have motivated the implementation of emission requirements for internal combustion engines throughout much of the world. Governmental agencies, such as the Environmental Protection Agency (EPA) in the United States, carefully monitor the emission quality of engines and set acceptable emission standards, to which all engines must comply. Generally, emission requirements vary according to engine type. Emission tests for compression-ignition (diesel) engines typically monitor the release of diesel particulate matter (PM), nitrogen oxides (NO x ), and unburned hydrocarbons (UHC). Catalytic converters implemented in an exhaust gas after-treatment system have been used to eliminate many of the pollutants present in exhaust gas. However, to remove diesel particulate matter, typically a diesel particulate filter (DPF) must be installed downstream from a catalytic converter, or in conjunction with a catalytic converter.
A common diesel particulate filter comprises a porous ceramic matrix with parallel passageways through which exhaust gas passes. Particulate matter subsequently accumulates on the surface of the filter, creating a buildup which must eventually be removed to prevent obstruction of the exhaust gas flow. Common forms of particulate matter are ash and soot. Ash, typically a residue of burnt engine oil, is substantially incombustible and builds slowly within the filter. Soot, chiefly composed of carbon, results from incomplete combustion of fuel and generally comprises a large percentage of particulate matter buildup. Various conditions, including, but not limited to, engine operating conditions, mileage, driving style, terrain, etc., affect the rate at which particulate matter accumulates within a diesel particulate filter.
Accumulation of particulate matter typically causes backpressure within the exhaust system. Excessive backpressure on the engine can degrade engine performance. Particulate matter, in general, oxidizes in the presence of NO 2 at modest temperatures, or in the presence of oxygen at higher temperatures. If too much particulate matter has accumulated when oxidation begins, the oxidation rate may get high enough to cause an uncontrolled temperature excursion. The resulting heat can destroy the filter and damage surrounding structures. Recovery can be an expensive process.
To prevent potentially hazardous situations, accumulated particulate matter is commonly oxidized and removed in a controlled regeneration process before excessive levels have accumulated. To oxidize the accumulated particulate matter, exhaust temperatures generally must exceed the temperatures typically reached at the filter inlet. Consequently, additional methods to initiate regeneration of a diesel particulate filter may be used. In one method, a reactant, such as diesel fuel, is introduced into an exhaust after-treatment system to initiate oxidation of particulate buildup and to increase the temperature of the filter. A filter regeneration event occurs when substantial amounts of soot are consumed on the particulate filter. Partial or complete regeneration may occur depending on the duration of time the filter is exposed to elevated temperatures and the amount of particulate matter remaining on the filter. Partial regeneration can contribute to irregular distribution of particulate matter across the substrate of a particulate filter.
Controlled regeneration traditionally has been gauged by set intervals, such as distance traveled or time passed. Interval based regeneration, however, has proven to be inadequate for several reasons. First, regenerating a particulate filter with little or no particulate buildup lessens the fuel economy of the engine and exposes the particulate filter to unnecessary high temperature cycles. Second, if particulate matter accumulates excessively before the next regeneration, backpressure from blockage of the exhaust flow can negatively affect engine performance. In addition, regeneration with excessive levels of particulates present can potentially cause filter failure or the like. Consequently, particulate filters regenerated on a set interval must be replaced frequently to maintain the integrity of an exhaust gas after-treatment system.
Aftertreatment systems must generally be produced with no knowledge of the specific final application for each system. The final application affects the regeneration opportunities available to the aftertreatment system. For example, some systems will be installed in applications that haul heavy loads for long distances, and the aftertreatment system can achieve a controlled regeneration whenever desired because it is always easy to generate temperature in the exhaust stream. Some systems will be installed in applications like a lightly loaded stop and go delivery vehicle, and the aftertreatment system can only achieve short periods of temperature generation.
The aftertreatment system cannot be produced with the final application specifically known, and even if the aftertreatment system can know the initial application after the first sale of the system, the subsequent applications of the system cannot be known because the initial user is not generally restricted from selling or changing the usage of the device on which the aftertreatment system is installed. Without a way to determine the final application while the aftertreatment system is in use, the aftertreatment system must be built for the extremes of the possible applications. This means that either all of the aftertreatment systems will be produced to handle the worst regeneration opportunity situations, and therefore the systems will have lower fuel economy than otherwise possible, or the designer will have to accept a relatively higher level of risk for those systems that have fewer regeneration opportunities than the aftertreatment systems are designed for, and thus a number of particulate filters will overload with soot and be subjected to an uncontrolled regeneration event.
If a controller could know the application usage profile, then the controller could take mitigating actions to make successful regeneration more likely in a given application. For example, if the controller knew the application was a stop and go, lightly loaded application, the controller could take advantage of every available regeneration opportunity, regardless of whether the “standard” control setup would require a regeneration each time. Likewise, in a heavy hauling application, the controller could allow the particulate filter to fill up each time, knowing that when regeneration is attempted it will succeed, and therefore maximize the fuel economy and minimize the number of thermal cycles, and thus thermal fatigue, on the components of the aftertreatment system. Ideally, the controller would track regeneration success against various operating parameters to determine the likelihood of a regeneration success, and to diagnose problems when the regeneration success rate degrades for a given operating condition.
From the foregoing discussion, it should be apparent that a need exists for an apparatus, system, and method for detecting and evaluating the regeneration opportunities available to a specific application in the field, which can be termed a regeneration availability profile. Beneficially, such an apparatus, system, and method provide the aftertreatment system with the overall profile of regeneration opportunities, as well as provide information to allow a controller to recognize abnormal events within the overall profile. Thus, the apparatus, system, and method would enable tailoring of regeneration controls to specific applications, and therefore increase the fuel economy and reduce the uncontrolled regeneration events for aftertreatment systems.
SUMMARY OF THE INVENTION
The present invention has been developed in response to the present state of the art, and in particular, in response to the problems and needs in the art that have not yet been fully solved by currently available exhaust gas after-treatment systems requiring particulate filter regeneration. Accordingly, the present invention has been developed to provide an apparatus, system, and method to determine a regeneration availability profile that overcomes many or all of the above-discussed shortcomings in the art.
In one aspect of the invention, an exhaust gas aftertreatment system includes an exhaust gas aftertreatment component which treats the exhaust gas, and the component requires periodic regenerations under specific conditions. The exhaust gas aftertreatment system includes a controller, in one embodiment, that may have an achievement data module, an operating condition module, a starting regeneration availability profile (RAP) module, an RAP adjustment module, and a storage module.
The achievement data module may be configured to determine achievement data determined from the current conditions of the exhaust gas aftertreatment component relative to the conditions required to achieve regeneration of the exhaust gas aftertreatment component. The operating condition module may be configured to determine the operating conditions—an engine speed and load, in one example—of a power application associated with the aftertreatment component. The starting RAP module may be configured to read a starting RAP from computer memory. The RAP adjustment module may be configured to adjust the starting RAP, based on the achievement data, the current conditions of the exhaust gas aftertreatment system, and the power application operating conditions, to generate an adjusted RAP. In one embodiment, the storage module records the adjusted RAP into computer memory, and the storage module may store historical RAP information beyond just the most recent RAP.
In a further aspect of the invention, a method comprises determining achievement data from the current conditions of an exhaust gas aftertreatment component relative to the conditions required to achieve regeneration of the exhaust gas aftertreatment component. The method may further comprise reading a starting RAP. In one embodiment, the method further comprises determining the operating conditions of a power application associated with the aftertreatment component. The method may proceed to generate an adjusted RAP from the achievement data, the starting RAP, and the current operating conditions of the power application associated with the aftertreatment component.
In a further aspect of the invention, the adjusted RAP comprises a regeneration success value for each of a set of data segments, where each data segment corresponds to one of the potential operating conditions for the power application. Generating the adjusted RAP may comprise adjusting each regeneration success value based upon the current operating condition and the achievement data. The method may proceed to store the adjusted RAP after the adjusted RAP is generated.
Reference throughout this specification to features, advantages, or similar language does not imply that all of the features and advantages that may be realized with the present invention should be or are in any single embodiment of the invention. Rather, language referring to the features and advantages is understood to mean that a specific feature, advantage, or characteristic described in connection with an embodiment is included in at least one embodiment of the present invention. Thus, discussion of the features and advantages, and similar language, throughout this specification may, but do not necessarily, refer to the same embodiment.
Furthermore, the described features, advantages, and characteristics of the invention may be combined in any suitable manner in one or more embodiments. One skilled in the relevant art will recognize that the invention may be practiced without one or more of the specific features or advantages of a particular embodiment. In other instances, additional features and advantages may be recognized in certain embodiments that may not be present in all embodiments of the invention. These features and advantages of the present invention will become more fully apparent from the following description and appended claims, or may be learned by the practice of the invention as set forth hereinafter.
BRIEF DESCRIPTION OF THE DRAWINGS
In order that the advantages of the invention will be readily understood, a more particular description of the invention briefly described above will be rendered by reference to specific embodiments that are illustrated in the appended drawings. Understanding that these drawings depict only typical embodiments of the invention and are not therefore to be considered to be limiting of its scope, the invention will be described and explained with additional specificity and detail through the use of the accompanying drawings, in which:
FIG. 1 is a schematic block diagram illustrating one embodiment of an exhaust gas after-treatment system in accordance with the present invention;
FIG. 2 is a schematic block diagram illustrating one embodiment of a controller in accordance with the present invention;
FIG. 3 is a schematic flow chart diagram illustrating one embodiment of a regeneration availability profile of the present invention; and
FIG. 4 is a schematic flow chart diagram illustrating one embodiment of a method to calculate a regeneration availability value in accordance with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Many of the functional units described in this specification have been labeled as modules, in order to more particularly emphasize their implementation independence. For example, a module may be implemented as a hardware circuit comprising custom VLSI circuits or gate arrays, off-the-shelf semiconductors such as logic chips, transistors, or other discrete components. A module may also be implemented in programmable hardware devices such as field programmable gate arrays, programmable array logic, programmable logic devices or the like.
Modules may also be implemented in software for execution by various types of processors. An identified module of executable code may, for instance, comprise one or more physical or logical blocks of computer instructions which may, for instance, be organized as an object, procedure, or function. Nevertheless, the executables of an identified module need not be physically located together, but may comprise disparate instructions stored in different locations which, when joined logically together, comprise the module and achieve the stated purpose for the module.
Indeed, a module of executable code may be a single instruction, or many instructions, and may even be distributed over several different code segments, among different programs, and across several memory devices. Similarly, operational data may be identified and illustrated herein within modules, and may be embodied in any suitable form and organized within any suitable type of data structure. The operational data may be collected as a single data set, or may be distributed over different locations including over different storage devices, and may exist, at least partially, merely as electronic signals on a system or network.
Reference throughout this specification to “one embodiment,” “an embodiment,” or similar language means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, appearances of the phrases “in one embodiment,” “in an embodiment,” and similar language throughout this specification may, but do not necessarily, all refer to the same embodiment.
Reference to a signal bearing medium may take any form capable of generating a signal, causing a signal to be generated, or causing execution of a program of machine-readable instructions on a digital processing apparatus. A signal bearing medium may be embodied by a transmission line, a compact disk, digital-video disk, a magnetic tape, a Bernoulli drive, a magnetic disk, a punch card, flash memory, integrated circuits, or other digital processing apparatus memory device.
Furthermore, the described features, structures, or characteristics of the invention may be combined in any suitable manner in one or more embodiments. In the following description, numerous specific details are provided, such as examples of programming, software modules, user selections, network transactions, database queries, database structures, hardware modules, hardware circuits, hardware chips, etc., to provide a thorough understanding of embodiments of the invention. One skilled in the relevant art will recognize, however, that the invention may be practiced without one or more of the specific details, or with other methods, components, materials, and so forth. In other instances, well-known structures, materials, or operations are not shown or described in detail to avoid obscuring aspects of the invention.
FIG. 1 depicts one embodiment of an exhaust gas aftertreatment system 100 , in accordance with the present invention. As illustrated, the exhaust gas aftertreatment system 100 may include a diesel engine 110 , a controller 130 , fuel injectors 135 , a first catalytic component 140 , a second catalytic component 142 , particulate filter 150 , and fuel tank 180 .
The engine system 100 may further include an air inlet 112 , intake manifold 114 , exhaust manifold 116 , turbocharger turbine 118 , turbocharger compressor 120 , exhaust gas recirculation (EGR) cooler 122 , various temperature sensors 124 , and various pressure sensors 126 . In one embodiment, an air inlet 112 vented to the atmosphere enables air to enter the engine system 100 . The air inlet 112 may be connected to an inlet of the intake manifold 114 . The intake manifold 114 includes an outlet operatively coupled to the combustion chambers of the engine 110 . Within the engine 110 , compressed air from the atmosphere is combined with fuel from the injectors 135 to power the engine 110 , which comprises operation of the engine 110 . The fuel comes from the fuel tank 180 through a fuel delivery system including, in one embodiment, a fuel pump and common rail (not shown) to the fuel injectors 135 , which inject fuel into the combustion chambers of the engine 110 . The timing of the fuel injection is controlled by the controller 130 . Combustion of the fuel produces exhaust gas that is operatively vented to the exhaust manifold 116 . From the exhaust manifold 116 , a portion of the exhaust gas may be used to power a turbocharger turbine 118 . The turbine 118 may drive a turbocharger compressor 120 , which compresses engine intake air before directing it to the intake manifold 114 .
At least a portion of the exhaust gases output from the exhaust manifold 116 is directed to the particulate filter 150 for filtering of particulate matter before venting to the atmosphere. The exhaust gas may pass through one or more catalytic components 140 , 142 , the catalytic components, in one embodiment, configured to further reduce the number of pollutants and to assist in oxidizing added hydrocarbons to generate temperature. For example, in one embodiment, catalytic component 140 comprises a diesel oxidation catalyst configured to oxidize hydrocarbons in the exhaust gas, while component 142 comprises a NO x adsorber configured to capture NO and NO 2 from the exhaust gas, and convert it to N 2 upon later release during a regeneration event.
A differential pressure sensor 160 is used, in one embodiment, to determine the amount of particulate matter accumulated on the particulate filter. A fuel delivery mechanism 190 is used to add hydrocarbons to the exhaust stream to generate temperature. The fuel delivery mechanism may inject hydrocarbons into the exhaust stream in front of at least one catalytic component 140 , 142 as shown, or the fuel injectors 135 may be configured to inject hydrocarbons into the exhaust stream by injecting into the engine 110 at a time when those hydrocarbons will not combust within the engine 110 .
Some amount of the exhaust gas may be re-circulated to the engine 110 , according to a proportion set by the controller 130 utilizing the EGR valve 154 . In certain embodiments, the EGR cooler 122 , which is operatively connected to the inlet of the intake manifold 114 , cools exhaust gas in order to facilitate increased engine air inlet density. In one embodiment, an EGR bypass 152 diverts some or all of the EGR gas around the EGR cooler 122 , using bypass valves (not shown) to manipulate the temperature and pressure of the gases in the intake manifold 114 .
Various sensors, such as temperature sensors 124 , pressure sensors 126 , flow sensors on any system section (not shown) and the like, may be strategically disposed throughout the engine system 100 and may be in communication with the controller 130 . In some cases a pressure sensor measures a value of a pressure, either gauge or absolute, and in some cases a pressure sensor is measuring a pressure differential between two system locations. In a given embodiment, when a sensor is present, the sensor may be a virtual sensor—a value for the parameter in question that is determined by the controller 130 based upon other measured parameters, and not an input from a direct physical measurement.
FIG. 2 shows one embodiment of a controller 130 to determine an RAP according to the present invention. The controller 130 may comprise an achievement data module 202 , an operating condition module 204 , a starting RAP module 206 , an RAP adjustment module 208 , and a storage module 210 .
In one embodiment, the achievement data module 202 is configured to receive required regeneration conditions 212 and current component conditions 214 . The required regeneration conditions 212 may comprise the conditions required at the exhaust component to achieve a regeneration. In one embodiment, the exhaust component is the particulate filter 150 , and the required regeneration conditions 212 are a minimum temperature after the catalytic component 142 . Any set of parameters which can be measured or estimated, and which would be indicative of successful regeneration of the exhaust aftertreatment component, will suffice as the required regeneration conditions 212 .
The achievement data module 202 is further configured, in one embodiment, to receive the current component conditions 214 . The achievement data module 202 compares the required regeneration conditions 212 with the current component conditions 214 to determine whether a regeneration attempt is successful. In one embodiment, the achievement data module 202 provides a Boolean flag to indicate successful regeneration (e.g. —TRUE) or unsuccessful regeneration (e.g. —FALSE). In a further embodiment, the achievement data module 202 provides the Boolean flag only when the system 100 is in a condition where a regeneration of the exhaust aftertreatment component is being attempted.
The operating condition module 204 is configured, in one embodiment, to receive the current operating condition 216 . The operating condition 216 describes selected operating parameters of the system 100 . The operating parameters selected can vary widely, but typically will be operating parameters that tend to affect the difficulty of the system 100 to achieve regeneration. For example, if the temperature of the ambient environment affects the ability of the system 100 to achieve a regeneration, the operating condition 216 may be the current ambient temperature. The operating condition 216 may be lumped into discrete categories. For example, if the operating condition 216 were current ambient temperature lumped into discrete categories, then the operating condition 216 may be a value “A,” “B,” or “C” where the operating condition 216 is “A” at ambient temperatures greater than 30° C., “C” at ambient temperatures less than 5° C., and “B” at temperatures between “A” and “C.” In one embodiment, the operating condition 216 is a two-dimensional combination of engine speed and engine torque, comprising a value from 1 to 5, where each of 1 to 5 correspond to a range of engine speed and torque values (see FIG. 3 ).
The starting RAP module 206 is configured, in one embodiment, to read a starting RAP 218 . In one embodiment, the starting RAP 218 is a profile that is pre-loaded into the system 100 by a manufacturer or calibrator of the system 100 . The data for pre-loading the starting RAP 218 may be selected from regeneration availability data for the primary market segment of the exhaust gas aftertreatment component, from the highest risk market segment of significant size for the exhaust gas aftertreatment component, or any other desired source. For example, if the highest risk market segment for the exhaust gas aftertreatment component were known to be capable of regenerating 15% of the time requested, the initial factory calibration might be set to pre-load 15% as the starting RAP 218 . In a preferable embodiment, the primary market segment is selected for pre-loading data to maximize fuel economy for a group of exhaust gas aftertreatment components, while the highest risk market segment is selected to minimize the risk of the default control system being initially too aggressive for a high risk application. The starting RAP 218 may be stored on the controller 130 in a memory storage device, or it may reside on some other part of the system 100 and be read into the controller 130 , for example over a datalink.
The starting RAP 218 , in one embodiment, is not stored directly but is derived by the starting RAP module 206 at run-time from other data that is stored directly. For example, the starting RAP 218 , in one embodiment, may comprise a percentage value representing the percentage of time that the system 100 successfully regenerates while attempting a regeneration, like 41%. The system 100 may have the starting RAP 218 stored directly as 41%, and the starting RAP module 206 may be configured to read in that value. The system 100 may have the underlying data stored, for example 4,100 seconds of successful regeneration, and 10,000 seconds of attempted regeneration, and the starting RAP module 206 may be configured to read in the underlying data and translate that information to a starting RAP 218 of 4,100/10,000=41%. In one embodiment, the starting RAP 218 read in by the starting RAP module 206 comprises the adjusted RAP 220 from a previous execution cycle of the controller 130 .
The RAP adjustment module 208 is configured, in one embodiment, to utilize achievement data provided by the achievement data module 202 , the starting RAP 218 , and the current power application operating condition 216 , to generate an adjusted RAP 220 . In one embodiment, the RAP adjustment module 208 generates an adjusted RAP 220 which reflects the aggregate regeneration availability of the system 100 . Advantageously, in another embodiment, the RAP adjustment module 208 generates an adjusted RAP 220 which reflects the regeneration availability of the system 100 at each of a set of potential operating conditions 216 .
As a first example, we show an embodiment where the RAP adjustment module 208 generates and adjusted RAP 220 which reflects the aggregate regeneration availability of the system 100 . In this embodiment, the RAP adjustment module 208 may be configured to track the total time wherein the system 100 attempts a regeneration of the exhaust aftertreatment component, and the total time wherein the system 100 succeeds in meeting the conditions to regenerate the exhaust aftertreatment component. For example, the RAP adjustment module 208 may track the total time (T 1 ) wherein the achievement data module 202 provides a FALSE or TRUE, reflecting the total time where the system 100 is attempting a regeneration, and the RAP adjustment module may track the total time (T 2 ) wherein the achievement data module 202 provides only a TRUE, reflecting the total time where the system 100 succeeds at regenerating the exhaust aftertreatment component. In one embodiment, the adjusted RAP 220 may simply be T 1 /T 2 . For example if T 1 is 4,100 seconds, and T 2 is 10,000 seconds, then the adjusted RAP 220 would be 0.41, or 41%. To clarify the operations of the timers for the example, if the succeeding 30 seconds involve the system 100 successfully attempting a regeneration, T 1 increments to 4,130 while T 2 increments to 10,030, and the adjusted RAP 220 moves to 0.412, or 41.2%.
An enhancement to the first example might be to weight recent information more heavily than older information. Those of skill in the art will recognize many methods to implement the enhancement, but the use of a first-order filter is illustrated as one embodiment. In this example, a maximum value for T 1 and T 2 is selected, preferably on the order of a time value that should be “reflected” by the adjusted RAP 220 . For example, if the adjusted RAP 220 should reflect the last 4 days worth of attempted regeneration availability, the maximum time value should be set to approximately 345,000 seconds. In this example enhancement, T 1 and T 2 should be adjusted according to the following equation:
T new =FC* T old +FC*(MaxVal,0) Equation 1
Where T new is the adjusted value of T 1 or T 2 , T old is the value of T 1 or T 2 from the previous execution. The value (MaxVal,0) is either MaxVal or 0 (zero), where MaxVal is the selected maximum value for T 1 and T 2 . The value MaxVal should be selected in equation 1 for T 1 whenever the system 100 is attempting a regeneration and is successful at achieving the regeneration conditions, while the value 0 should be selected in equation 1 for T 1 at all other times. The value MaxVal should be selected in equation 1 for T 2 whenever the system 100 is attempting a regeneration, and the value 0 should be selected in equation 1 for T 2 whenever the system 100 is not attempting a regeneration. FC is a first order filter constant determined from Equation 2:
F
C
=
ⅇ
(
-
1
Max
Val
)
.
Equation
2
As a second example, we show an embodiment where the RAP adjustment module 208 generates an adjusted RAP 220 which reflects the regeneration availability of the system 100 at each of a set of potential operating conditions 216 . For this example, the RAP adjustment module 208 maintains a set of 5 potential power application operating conditions as shown in FIG. 3 . The 5 potential power application operating conditions are described by ranges of engine speed 304 and engine torque 302 , and bounded by a torque curve 306 associated with the engine 110 .
The adjusted RAP 220 comprises a set of 5 regeneration success values, each regeneration success value comprising a T x1 and a T x2 corresponding to a power application operating condition, where x is the number of the corresponding power application operating condition. In one embodiment, the value T x1 is incremented whenever the system 100 is operating within the operating condition x, the system 100 is attempting a regeneration, and the system 100 is successful in achieving the required regeneration conditions 212 . Likewise, T x2 is incremented whenever the system 100 is operating within the operating condition x and the system 100 is attempting a regeneration, regardless of whether the required regeneration conditions 212 are met.
An enhancement to the second example weights recent information more heavily than older information, and may utilize a first-order filter using equations 1 and 2. In one embodiment, the enhancement applies equations 1 to T x1 every execution step, using MaxVal in equation 1 if the system 100 is operating within the operating condition x, the system 100 is attempting a regeneration, and the required regeneration conditions 212 are met. For example, if the system 100 is operating within operating condition 1 , attempting a regeneration, and the required regeneration conditions 212 are currently met, the RAP adjustment module 208 will apply equation 1 to T 11 , T 21 , T 31 , T 41 , and T 51 , and will use the value 0 in equation 1 for T 21 -T 51 , but use the value MaxVal for T 11 . In the example, if the system 100 is operating within the operating condition x, and the system 100 is attempting a regeneration, the RAP adjustment module 208 applies equation 1 to Tx 2 using MaxVal in equation 1, regardless of whether the required regeneration conditions 212 are met. The RAP adjustment module 208 applies equation 1 to T x1 -T x5 using 0 in equation 1 in all other circumstances, in the example.
One of skill in the art will note, in the example embodiment, that when the system 100 is operating in a condition other than x, the values T x1 and T x2 will both shrink such that the ratio T x1 /T x2 remains constant, indicating that the amount of regeneration success in the operating condition x, but that the absolute size of T x1 and T x2 will shrink. Likewise, if the system 100 operates within the region x, the ratio T x1 /T x2 remains constant if there is no regeneration attempted, the ratio T x1 /T x2 decreases if a regeneration is attempted but unsuccessful, and the ratio T x1 /T x2 increases if a regeneration is attempted, successful, and the value of T x1 is less than MaxVal. One of skill in the art will further note that equations 1 and 2 work together as a rising filter to a selected high value (MaxVal) when equation 1 is used with MaxVal, and equations 1 and 2 work together as a falling filter to a selected low value when equation 1 is used with 0 (or another low value).
The storage module 210 , in one embodiment, stores the adjusted RAP 220 . Storing the adjusted RAP 220 may comprise writing the value into a memory device on the controller 130 , or providing the value to a datalink for use elsewhere in the system 100 . Further, storing the adjusted RAP 220 may comprise storing data used to derive the adjusted RAP 220 .
FIG. 3 illustrates one embodiment of an adjusted RAP 314 in accordance with the present invention. The adjusted RAP 314 of FIG. 3 comprises a set of regeneration availability data segments 316 corresponding to a set of potential operating conditions 318 . One line-item 320 from the adjusted RAP 314 indicates the time in operating condition 1 is 51,840, the time that regenerations have been attempted within operating condition 1 is 12,960, and the time that the required regeneration conditions 212 have been achieved within operating condition 1 is 648.
In one embodiment, the units of the times within the adjusted RAP 314 are in seconds. In one embodiment, the enhanced example shown above using equations 1 and 2 was utilized in generating the adjusted RAP 314 , with a MaxVal of 345,600, and the times 316 reflected within the adjusted RAP 314 reflect approximately the last 345,600 seconds of system 100 operation. In another embodiment, the times reflected within the adjusted RAP 314 reflect total accumulated times, and the values for all of these times 316 will always increase with further system 100 operation.
The adjusted RAP 314 shows a vehicle application label 322 , which is simply the sum of successful regeneration time over the sum of attempted regeneration time, in the given example. The vehicle application label could be a quantity derived from the data available within the adjusted RAP 314 reflecting some other priority—for example utilizing only one of the system 100 operating conditions. In one embodiment, the vehicle application label 322 could be a discrete category label derived from a calculated value. For example, the vehicle application label could use the same ratio shown in the adjusted RAP 314 , but have a category “A” for values 0-0.25, “B” for values 0.25-0.6, and “C” for values 0.6-1.0. Many other implementations are possible from the type of data available for the adjusted RAP 314 , and the specific selection for the vehicle application label depends upon the priorities of the system 100 . The vehicle application label 322 could also be series of values, for example a historical list of values to look for trends over time in the adjusted RAP 314 .
The power application operating condition diagram 300 illustrates one embodiment of a series of potential power application operating conditions 318 . The selected criteria for defining the power application operating conditions are an engine speed axis 304 and an engine torque axis 302 . When the current engine 110 speed and torque fall within the area labeled 3 , the current power application operating condition is 3. For example, if the system 100 is operating at point 308 , with corresponding engine speed 312 (approximately 400 units) and engine torque 310 (approximately 1000 units), then the system 100 is operating within the power application operating condition 4 . The boundary 306 , in one embodiment, is the torque curve for the engine 110 .
FIG. 4 is a schematic flow chart diagram illustrating one embodiment of a method 400 to determine an RAP in accordance with the present invention. The method 400 starts with pre-loading 402 the starting RAP 218 , in one embodiment. The achievement data module 202 may proceed with receiving 404 achievement data relative to successfully achieving regeneration conditions of an exhaust gas aftertreatment component. The achievement data may comprise required regeneration conditions 212 and current component conditions 214 . The starting RAP module 206 may then read 406 the starting RAP 218 , and the operating condition module may determine 408 the current power application operating condition.
The method 400 proceeds, in one embodiment, with generating 410 and adjusted RAP 220 utilizing the achievement data, the starting RAP 218 , and the current power application operating condition. In one embodiment, generating 410 the adjusted RAP 220 comprises selecting the line-item 320 corresponding to the next operating condition 318 , adjusting the line-item 320 values 316 according to the current operating condition 308 , and achievement data. Generating 410 the adjusted RAP 220 may further comprise checking 416 that all operating conditions 318 have been checked, by iterating back to selecting 412 the next line-item 320 until all operating conditions 318 are checked. The method 400 may conclude with the storage module 210 storing 420 the adjusted RAP 220 .
The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope. | An apparatus, system, and method are disclosed for determining a regeneration availability profile for an exhaust gas aftertreatment system. The method, in one embodiment, tracks historical attempts and success to determine the availability of regeneration for the system. In a further embodiment, the method divides the system operation into segments according to desired conditions which affect regeneration, for example the workload of an engine, and tracks separate success ratios for each operating condition. This allows prediction of success of a given regeneration based upon the current operating condition, as well as diagnostics of regeneration problems where an operating condition experiences trouble regenerating when historically it should not. | 5 |
BACKGROUND OF THE INVENTION
The present invention relates to a system for creating a fault diagnosis on production machines using a knowledge-based evaluation of signals representing the quality of the products produced, having a knowledge base containing the expert knowledge required for the evaluation, having software units intended for access to the said base, and having a user interface.
Systems of this type, which are referred to as expert systems, have been known for some time, in particular for the fault and defect diagnosis of electronic components; see in this respect, for example, the article "An Expert System for Help to Fault Diagnoses on VLSI Memories" by T. Viacroze et al in the Journal for the International Symposium for Testing and Failure Analysis (ISTFA), October/November 1988, Los Angeles, pp. 153-158. The system described in this article first of all analyses the data of the tester and then derives from the knowledge of the knowledge base the appropriate rules for the causes of the defects. Then, at a second stage, a further analysis takes place in dialog with the operator and, finally, a defect diagnosis takes place, which provides forward and backward adjustment.
Systems which are to be used efficiently for diagnosis in the case of complexly constructed machines must be capable of describing at least several hundred individual parts and their arrangement in subassemblies or subsystems, as well as of applying typically up to 100 or 200 rules. In addition, a good integration into a conventional and extensive program environment, which carries out the storage and preprocessing of the signals mentioned, must be ensured. In practice, moreover, a response time in the range of seconds, where possible even less, is expected. At present, such requirements can be met only by large systems, the use of which is out of the question for the typical user, for reasons of cost.
The invention has the object of designing a system of the type mentioned at the beginning in such a way that a rapid and reliable fault diagnosis is possible with an inexpensive computer. This requirement is significantly more important in the case of production machines than in the case of test systems for electronic circuits, since in the case of these machines every defect generally results in defective or deficient products and therefore has to be rectified in the shortest possible time.
SUMMARY OF THE INVENTION
The object set is achieved according to the invention by the knowledge base having a description of the machine parts belonging to the production machine concerned, by means of a component hierarchy which is divided in the form of a tree structure and in which each object is described by a node in the tree structure and can be addressed by a path name assigned to the respective node, and in which each dependent node is dependent on precisely one superordinate node.
By this special structuring of the knowledge base, success has been achieved in meeting the requirements mentioned with an inexpensive computer, for example a personal computer.
The invention further relates to an application of the said system on textile machines for the production of fibre or filament structures.
Applications of expert systems for textile machines are still virtually unknown today. This is so since the systems referred to in the literature as expert systems are typically not knowledge-based, but achieve process control or process optimisation by conventional methods. For example, a method is described in U.S. Pat. No. 4,916,625 for optimising the operation of a spinning machine using a knowledge base, in which however, it is in fact indicated only to the operating personnel when a full bobbin has to be removed from the machine. Although the knowledge base draws certain conclusions from the signals of sensors as to the time of the occurrence of certain events, it cannot create any fault diagnoses or make any statements as to the cause in the event of faults. As a distinction from this, the application according to the invention of the system on textile machines is intended to make an exact fault diagnosis possible.
This object is achieved according to the invention by signals representing the quality of the products produced being formed by spectograms obtained in the investigation of parameters of the fibre or filament structures, by a first evaluation unit being provided for the detection of characteristic deviations of the spectograms, which unit generates a so-called fault descriptor for each such deviation, and by a second evaluation unit being provided, which determines possible fault causes for each fault descriptor using the knowledge base.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is explained in more detail below with reference to an exemplary embodiment and the drawings, in which:
FIG. 1 shows a diagrammatic representation of the overall concept of an expert system according to the invention,
FIG. 2 shows a diagrammatic representation of the description of the machine structure in the knowledge base of the expert system of FIG. 1,
FIG. 3 shows a diagrammatic representation of the sequence of the diagnoses,
FIGS. 4, 5 show an example of the dialog with the system via a user interface, and
FIGS. 6-8 show a representation of a practical example.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows a possible representation of the overall concept of an expert system according to the invention, in which the knowledge base WB takes central importance. The knowledge base WB contains the necessary expert knowledge, that is for example textiles knowledge, in the form of rules and structural descriptions of the corresponding production machines (textile machines) together with the parameters necessary for the evaluation, such as for example drafts, diameters of rollers and cylinders, and the like. Also included in the knowledge base WB are references to graphics and texts, which can appear on a screen in a consultation.
A series of software units which are intended for various functions can access the knowledge base WB. For all applications, the same general knowledge editor KM is available, with which the knowledge base WB can be set up and maintained, the access to the knowledge base being unrestricted for this editor in any event. For specific applications, more simple editing modules EM may be made available, in which however the access to the knowledge base WB is subjected to greater restrictions to preserve consistency.
The information items included in the knowledge base WB are utilized by a "Production System" PS, which offers the user a consultation and includes in particular a user interface BS, having a screen. According to the representation, three classes of production systems are provided, namely control-application systems PS-H for simple control processing, diagnosis systems PS-D and systems PS-X for specific applications. These three classes differ in particular in the type of processing of the content of the knowledge base, such as for example in the search strategy or in the control processing.
FIG. 2 shows the structuring of the knowledge base WB, which creates a list with diagnosis proposals for each deviation, indicating a fault, of the monitored signal. Since, in practice, a great number of possible fault causes have to do with defective machine parts, the system requires as accurate a description as possible of the construction of the respective textile machine. In particular, it must be known of which part-systems, such as card, drafting frame etc, the production line is made up. These part-systems can for their part be subdivided into subsystems, etc., until finally one arrives at defect-causing components (for example cylinders, aprons).
In the case of the expert system according to the invention, each object is described by a node in a tree structure, each node, with the exception of the root node, being dependent on precisely one superordinate node. This dependence is usually to be interpreted as a "part of" or as an "is a" relation. The addressing of individual nodes takes place with a path name, which begins with the name of the node and, for precise identification, may also comprise the names of hierarchically higher nodes. These path names prove to be very useful in particular if there is a plurality of nodes of the same name in the system, because then reference can be made both to all objects of the same name and also only to a specific object.
For example, the address "drafting system" denotes each and every drafting system, the address "drafting system flyer" denotes each drafting system on a flyer, and the address "drafting system --"RS"-- "M3" denotes the drafting system of the specific ring spinning machine M3. This name convention implicitly also comprises the principle of inheritance. This means that, although on the one hand each node can be uniquely identified by its position in the tree structure, on the other hand it also inherits all the references or values which relate to a general object which is not uniquely addressable due to a shortened path name and is therefore fictitious (for example "drafting system").
As can be seen from the nodes "upper roller", "middle cylinder", "upper apron" and "lower apron" in FIG. 2, subordinate to the node "middle part", each node can be assigned data or values (for example dimensions such as diameter or length, circumferential speeds, states and the like). In the case of nodes having the same value which occur more than once, use is made of the shortened path name, in order to have to enter the data only once.
With the nodes themselves, only individual objects can ever be described. In addition, however, relations between, in each case, two nodes can also be provided with a name, which is symbolised in FIG. 2 by the thickly drawn-in arrows. With the relations, to which likewise any number of values can be assigned, it is possible to denote, for example, the power transmission in a gear unit or the draft of a fibre structure between two clamping points. An example of what can be stored as knowledge is that the fibre material runs from the rear cylinders to the front cylinders and that in this case a draft of 1.3 occurs.
Finally, also used as further units of knowledge are rules, which comprise a number (or a name) uniquely identifying the rule, a series of conditions and a single consequence. One rule, and consequently also its consequence, is considered satisfied if all the conditions are met. The consequence and each individual condition form the basic elements of a rule. These basic elements may be any texts ("the yarn twist is too low"), negated expressions or expressions with a location specification. Both in the case of conditions and in the consequence part, reference can be made to nodes or relations between nodes. This possibility of being able to make reference in the rule directly to nodes is very useful specifically for the search strategy in the case of diagnostic problems or in the case of operating instructions.
The expert system may be realised with the assistance of any programming language. By virtue of its outstanding suitability for the evaluation of the knowledge base WB, however, the programming language Prolog is preferably used (W. F. Clocksin & C. S. Mellish "Programming in Prolog", Springer Verlag 1981).
FIG. 3 shows in a different type of representation than FIG. 1 the construction of an expert system for creating a fault diagnosis on textile machines and gives an overview of the sequence of diagnosis, this system receiving from a tester or from an on-line data system quality data, in particular evenness data, of a textile intermediate or final product, detecting significant deviations from predetermined set values or set curves and determining the technical causes of these deviations.
According to the representation, the expert system comprises the three modules data storage/data administration DV, numerical evaluation unit NA and knowledge-based evaluation unit WA.
The data storage/data administration module DV serves for permanent storage of the received test data, it being possible for the stored data to be made available at any time for an evaluation. For the storage and administration of the test data, any conventional database system may be used, assuming it has the following in terms of functionality:
Acceptance of the data from the tester or on-line system.
Storage of the test data on a long-term storage medium (for example hard disk),
Provision of a user interface, which enables the user to retrieve the stored data.
Copying of the data selected by the user into the system memory (RAM) of the computer, from where said data can be read by the downstream evaluation units.
Provision of the measured values; according to the representation, these are the points of a spectrogram, for example an evenness spectrogram, a hairiness spectrogramor a twist spectrogram (on the spectrogram subject, see for example the publication by R. Furter "Evenness Testing in Yarn Production: Part I", The Textile Institute 1982 and the article "Neue Wege zur Messung der Haarigkeit yon Garnen" (New Ways of Measuring the Hairiness of Yarns) by R. Furter, P. Ha/ ttenschwiler and H. Wampfler in MELLIAND TEXTILBERICHTE 69 (1988), 617-619).
Provision of additional information items on the sample, such as for example yarn count, yarn twist, roving yarn number, file name of the knowledge base and the like.
The numerical evaluation unit compares the spectrogram continuously with a predetermined limit value, in order to detect so-called "stacks", which are caused by periodic fluctuations, protrude beyond the normal curve and occur at the period length (wavelength). Due to this stack, the so-called coefficient of variation (CV %) also increases, that is the square unevenness, which may mean a disturbing loss in quality of the spun yarn concerned. This CV increase is given by the formula: ##EQU1## In this formula, S i denotes the amplitude of the measured spectrogram at channel i, S i , R denotes the amplitude of the reference spectrogram at channel i, a, b denotes the channel numbers for the beginning and end of the stack and K is a sensor-specific proportionality factor.
For detection of a disturbing stack, the numerical evaluation unit NA compares the value of the increase in coefficient of variation with a predetermined limit value. If the latter is exceeded, a fault descriptor SD is generated, which contains the following information items on the stack:
Spectrogram identification
Wavelength range in millimeters
CV increase in %
Number of channels over which the stack extends.
If the Prolog programming language is being used, this fault descriptor is stored by means of "assert" in the database (that is the main memory of the Prolog system) as the so-called "Prolog fact" (that is a Prolog structure existing in the database).
The knowledge-based evaluation unit WA creates for this fault descriptor a list with diagnosis proposals. Since, as already mentioned in the case of FIG. 2, in practice a great number of possible fault causes have to do with defective machine parts, the system includes as accurate a description as possible of the construction of the textile machines. These information items form together with the "IF-THEN" rules, which verify or disprove a diagnosis suspicion, the knowledge base WB described with reference to FIG. 2. in practice, the said knowledge base takes the form of an ASCII file, in which the units of knowledge described with reference to FIG. 2 (nodes, values, relations between nodes, rules) are contained as Prolog facts. The knowledge base WB is read into the database by a suitable instruction.
For preparation of the knowledge base WB, the file name of the knowledge base WB is taken from a memory area made available by the data storage/data administration DV and is read into the database. Then, the part-drafts on the machine which were not yet known at the time of creation of the knowledge base WB are calculated. An example which may be given here is that of the drafts on the ring spinning machine, which vary greatly in practice, and in this case the preliminary draft being fixed in the knowledge base WB and the overall draft being obtained from the count of the roving yarn divided by the yarn count.
Subsequently, for each machine component which can induce a periodic fluctuation in mass or hairiness or possibly twist in the fibre structure, the corresponding wavelength of this fluctuation is calculated, to be precise as a product of the wavelength at the location of the component and all drafts between the location of the component and the removal point of the sample. The wavelengths thus calculated are then entered by the knowledge-based evaluation unit WA as Prolog fact in the database.
If there is then at the same time in the database a Prolog fact "calculated wavelength" and a Prolog fact "fault descriptor", the value of the calculated wavelength lying in the wavelength range of the fault descriptor, a Prolog fact "theoretical cause" is entered into the database, whereby the theoretical cause of a fault is hence determined.
The next step is the determination of the plausible causes, a (theoretical) fault cause being referred to as plausible whenever it is substantiated by a rule. For this purpose, for each "theoretical cause" Prolog fact, the knowledge-based evaluation unit WA searches in the database for a Prolog fact representing a rule having an expression affirming or negating a fault cause at the machine part concerned. In both cases, first of all the list of conditions included in the respective rule is processed. The locating of an affirming rule substantiates a machine component as responsible for the cause, the locating of a rule with a negating expression excludes the respective component as responsible for the cause, so that, after verification of the rule, the corresponding "theoretical cause" Prolog fact is erased.
It was mentioned in .the description of FIG. 1 that the expert system has a production system PS, which offers the user a consultation and includes in particular a user interface BS having a screen. The user interface BS, which is standard for all production systems, primarily takes the form of a "dialog" screen, which according to FIG. 4 has four areas or windows:
In the so-called "Info" window IF, items of explanatory information are displayed, which should assist the user in answering questions posed by the system. These information items may be short explanatory texts or graphics or both. In FIG. 4, the "Info" window contains a graphic with a hairiness diagram.
In the "Dialog" window DF, there appear on the one hand the questions to the operator and on the other hand his answers to the system.
The "Menu" window MF serves to facilitate input, by the user being able to perform this input via a menu. Only if the system does not present a menu for answering a question must the answer be input in the "Dialog" window.
In the "Answer" window AF, the course of the dialog is displayed. If it is wished to correct an answer given earlier, said answer can be selected in the "Answer" window AF and the dialog is recommenced from this point, all previous answers being preset as standard answers in the windows DF or MF and can be re-input by pressing a button.
The screen content represented in FIG. 4 shows a step of a dialog in a control application system PS-H (FIG. 1) which provides assistance in the interpretation of the reports supplied by a yarn testing system USTER TESTER 3 (USTER--registered trademark of Zellweger Uster AG).
Starting point: An unskilled laboratory assistant receives a hairiness diagram in which abrupt changes in average value are plotted, and uses the expert system as an interpretation aid, proceeding with the dialog specified below. In each step of the dialog, the content of the windows of the dialog screen is specified; the term of the menu underlined in each case in the indication of the menu window denotes the input by the laboratory assistant.
First step
IF: USTER EXPERT provides you with assistance in interpretation of reports from USTER TESTER 3.
DF: Which report is to be interpreted?
MF: Diagram, variation in length, spectrogram, listing
Second step
IF: With the USTER TESTER you can test fluctuations in mass, hairiness or twist.
DF: Which yarn properties are to be interpreted?
MF: Hairiness, mass, twist
AF: Which report is to be interpreted?
Diagram
Third step
IF: Here there are two possibilities
EXPERT helps you in creating the diagnosis for a specific yarn defect.
Explanation of the principles of hairiness and fluctuations in hairiness
DF: Which information do you require?
MF: Interpretation of a specific defect
General tips on the measuring principle
AF: Which report is to be interpreted?
Diagram
Which yarn property is to be interpreted?
Hairiness
Fourth step, see FIG. 4
(This step can also take place automatically by the system automatically detecting the abrupt change in average value, so that no question has to be posed to the user.)
Fifth step
IF: None
DF: Test piece
MF: Package, cross-wound bobbin, roving yarn, twisted yarn
AF: Which report is to be interpreted?
Diagram
Which yarn property is to be interpreted?
Hairiness
Which information do you require?
Interpretation of a specific defect
Does your diagram show such abrupt changes in average value?
Yes
Sixth step
IF: No indication
DF: Spinning system?
MF: Ring combed, ring carded, rotor combed, rotor carded, combed yarn
AF: Which yarn property is to be interpreted?
Hairiness
Which information do you require?
Interpretation of a specific defect
Does your diagram show abrupt such changes in average value?
Yes
Test piece?
Cross-wound bobbin
Seventh step
IF: Indication of a curve with abrupt changes in average value and of a line which indicates the package lengths
DF: At what intervals do the abrupt changes in average value take place?
MF: As in the graphic for the package lengths at shorter intervals
AF: Which information do you require?
Interpretation of a specific defect
Does your diagram show such abrupt changes in average value?
Yes
Test piece?
Cross-wound bobbin
Spinning system
Ring carded
Eighth and final step, see FIG. 5.
For better representation of the statement or diagnoses, extensive text files and/or graphics are available, which are not tied to the format of the "Info" window. The actual sequence of a dialog together with the associated displays is fixed on the one hand by the rules entered beforehand with the knowledge editor KM (FIG. 1), and on the other hand by the data and answers to the questions of the system.
As can be seen without difficulty from the dialog reproduced, the production system PS-H primarily specialises in the application of rules and therefore can, for example, fulfill a type of manual function, the content of the manual having to be structured for the construction of the knowledge base WB hierarchically in the form of a decision tree. For example, the manual can be divided into chapters, sub-chapters, etc and it can be decided by selective questions into which sub-path the operator is guided. The rules and the answers of the operator thus fix the course of a consultation. The rules also state in addition which information items the user receives.
The production system PS-D is a diagnosis system in which the search strategy is fixed primarily by the hierarchical structure of the object to be investigated, then possibly by functional relationships between subsystems and only finally by rules.
If, for example, a ring spinning machine is structured into run-in part, middle part, run-out part etc., the diagnosis system first of all attempts to localise a fault to one of these subassemblies, it also being possible to take into consideration functional relationships between these subassemblies (for example the influence of a defective component in the run-out part on the middle part). Subsequently, the system then searches one stage lower, by looking at the subdivision into lower cylinder, upper roller, etc. (see in this respect FIG. 2).
In the case of the production system PS-X, the knowledge-based part essentially comprises a PS-H or a PS-D system and is integrated in a conventional environment. Before the application of rules and/or the creation of diagnoses, a problem-specific module can be used to combine information items from the knowledge base with current data and consequently generate new facts relevant for the rules. Diagnosis and instructions (for example repair instructions) are supported as extensively as possible by graphics. For example, gear unit plans are displayed and there is the possibility of marking an individual object (for example a gear wheel) by an arrow and/or emphasising it in colour, possibly including its designation.
For the experienced user, there is the possibility of explicitly confirming, modifying or rejecting results of a diagnosis. If, for example, a periodic fault has been found and is displayed together with the diagnosis of the presumed cause of the defect, the user can then
substantiate a proposed diagnosis,
reject a proposed diagnosis,
specify a new cause (not proposed by the system) for the period, or
mark the period as uncritical.
The information items input in this way by the user influence the expert knowledge stored in the knowledge base and are included in considerations in future evaluations. As a result, the system becomes a learnable expert system.
The dialog may also proceed by the system asking the user when it specifies a diagnosis proposal whether he can accept the proposal and stipulate to him the following menu for the answer:
I don't know
Yes, certainly
Yes, but only if . . .
No
No, if . . .
A further possibility for learnability is obtained by the system registering the frequency of the answers from a certain menu and, using the frequencies to perform a weighting and/or stringing of the possible answers, making the menus clearer and easier to use.
A practical example of the diagnosis of evenness spectrograms obtained by an USTER TESTER 3 is represented in FIGS. 6 to 8: FIG. 6 shows the spectrograms of 10 different samples represented on one image (see in this respect EP-A-249 741). It can be seen that samples 3, 7 and 9 have a periodic defect (first defect) at a wavelength of 271 mm and samples 5 and 10 have such a defect (second defect) at 1.89 m.
FIG. 7 shows the spectrogram diagnosis with the two defects, the number of respective defective channels (in the case of the first defect there are three channels and in the case of the second defect there is one channel), with the CV % increase, the proportion of defective samples in % and with the number of the defective samples. For the first defect, "flyer vibrations" is determined as the cause of the defect on the basis of an USTER EXPERT rule (No. 6) and two possible causes are specified for the second defect:
Preliminary draft change gear unit middle-lower cylinder
Middle part ring spinning machine: gt
Middle-lower cylinder middle part ring spinning machine: d
(The letter d in the case of the second cause stands for "diameter" and gt in the case of the first cause stands for "gear unit").
To be able to decide which of the two causes applies, the system subsequently poses the question whether the defect occurs in the case of more than one sample. If the answer is yes (yes there are two defective samples), the system decides on the second cause. This is because a defect in the preliminary draft change must affect more than one sample, on the other hand a defect in the middle-lower cylinder does not have to.
To illustrate this better, USTER EXPERT then additionally shows as an aid the machine plan, of which sections are shown in FIG. 8 and in which the defective point is denoted clearly visibly: in a small box marked in colour there appears (vw) for a preliminary draft change in the gear unit of the ring spinning machine.
Since the example represented in FIGS. 6 to 8 is a case from practice, it was possible to verify the diagnosis of the system. Checking back with the person in charge of ring spinning revealed that the preliminary draft change had been moved out to the machine in question for servicing purposes and subsequently not reset again in the regulation way.
As has been shown, the system determines the stacks in the spectrogram automatically, thus does not require any indications from the operator that a defect exists. However, when the system has built up adequate expert knowledge, the degree of automation can be further increased by allowing the dialog to proceed automatically, which does not present any difficulties in as much as the system does have most of the items of information itself. For instance, the system knows itself in the case just described that the defect occurs in the case of more than one sample. This automation has proved to be particularly advantageous in operational practice. | The creation of fault diagnosis takes place using a knowledge-based evaluation of signals which signal the quality of the products produced, for example using spectrograms obtained in the investigation of parameters of textile fiber or filament structures. A first evaluation unit (NA) is provided for the detection of characteristic deviations of the spectrograms, which unit generates a so-called fault descriptor (SD) for each such deviation. A second evaluation unit (WA) uses a knowledge base (WB) to determine possible fault causes for each fault descriptor. | 3 |
CROSS-REFERENCES TO RELATED APPLICATIONS
This application is a divisional of U.S. application Ser. No. 09/856,850, filed Sep. 19, 2001 now U.S. Pat. No. 7,030,220; which is the National Stage of PCT/EP00/09423, filed Sep. 27, 2000, now International Patent WO 01/23583 A2, which claims priority to EP Application No. 99119268.3, filed Sep. 28, 1999, each of these applications are incorporated by reference.
STATEMENT AS TO RIGHTS TO INVENTIONS MADE UNDER FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not Applicable
REFERENCE TO A “SEQUENCE LISTING,” A TABLE, OR A COMPUTER PROGRAM LISTING APPENDIX SUBMITTED ON A COMPACT DISK
Not Applicable
BACKGROUND OF THE INVENTION
The present invention is related to the field of molecular biology, and more particular, to polynucleotide synthesis. The present invention also relates to a substantially pure thermostable exonuclease, the cloning and expression of a thermostable exonuclease III in E. coli , and its use in amplification reactions. The invention facilitates the high fidelity amplification of DNA under conditions which allow decontamination from carry over and the synthesis of long products. The invention may be used for a variety of industrial, medical and forensic purposes.
In vitro nucleic acid synthesis is routinely performed with DNA polymerases with or without additional polypeptides. DNA polymerases are a family of enzymes involved in DNA replication and repair. Extensive research has been conducted on the isolation of DNA polymerases from mesophilic microorganisms such as E. coli . See, for example, Bessman et al. (1957) J. Biol. Chem. 223:171-177, and Buttin and Komberg, (1966) J. Biol. Chem. 241:5419-5427.
Research has also been conducted on the isolation and purification of DNA polymerases from thermophiles, such as Thermus aquaticus . Chien, A. et al., (1976) J. Bacteriol. 127:1550-1557 discloses the isolation and purification of a DNA polymerase with a temperature optimum of 80° C. from Thermus aquaticus YT1 strain. U.S. Pat. No. 4,889,818 discloses a purified thermostable DNA polymerase from T. aquaticus , Taq polymerase, having a molecular weight of about 86,000 to 90,000 daltons. In addition, European Patent Application 0 258 017 discloses Taq polymerase as the preferred enzyme for use in the PCR process.
Research has indicated that while Taq DNA polymerase has a 5′-3′ polymerase-dependent exonuclease function, Taq DNA polymerase does not possess a 3′-5′ exonuclease III function (Lawyer, F. C. et al., (1989) J. Biol. Chem., 264:6427-6437; Bemad A., et al. (1989) Cell 59:219). The 3′-5′ exonuclease activity of DNA polymerases is commonly referred to as “proofreading activity”. The 3′-5′ exonuclease activity removes bases which are mismatched at the 3′ end of a primer-template duplex. The presence of 3′-5′ exonuclease activity may be advantageous as it leads to an increase in fidelity of replication of nucleic acid strands and to the elongation of prematurely terminated products. As Taq DNA polymerase is not able to remove mismatched primer ends it is prone to base incorporation errors, making its use in certain applications undesirable. For example, attempting to clone an amplified gene is problematic since any one copy of the gene may contain an error due to a random misincorporation event. Depending on the cycle in which that error occurs (e.g., in an early replication cycle), the entire DNA amplified could contain the erroneously incorporated base, thus, giving rise to a mutated gene product.
There are several thermostable DNA polymerases known in the art which exhibit 3′-5′ exonuclease activity, like B-type polymerases from thermophilic Archaebacteria which are used for high fidelity DNA amplification. Thermostable polymerases exhibiting 3′-5′ exonuclease activity may be isolated or cloned from Pyrococcus (Purified thermostable Pyrococcus furiosus DNA polymerase, Mathur E., Stratagene, WO 92/09689, U.S. Pat. No. 5,545,552; Purified thermostable DNA polymerase from Pyrococcus species, Comb D. G. et al., New England Biolabs, Inc., EP 0 547 359; Organization and nucleotide sequence of the DNA polymerase gene from the archaeon Pyrococcus furiosus , Uemori T. et al. (1993) Nucl. Acids Res., 21:259-265.), from Pyrodictium spec. (Thermostable nucleic acid polymerase, Gelfand D. H., F. Hoffmann-La Roche AG, EP 0 624 641; Purified thermostable nucleic acid polymerase and DNA coding sequences from Pyrodictium species, Gelfand D. H., Hoffmann-La Roche Inc., U.S. Pat. No. 5,491,086), from Thermococcus (e.g. Thermostable DNA polymerase from Thermococcus spec. TY, Niehaus F., et al. WO 97/35988; Purified Thermocccus barossii DNA polymerase, Luhm R. A., Pharmacia Biotech, Inc., WO 96/22389; DNA polymerase from Thermococcus barossii with intermediate exonuclease activity and better long term stability at high temperature, useful for DNA sequencing, PCR etc., Dhennezel O. B., Pharmacia Biotech Inc., WO 96/22389; A purified thermostable DNA polymerase from Thermococcus litoralis for use in DNA manipulations, Comb D. G., New England Biolabs, Inc., U.S. Pat. No. 5,322,785, EP 0 455 430; Recombinant thermostable DNA polymerase from Archaebacteria, Comb D. G., New England Biolabs, Inc., U.S. Pat. No. 5,352,778, EP 0 547 920, EP 0 701 000; New isolated thermostable DNA polymerase obtained from Thermococcus gorgonarius , Angerer B. et al. Boehringer Mannheim GmbH, WO 98/14590.
Another possibility of conferring PCR in the presence of a proofreading function is the use of a mixture of polymerase enzymes, one polymerase exhibiting such a proofreading activity. (e.g. Thermostable DNA polymerase with enhanced thermostability and enhanced length and efficiency of primer extension, Barnes W. M., U.S. Pat. No. 5,436,149, EP 0 693 078; Novel polymerase compositions and uses thereof, Sorge J. A., Stratagene, WO 95/16028). It is common practice to use a formulation of a thermostable DNA polymerase comprising a majority component of at least one thermostable DNA polymerase which lacks 3′-5′ exonuclease activity and a minority component exhibiting 3′-5′ exonuclease activity e.g. Taq polymerase and Pfu DNA polymerase. In these mixtures the processivity is conferred by the pol I-type enzyme like Taq polymerase, the proofreading function by the thermostable B-type polymerase like Pfu. High fidelity DNA synthesis is one desirable parameter in nucleic acid amplification, another important feature is the possibility of decontamination.
The polymerase chain reaction can amplify a single molecule over a billionfold. Thus, even minuscule amounts of a contaminant can be amplified and lead to a false positive result. Such contaminants are often poducts from previous PCR amplifications (carry-over contamination). Therefore, researchers have developed methods to avoid such a contamination.
The procedure relies on substituting dUTP for TTP during PCR amplification to produce uracil-containing DNA (U-DNA). Treating subsequent PCR reaction mixtures with Uracil-DNA-Glycosylase (UNG) prior to PCR amplification the contaminating nucleic acid is degraded and not suitable for amplification. dUTP can be readily incorporated by poll-type thermostable polymerases but not B-type polymerases (G. Slupphaug, et al. (1993) Anal. Biochem. 211:164-169) Low incorporation of dUTP by B-type polymerases limits their use in laboratories where the same type of template is repeatedly analyzed by PCR amplification.
Thermostable DNA polymerases exhibiting 3′-5′ exonuclease activity were also isolated from eubacterial strains like Thermotoga (Thermophilic DNA polymerases from Thermotoga neapolitana , Slater M. R. et al. Promega Corporation, WO 96/41014; Cloned DNA polymerases from Thermotoga neapolitana and mutants thereof, Hughes A. J. et al., Life Technologies, Inc. WO 96/10640; Purified thermostable nucleic acid polymerase enzyme from Termotoga maritima , Gelfand D. H. et al., CETUS Corporation, WO 92/03556) These enzymes have a strong 3′-5′ exonuclease activity which is able to eliminate misincorporated or mismatched bases. A genetically engineered version of this enzyme is commercially available as ULTma, a DNA polymerase which can be used without additional polypeptides for the PCR process. This enzyme is able to remove misincorporated bases, incorporate dUTP, but the fidelity is for unknown reasons not higher than that of Taq polymerase (Accuracy of replication in the polymerase chain reaction. Diaz R. S. et al. Braz. J. Med. Biol. Res . (1998) 31: 1239-1242; PCR fidelity of Pfu DNA polymerase and other thermostable DNA polymerases, Cline J. et al., Nucleic Acids Res . (1996) 24:3546-3551).
For high fidelity DNA synthesis another alternative to the use of B-type polymerases or mixtures containing them is the use of thermophilic DNA polymerase III holoenzyme, a complex of 18 polypeptide chains. These complexes are identical to the bacterial chromosomal replicases, comprising all the factors necessary to synthesize a DNA strand of several hundred kilobases or whole chromosomes. The 10 different subunits of this enzyme, some of which are present in multiple copies, can be produced by recombinant techniques, reconstituted and used for in vitro DNA synthesis. As a possible use of these complexes PCR amplification of nucleic acis of several thousand to hundreds of thousand base pairs is proposed. (Enzyme derived from thermophilic organisms that functions as a chromosomal replicase, and preparation and uses thereof, Yurieva O. et al., The Rockefeller University, WO 98/45452; Novel thermophilic polymerase III holoenzyme, McHenry C., ENZYCO Inc., WO 99/13060)
It was aimed according to this invention to develop a high fidelity PCR system which is preferably concomitantly able to incorporate dUTP. According to the present invention a thermostable enzyme exhibiting 3′-exonuclease-activity but essentially no DNA polymerase activity is provided whereas this enzyme enhances fidelity of an amplification process when added to a second enzyme exhibiting polymerase activity. The enzyme provided can excise mismatched primer ends to allow the second enzyme exhibiting polymerase activity as e.g. Taq polymerase to reassociate and to reassume elongation during a process of synthezising DNA. The inventive enzyme is able to cooperate as proofreading enzyme with a second enzyme exhibiting polymerase activity. The enzyme that was found to be suitable for this task is e.g. a thermostable exonuclease III. Preferred is an exonuclease III working from the 3′ to 5′ direction, cleaving 5′ of the phosphate leaving 3′ hydroxyl groups and ideally working on double stranded DNA only. The 3′-5′ exonuclease functions of DNA polymerases are active on double and single stranded DNA. The latter activity may lead to primer degradation, which is undesired in PCR assays. It is preferred that the enzyme is active at 70° C. to 80° C., stable enough to survive the denaturation cycles and inactive at lower temperatures to leave the PCR products undegraded after completion of the PCR process. Enzymes exhibiting these features can be derived from thermophilic eubacteria or related enzymes from thermophilic archaea. Genomes of three thermostable archaebacteria are sequenced, Methanococcus jannaschii (Complete Genome Sequence of the Methanogenic Archaeon, Methanococcus jannaschii , Bult C. J. et al., (1996) Science 273: 1058-1072), Methanobacterium thermoautotrophicum (Complete genomic sequence of Methanobacterium thermoautotrophicum ΔH: Functional Analysis and Comparative Genomics, Smith D. R. et al., J of Bacteriology (1997) 179: 7135-7155) and Archaeoglobus fulgidus (The complete genome sequence of the hyperthermophilic, sulfate-reducing archaeon Archaeoglobus fulgidus , Klenk H.-P. et al. (1997) Nature 390: 364-370).
In particular, there is provided a thermostable enzyme obtainable from Archaeoglobus fulgidus , which catalyzes the degradation of mismatched ends of primers or polynucleotides in the 3′ to 5′ direction in double stranded DNA. The gene encoding the thermostable exonuclease III obtainable from Archaeoglobus fulgidus (Afu) was cloned, expressed in E. coli and isolated. The enzyme is active under the incubation and temperature conditions used in PCR reactions. The enzyme supports DNA polymerases like Taq in performing DNA synthesis at low error rates and synthesis of products of more than 3 kb on genomic DNA—the upper range of products synthesized by Taq polymerase—in good yields with or without dUTP present in the reaction mixture. Preferably, 50-500 ng of the exonuclease III obtainable from Afu were used per 2,5 U of Taq polymerase in order to have an optimal PCR performance. More preferably is the use of 67 ng to 380 ng of the exonuclease III obtainable from Afu per 2,5 U of the Taq polymerase in the PCR reaction.
DNA sequence (SEQ ID NO: 20) and the deduced amino acid sequence (SEQ ID NO: 21) of the gene encoding the DNA polymerase from exonuclease III Archaeoglobus fulgidis.
Further, subject of the present invention is a composition comprising a first thermostable enzyme exhibiting 3′-exonuclease-activity but essentially no DNA polymerase activity and a second enzyme exhibiting polymerase activity whereas the fidelity of an amplification process is enhanced by the use of this composition in comparison to the use of the second enzyme alone. The inventive thermostable enzyme exhibiting 3′-exonuclease-activity but essentially no DNA polymerase activity also includes appropriate enzymes exhibiting reduced DNA polymerase activity or no such activity at all. Reduced DNA polymerase activity according to the invention means less than 50% of said activity of an enzyme exhibiting DNA polymerase activity. In a preferred embodiment the second enzyme of the inventive composition is lacking proofreading activity. In particular preferred, the second enzyme is Taq polymerase.
A further subject of the present invention is a method of DNA synthesis using a mixture comprising a first thermostable enzyme exhibiting 3′-exonuclease-activity but essentially no DNA polymerase activity and a second enzyme exhibiting polymerase activity. According to this method prematurely terminated chains are trimmed by degradation from 3′ to 5′. Mismatched ends of either a primer or the growing strand are removed according to this method.
The invention further comprises a method according to the above description whereas dUTP is present in the reaction mixture, replacing partly or completely TTP. It is preferred that according to this method uracil DNA glycosylase (UDG or UNG) is used for degradation of contaminating nucleic acids.
Preferably according to this method the mixture of a
first thermostable enzyme exhibiting 3′-exonuclease-activity but essentially no DNA polymerase activity and a second enzyme exhibiting polymerase activity produces PCR products with lower error rates compared to PCR products produced by the second enzyme exhibiting polymerase activity in absence of the first thermostable enzyme exhibiting 3′-exonuclease-activity but essentially no DNA polymerase activity. The method in which the mixture of first thermostable enzyme exhibiting 3′-exonuclease-activity but essentially no DNA polymerase activity and a second enzyme exhibiting polymerase activity produces PCR products of greater length compared to PCR products produced by the second enzyme exhibiting polymerase activity in absence of the first thermostable enzyme exhibiting 3′-exonuclease-activity but essentially no DNA polymerase activity. Further, the first thermostable enzyme exhibiting 3′-exonuclease-activity but essentially no DNA polymerase activity is related to the Exonuclease III of E. coli , but thermostable according to this method. A further embodiment of the above described method is the method whereas PCR products with blunt ends are obtained.
Subject of the present invention are also methods for obtaining the inventive thermostable enzyme exhibiting 3′ exonuclease-activity but essentially no DNA polymerase activity and means and materials for producing this enzyme as e.g. vectors and host cells (e.g. DSM no. 13021).
The following examples are offered for the purpose of illustrating, not limiting, the subject invention.
BRIEF SUMMARY OF THE INVENTION
Brief Description of the Drawings
FIG. 1 : DNA sequence SEQ ID No: 20) and the deduced amino acid sequence (SEQ ID NO: 21) of the gene encoding the DNA polymerase from exonuclease III of Archaeoglobus fulgidus.
FIG. 2 : Resistance to heat denaturation of the recombinant exonuclease III of Archaeoglobus fulgidus expressed in E. coli as described in Example V.
Lane 1: Incubation at 50° C. Lane 2: Incubation at 60° C. Lane 3: Incubation at 70° C. Lane 4: Incubation at 80° C. Lane 5: Incubation at 90° C. Lane 6: E. coli host cell extract not transformed with gene encoding Afu exonuclease III Lane 7: Exonuclease III of E. coli Lane 8: Molecular weight marker
FIG. 3 : Exonuclease activity of Afu exonuclease III on DNA fragments as described in Example VI.
Lane 1: 10 units E. coli exonuclease III, incubation at 37° C. Lane 2: 50 ng of Afu exonuclease III, incubation at 72° C. Lane 3: 100 ng of Afu exonuclease III, incubation at 72° C. Lane 4: 150 ng of Afu exonuclease III, incubation at 72° C. Lane 5: 100 ng of Afu exonuclease III, incubation at 72° C. Lane 6: 200 ng of Afu exonuclease III, incubation at 72° C. Lane 7: 300 ng of Afu exonuclease III, incubation at 72° C. Lane 8: 250 ng of Afu exonuclease III, incubation at 72° C. Lane 9: 750 ng of Afu exonuclease III, incubation at 72° C. Lane 10: 1 μg of Afu exonuclease III, incubation at 72° C. Lane 11: 500 ng of Afu exonuclease III, incubation at 72° C. Lane 12: 1 μg of Afu exonuclease III, incubation at 72° C. Lane 13: 1.5 μg of Afu exonuclease III, incubation at 72° C. Lane 14: 1.5 μg of Afu exonuclease III, incubation at 72° C. Lane 15: 3 μg of Afu exonuclease III, incubation at 72° C. Lane 16: 4.5 μg of Afu exonuclease III, incubation at 72° C. Lane 17: 7.6 μg of Afu exonuclease III, incubation at 72° C. Lane 18: 15.2 μg of Afu exonuclease III, incubation at 72° C. Lane 19: 22.8 μg of Afu exonuclease III, incubation at 72° C. Lane 20: no exonuclease added
FIG. 4 : Principle of the mismatch correction assay.
FIG. 5 : Mismatched primer correction in PCR as described in Example VII.
Lane 1: DNA Molecular Weight Marker V (ROCHE Molecular Biochemicals No. 821705) Lane 2: G:A mismatched primer, amplification with Taq DNA polymerase Lane 3: same as in lane 2, but subsequently cleaved with BsiEI Lane 4: G:A mismatched primer, amplification with Expand HiFi PCR System Lane 5: same as in lane 4, but subsequently cleaved with BsiEI Lane 6: G:A mismatched primer, amplification with Taq polymerase/Afu exonuclease III Lane 7: same as in lane 6, but subsequently cleaved with BsiEI Lane 8: G:A mismatched primer, amplification with Tgo DNA polymerase Lane 9: same as in lane 8, but subsequently cleaved with BsiEI Lane 10: G:T mismatched primer, amplification with Taq DNA polymerase Lane 11: same as in lane 10, but subsequently cleaved with BsiEI Lane 12: G:T mismatched primer, amplification with Expand HiFi PCR System Lane 13: same as in lane 12, but subsequently cleaved with BsiEI Lane 14: G:T mismatched primer, amplification with Taq polymerase/Afu exonuclease III Lane 15: same as in lane 14, but subsequently cleaved with BsiEI Lane 16: G:T mismatched primer, amplification with Tgo DNA polymerase Lane 17: same as in lane 16, but subsequently cleaved with BsiEI Lane 18: DNA Molecular Weight Marker V Lane 19: DNA Molecular Weight Marker V Lane 20: G:C mismatched primer, amplification with Taq DNA polymerase Lane 21: same as in lane 20, but subsequently cleaved with BsiEI Lane 22: G:C mismatched primer, amplification with Expand HiFi PCR System Lane23: same as in lane 22, but subsequently cleaved with BsiEI Lane 24: G:C mismatched primer, amplification with Taq polymerase/Afu exonuclease III Lane 25: same as in lane 24, but subsequently cleaved with BsiEI Lane 26: G:C mismatched primer, amplification with Tgo DNA polymerase Lane 27: same as in lane 26, but subsequently cleaved with BsiEI Lane 28: CG:AT mismatched primer, Taq DNA polymerase Lane 29: same as in lane 28, but subsequently cleaved with BsiEI Lane 30: CG:AT mismatched primer, Expand HiFi PCR System Lane 31: same as in lane 2, but subsequently cleaved with BsiEI Lane32: CG:AT mismatched primer, Taq polymerase/Afu exonuclease III Lane 33: same as in lane 2, but subsequently cleaved with BsiEILane 34: CG:AT mismatched primer, amplification with Tgo DNA polymerase Lane 35: same as in lane 2, but subsequently cleaved with BsiEI Lane 36: DNA Molecular Weight Marker V.
FIG. 6A : Error rates of different polymerases in PCR
FIG. 6B : Improvement of fidelity by Afu exonuclease III present in the PCR mixture as described in Example VIII.
The ratio of blue:white colonies were blottet and various mixtures of Taq DNA polymerase and Afu exonuclease III (Taq/Exo 1:30, Taq/Exo 1:20, Taq/Exo 1:15, Taq/Exo 1: 12,5, Taq/Exo 1:10 corresponding to 2.5 units of Taq DNA polymerase mixed with 125 ng, 175 ng, 250 ng, 375 ng and 500 ng of Afu exonuclease III, respectively) were tested in comparison to Taq DNA polymerase (Taq), Expand HiFi PCR System (HiFi) and Pwo DNA polymerase (Pwo).
FIG. 7 : Incorporation of dUTP by the Taq DNA polymerase/Afu exonuclease III mixture as described in Example IX.
Lane 1: DNA Molecular Weight Marker XIV (Roche Molecular Biochemicals No. 1721933) Lane 2: Amplification with 2.5 units Taq DNA polymerase Lane 3: Amplification with 2.5 units Taq DNA polymerase and 125 ng of Afu exonuclease III Lane 4: Amplification with 2.5 units Taq DNA polymerase and 250 ng of Afu exonuclease III Lane 5: Amplification with 2.5 units Taq DNA polymerase and 375 ng of Afu exonuclease III Lane 6: Amplification with 2.5 units Taq DNA polymerase and 500 ng of Afu exonuclease III
FIG. 8 : Degradation of dUTP containing PCR products by Uracil-DNA Glycosylase as described in Example IX.
Lane 1: DNA Molecular Weight Marker XIV (Roche Molecular Biochemicals No. 1721933) Lane 2: 1 μl of the amplification product obtained with Taq DNA polymerase and 125 ng of Afu exonuclease III and subsequent UNG and heat treatment. Lane 3: 2 μl of the amplification product obtained with Taq DNA polymerase and 125 ng of Afu exonuclease III and subsequent UNG and heat treatment. Lane 4: 3 μl of the amplification product obtained with Taq DNA polymerase and 125 ng of Afu exonuclease III and subsequent UNG and heat treatment. Lane 5: 4 μl of the amplification product obtained with Taq DNA polymerase and 125 ng of Afu exonuclease III and subsequent UNG and heat treatment. Lane 6: 5 μl of the amplification product obtained with Taq DNA polymerase and 125 ng of Afu exonuclease III and subsequent UNG and heat treatment. Lane 7: 5 μl of the amplification product obtained with Taq DNA polymerase and 125 ng of Afu exonuclease III no subsequent UNG or heat treatment. Lane 8: 5 μl of the amplification product obtained with Taq DNA polymerase and 125 ng of Afu exonuclease III no subsequent UNG but heat treatment. Lane 9: DNA Molecular Weight Marker XIV (Roche Molecular Biochemicals No. 1721933)
FIG. 9 : Effect of Afu exonuclease III on PCR product length. The Taq DNA polymerase/Afu exonuclease III mixture was analyzed on human genomic DNA as described in Example X.
Lane 1:9,3 kb tPA fragment with Taq/Exo III Mix Lane 2: ” Taq-Pol. Lane 3: 12 kb tPA fragment with Taq/Exo III Mix Lane 4: ” Taq-Pol. Lane 5: 15 kb tPA fragment with Taq/Exo III Mix Lane 6: ” Taq-Pol.
FIG. 10 : Thermostable exonuclease III can be replaced by a polymerase mutant with reduced polymerase activity but increased 3′-exonucleoase-activity as described in Example XI.
Lane 1: Molecular Weight Marker Lane 2: reaction 1, Taq polymerase, 4.8 kb fragment Lane 3: reaction 2, Taq polymerase plus Tag polymerase mutant, 4.8 kb fragment Lane 4: reaction 3, no Taq polymerase, Tag polymerase mutant, 4.8 kb fragment Lane 5: reaction 4, Taq polymerase plus Afu ExoIII, 4.8 kb fragment Lane 6: reaction 5, Taq polymerase, 9.3 kb fragment Lane 7: reaction 6, Taq polymerase plus Tag polymerase mutant, 9.3 kb fragment Lane 8: reaction 7, no Taq polymerase, Tag polymerase mutant, 9.3 kb fragment Lane 9: reaction 8, Taq polymerase plus Afu ExoIII, 9.3 kb fragment Lane 10: Molecular Weight Marker
FIG. 11 . Afu exonuclease III is not active on linear single stranded DNA as described in Example XII
Lane 1: Afu Exo III, no incubation Lane 2: Afu Exo III, 1 h at 65° C. Lane 3: Afu Exo III, 2 h at 65° C. Lane 4: Afu Exo III, 3 h at 65° C. Lane 5: Afu Exo III, 4 h at 65° C. Lane 6: Afu Exo III, 5 h at 65° C. Lane 7: Reaction buffer without enzyme, no incubation Lane 8: Reaction buffer without enzyme, 5 h at 65° C. Lane 9: Molecular Weight Marker
FIG. 12 : Comparison of Afu exonuclease III with a thermostable B-type polymerase in primer degradating activity as described in Example XIII.
Lane 1: Molecular Weight Marker Lane 2: 1 u Tgo preincubated (reaction 1) Lane 3: 1.5 u Tgo, preincubated (reaction 2) Lane 4: 1 u Tgo, not preincubated (reaction 3) Lane 5: 1.5 u Tgo, not preincubated (reaction 4) Lane 6: 1 u Tgo, preincubated in the absence of dNTPs (reaction 5) Lane 7: 1.5 u Tgo, preincubated in the absence of dNTPs (reaction 6) Lane 8: 1 u Tgo, not preincubated in the absence of dNTPs (reaction 7) Lane 9: 1.5 u Tgo, not preincubated in the absence of dNTPs (reaction 8) Lane 10: 1 u Tgo, preincubated, in the absence of dNTPs, supplemented with additional primer (reaction 9) Lane 11: 1.5 u Tgo, preincubated in the absence of dNTPs, supplemented with additional primer (reaction 10) Lane 12: Taq polymerase, preincubated (reaction 11) Lane 13: Taq plus 37,5 ng Afu Exo III, preincubated (reaction 12) Lane 14: Taq plus 75 ng Afu Exo III, preincubated (reaction 13) Lane 15: Taq polymerase, not preincubated (reaction 14) Lane 16: Taq plus 37,5 ng Afu Exo III, not preincubated (reaction 15) Lane 17: Taq plus 75 ng Afu Exo III, not preincubated (reaction 16) Lane 18: Molecular Weight Marker
DETAILED DESCRIPTION OF THE INVENTION
EXAMPLE I
Isolation of Coding Sequences
The preferred thermostable enzyme herein is an extremely thermostable exodeoxyribonuclease obtainable from Archaeoglobus fulgidus VC-16 strain (DSM No. 4304). The strain was isolated from marine hydrothermal systems at Vulcano island and Stufe di Nerone, Naples, Italy (Stetter, K. O. et al., Science (1987) 236:822-824). This organism is an extremely thermophilic, sulfur metabolizing, archaebacteria, with a growth range between 60° C. and 95° C. with optimum at 83° C. (Klenk, H. P. et al., Nature (1997) 390:364-370). The genome sequence is deposited in the TIGR data base. The gene putatively encoding exonuclease III (xthA) has Acc. No. AF0580.
The apparent molecular weight of the exodeoxyribonuclease obtainable from Archaeoglobus fulgidus is about 32,000 daltons when compared with protein standards of known molecular weight (SDS-PAGE). The exact molecular weight of the thermostable enzyme of the present invention may be determined from the coding sequence of the Archaeoglobus fulgidus exodeoxyribonuclease III gene.
EXAMPLE II
Cloning of the Gene Encoding Exonuclease III from Archaeoglobus fulgidus
About 6 ml cell culture of DSM No. 4304 were used for isolation of chromosomal DNA from Archaeoglobus fulgidus.
The following primers were designed with restriction sites compatible to the multiple cloning site of the desired expression vector and complementary to the N- and C-terminus of the Archaeoglobus fulgidus exonuclease III gene:
SEQ ID NO.: 1
N-terminus (BamHI-site):
5′-GAA ACG AGG ATC CAT GCT CAA AAT CGC CAC C -3,
SEQ ID NO.: 2
C-terminus (PstI-site):
5′-TTG TTC ACT GCA GCT ACA CGT CAA ACA CAG C -3,
First the cells were collected by repeted centrifugation in one 2 ml eppendorf cap at 5,000 rpm. The DNA isolation may be performed with any described method for isolation from bacterial cells. In this case the Archaeoglobus fulgidus genomic DNA was prepared with the High Pure™ PCR Template Preparation Kit (ROCHE Diagnostics GmbH, No. 1796828). With this method about 6 μg chromosomal DNA were obtained with a concentration of 72 ng/μl.
PCR was performed with the primers described above, in the Expand™ High Fidelity PCR System (ROCHE Diagnostics GmbH, No. 1732641) and 100 ng Archaeoglobus fulgidus genomic DNA per cap in four identical preparations. PCR was performed with the following conditions:
1 × 94° C., 2 min;
10 × 94° C., 10 sec; 54° C., 30 sec; 68° C., 3 min;
20 × 94° C., 10 sec; 54° C., 30 sec; 68° C., 3 min
with 20 sec cycle elongation for each cycle;
1 × 68° C., 7 min;
After adding MgCl 2 to a final concentration of 10 mM the PCR product was cleaved with BamHI and Pst I, 10 units each, at 37° C. for 2 hours. The reaction products were separated on a low-melting agarose gel. After elecrophoresis the appropriate bands were cut out, the gel slices combined, molten, the DNA fragments isolated by agarase digestion and precipitated with EtOH. The dried pellet was diluted in 30 μl H 2 O.
The appropriate expression vector, here pDS56_T, was digested with the same restriction enzymes as used for the insert and cleaned with the same method.
After ligation of insert and vector with the Rapid DNA Ligation Kit (ROCHE Diagnostics GmbH, No. 1635379) the plasmid was transformed in the expression host E. coli 392 pUBS520 (Brinkmann, U. et al. (1989) Gene 85:109-114).
Plasmid DNA of the transformants was isolated using the High Pure™ Plasmid Isolation Kit (ROCHE Diagnostics GmbH, No. 1754777) and characterized by restriction digestion with BamHI and PstI and agarose gel electrophoresis.
Positive E. coli pUBS520 ExoIII transformants were stored in glycerol culture at −70° C. The sequence of the gene encoding exonuclease III was confirmed by DNA sequencing. It is shown in FIG. 1 .
Cloning and expression of exonuclease III from Archaeoglobus fulgidus or other thermophilic organisms may also be performed by other techniques using conventional skill in the art (see for example Sambrook et al. Molecular Cloning, A Laboratory Manual, Cold Spring Harbour Lab., 1989).
EXAMPLE III
Expression of Recombinant Afu Exonuclease III
The transformant from example I was cultivated in a fermentor in a rich medium containing appropriate antibiotic. Cells were harvested at an optical density of [A 540 ] 5.5 by centrifugation and frozen until needed or lyzed by treatment with lysozyme to produce a crude cell extract containing the Archaeoglobus fulgidus exonuclease III activity.
The crude extract containing the Archaeoglobus fulgidus exonuclease III activity is purified by the method described in example IV, or by other purification techniques such as affinity-chromatography, ion-exchange-chromatography or hydrophobic-interaction-chromatography.
EXAMPLE IV
Purification of Recombinant Afu Exonuclease III
E. coli pUBS520 ExoIII (DSM No. 13021) from example I was grown in a 10 l fermentor in media containing tryptone (20 g/l), yeast extract (10 g/l), NaCl (5 g/l) and ampicillin (100 mg/l) at 37° C., induced with IPTG (0.3 mM) at midexponential growth phase and incubated an additional 4 hours. About 45 g of cells were harvested by centrifugation and stored at −70° C. 2 g of cells were thawed and suspended in 4 ml buffer A (40 mM Tris/HCl, pH 7.5; 0.1 mM EDTA; 7 mM 2-mercaptoethanol; 1 mM Pefabloc SC). The cells were lyzed under stirring by addition of 1.2 mg lysozyme for 30 minutes at 4° C. and addition of 4.56 mg sodium deoxycholate for 10 minutes at room temperature followed by 20 minutes at 0° C. The crude extract was adjusted to 750 mM KCl, heated for 15 minutes at 72° C. and centrifuged for removal of denatured protein.
A heating temperature up to 90° C. is also possible without destroying (denaturation) the Archaeoglobus fulgidus exonuclease III. The supernatant was dialyzed against buffer B (buffer A containig 10% glycerol) adjusted to 10 mM MgCl 2 and applied to a Blue Trisacryl M column (SERVA, No. 67031) with the dimension 1×7 cm and 5.5 ml bed volume, equilibrated with buffer B. The column was washed with 16.5 ml buffer B and the exonuclease protein was eluted with a 82 ml linear gradient of 0 to 3 M NaCl in buffer B. The column fractions were assayed for Archaeoglobus fulgidus exodeoxyribonuclease protein by electrophoresis on 10-15% SDS-PAGE gradient gels. The active fractions, 16.5 ml, were pooled, concentrated with Aquacide II (Calbiochem No. 17851) and dialyzed against the storage buffer C (10 mM Tris/HCl, pH 7.9; 10 mM 2-mercptoethanol; 0.1 mM EDTA; 50 mM KCl; 50% glycerol). After dialysis Thesit and Nonidet P40 were added to a final concentration of 0.5% each. This preparation was stored at −20° C.
The Archaeoglobus fulgidus exonuclease III obtained was pure to 95% as estimated by SDS gel electrophoresis. The yield was 50 mg of protein per 2.3 g cellmass (wetweight).
EXAMPLE V
Thermostability of Recombinant Exonuclease III from Archaeoglobus fulgidus
The thermostability of the exonuclease III from Archaeoglobus fulgidus cloned as described in Example II was determined by analyzing the resistance to heat denaturation. After lysis as described in Example IV 100 μl of the crude extract were centrifuged at 15,000 rpm for 10 min in an Eppendorf centrifuge. The supernatant was aliquoted into five new Eppendorf caps. The caps were incubated for 10 minutes at five different temperatures, 50° C., 60° C., 70° C., 80° C. and 90° C. After centrifugation as described above, aliquotes of the supernatants were analyzed by electrophoresis on 10-15% SDS-PAGE gradient gels. As shown in FIG. 2 the amount of Archaeoglobus fulgidus exonuclease III protein after incubation at 90° C. was the same as that of the samples treated at lower temperatures. The was no significant loss by heat denaturation detectable. From this result it can be concluded that the half life is more than ten minutes at 90° C.
EXAMPLE VI
Activity of Afu Exonuclease III
Exonuclease III catalyzes the stepwise removal of mononucleotides from 3′-hydroxyl termini of duplex DNA (Rogers G. S. and Weiss B. (1980) Methods Enzymol. 65:201-211). A limited number of nucleotides are removed during each binding event. The preferred substrate are blunt or recessed 3′-termini. The enzyme is not active on single stranded DNA, and 3′-protruding termini are more resistant to cleavage. The DNA Molecular Weight Marker VI (ROCHE Molecular Biochemicals, No. 1062590) consists of BglI digested pBR328 mixed with HinfI digested pBR328. The products of the HinfI digest have 3′-recessive termini and are expected to be preferred substrates to degradation by exonuclease III, the products of BglI cleavage have 3′ protruding ends with 3 bases overhangs and should be more resistant to cleavage by exonuclease III.
Serial dilutions of Archaeoglobus fulgidus exonuclease III from Example IV were incubated for 2 hours at 72° C. with 0.5 μg DNA Molecular Weight Marker VI (ROCHE Molecular Biochemicals, No. 1062590) in 25 μl of the following incubation buffer: 10 mM Tris/HCl, pH 8.0; 5 mM MgCl 2 ; 1 mM 2-mercaptoethanol; 100 mM NaCl with Paraffin overlay. 10 units of exonuclease III of E. coli (ROCHE Molecular Biochemicals, No. 779709) was included as a control. The control reaction was performed at 37° C. After addition of 5 μl stop solution (0.2% Agarose, 60 mM EDTA, 10 mM Tris-HCl, pH 7.8, 10% Glycerol, 0.01% Bromphenolblue) the mixtures were separated on a 1% agarose gel. The result is shown in FIG. 3 . Afu exonuclease III discriminates between the two different types of substrate. The preferred substrate are the fragments with 3′-recessive ends (e.g. 1766 bp fragment) and the 3′-overhanging ends (e.g. 2176 bp, 1230 bp, 1033 bp fragments) are more resistant to degradation. With higher amounts of protein the substrate is degraded to a similar extent as in lane 1, where the products of exonuclease III of E. coli were analyzed. With increasing amounts of Afu exonuclease protein only little DNA substrate was left (lanes 15 to 19), the retardation of the remaining fragments may be due to DNA binding proteins as impurities of the preparation.
EXAMPLE VII
Mismatched Primer Correction in PCR with Afu Exonuclease III
The repair efficiency of the Afu exonuclease III/Taq polymerase mixture during PCR was tested with 3′ terminally mismatched primers, the principle of the assay is shown in FIG. 4 . For PCR amplification sets of primers are used in which the forward primer has one or two nucleotides at the 3′ end which cannot base pair with the template DNA. Excision of the mismatched primer end and amplification of the repaired primer generates a product which can subsequently be cleaved with the restriction endonuclease BsiEI, whereas the product arising from the mismatched primer is resistant to cleavage.
The primer sequences used:
(SEQ ID NO.: 3)
1. reverse:
5′- GGT TAT CGA AAT CAG CCA CAG CG -3′
(SEQ ID NO.: 4)
2. forward 1 (g:a mismatch):
5′- TGG ATA CGT CTG AAC TGG TCA CGG TCA -3′
(SEQ ID NO.: 5)
3. forward 2 (g:t mismatch):
5′- TGG ATA CGT CTG AAC TGG TCA CGG TCT -3′
(SEQ ID NO.: 6)
4. forward 3 (g:c mismatch):
5′- TGG ATA CGT CTG AAC TGG TCA CGG TCC -3′
(SEQ ID NO.: 7)
5. forward 4 (2 base mismatch):
5′- TGG ATA CGT CTG AAC TGG TCA CGG TAT -3′
PCR was carried out using 2.5 Units Taq DNA Polymerase (ROCHE Diagnostics GmbH, No. 1435094), 0.25 μg of Archaeoglobus fulgidus exonuclease III from Example IV, 10 ng of DNA from bacteriophage λ, 0.4 μM of each primer, 200 μM of dNTP's, 1.5 mM of MgCl 2 , 50 mM of Tris-HCl, pH 9.2, 16 mM of (NH 4 ) 2 SO 4 . PCR was performed in an volume of 50 μl PCR with the following conditions:
1 × 94° C., 2 min;
40 × 94° C., 10 sec; 60° C., 30 sec; 72° C., 1 min;
1 × 72° C., 7 min;
The function of the exonuclease/Taq polymerase mixture was compared to controls as 2.5 Units of Taq DNA polymerase, 0.3 Units of Tgo DNA polymerase (ROCHE Diagnostics GmbH) and to 0.75 μl of Expand™ High Fidelity PCR System (ROCHE Diagnostics GmbH, No. 1732641). As indicated by successful digestion of the PCR products with BsiEI A. fulgidus exonuclease III showed correcting activity of all described mismatches with an effectivity of 90 to 100% ( FIG. 5 ). Taq DNA Polymerase as expected showed no correcting activity, while Tgo DNA Polymerase with it's 3′-5′ exonuclease activity corrected completely as well. The Expand™ High Fidelity PCR System showed only with the two base mismatch 100% correcting activity. The other mismatches were repaired with an effectivity of approximately 50%.
EXAMPLE VIII
Fidelity of Afu Exonuclease III ITaq DNA Polymerase Mixtures in the PCR Process
The fidelity of Afu exonuclease III/Taq DNA polymerase mixtures in the PCR process was determined in an assay based on the amplification, circularisation and transformation of the pUC19 derivate pUCIQ17, containing a functional lac I q allele (Frey, B. and Suppmann B. (1995) Biochemica 2:34-35). PCR-derived mutations in lac I are resulting in a derepression of the expression of lac Zα and subsequent formation of a functional β-galactosidase enzyme which can be easily detected on X-Gal indicator plates. The error rates of Taq polymerase/Afu exonuclease mixtures determined with this lac I-based PCR fidelity assay were determined in comparison to Taq DNA polymerase and Expand HiFi PCR System (Roche Molecular Biochemicals) and Pwo DNA polymerase (Roche Molecular Biochemicals) as controls.
The plasmid pUCIQ 17 was linearized by digestion with DraII to serve as a substrate for PCR amplification with the enzymes tested.
Both of the primers used have ClaI sites at their 5 prime ends:
SEQ ID NO.: 8 Primer 1: 5′-AGCTTATCGATGGCACTTTTCGGGGAAATGTGCG-3′ SEQ ID NO.: 9 Primer 2: 5′-AGCTTATCGATAAGCGGATGCCGGGAGCAGACAAGC-3′
The length of the resulting PCR product is 3493 bp.
The PCR was performed in a final volume of 50 μl in the presence of 1.5 mM MgCl 2 , 50 mM Tris-HCl, pH 8.5 (25° C.), 12.5 mM (NH 4 ) 2 SO 4 , 35 mM KCl, 200 μM dNTPs and 2.5 units of Taq polymerase and 125 ng, 175 ng, 250 ng, 375 ng and 500 ng, respectively of Afu exonuclease III.
The cycle conditions were as follows:
1
×
denaturation
of
template
for
2
min
.
at
95
°
C
.
8
×
[
denaturation
at
95
°
C
.
for
10
sec
.
annealing
at
57
°
C
.
for
30
sec
.
elongation
at
72
°
C
.
for
4
min
.
16
×
[
denauration
at
95
°
C
.
for
10
sec
.
annealing
at
57
°
C
.
for
30
sec
.
elongation
at
72
°
C
.
for
4
min
.
+
cycle
elongation
of
20
sec
.
for
each
cycle
After PCR, the PCR products were PEG-precipitated (Barnes, W. M. (1992) Gene 112:229) the DNA restricted with ClaI and purified by agarose gel electrophoresis. The isolated DNA was ligated using the Rapid DNA Ligation Kit (Roche Molecular Biochemicals) and the ligation products transformed in E. coli DH5α, plated on TN Amp X-Gal plates. The α-complementing E. coli strain DH5α transformed with the resulting plasmid pUCIQ17 (3632 bp), shows white (lacI+) colonies on TN plates (1.5% Bacto Tryptone, 1% NaCl, 1.5% Agar) containing ampicillin (100 μg/ml) and X-Gal (0.004% w/v). Mutations result in blue colonies.
After incubation overnight at 37° C., blue and white colonies were counted. The error rate (f) per bp was calculated with a rearranged equation as published by Keohavong and Thilly (Keohavong, P. and Thilly, W. (1989) PNAS USA 86:9253):
f =−ln F/d×b bp
where F is the fraction of white colonies:
F=white (lacI + ) colonies/total colony number;
d is the number of DNA duplications:
2 d =output DNA/input DNA;
and b is the effective target size of the (1080 bp) lac I gene, which is 349 bp according to Provost et al. (Provost et al. (1993) Mut. Res. 288:133).
The results shown in FIG. 6A and FIG. 6B demonstrate that the presence of thermostable exonuclease III in the reaction mixure results in lower error rates. Dependent on the ratio of polymerase to exonuclease the error rate is decreasing. The fidelity achieved with the most optimal Taq polymerase/Afu exonuclease III mixture (4,44×10 −6 ) is in a similar range as that of the Taq/Pwo mixture (Expand HiFi; 2,06×10 −6 ). Evaluation of the optimal buffer conditions will further improve the fidelity. The ratio between polymerase and exonuclease has to be optimized. High amounts of exonuclease reduce product yield, apparently decreasing amplification efficiency (Taq/Exo 1:10 corresponding to 2.5 units of Taq polymerase and 500 ng of Afu exonuclease III).
The fidelity of this system may further be optimized using conventional skill in the art e.g. by altering the buffer components, optimizing the concentration of the individual components or changing the cycle conditions.
EXAMPLE IX
Incorporation of dUTP in the Presence of Afu Exonuclease III During PCR
The Afu exonuclease/Taq polymerase mixture was tested for DNA synthesis with TTP completely replaced by dUTP. Comparisation of either TTP or dUTP incorporation was determinated in PCR using 2.5 Units of Taq DNA Polymerase, in presence of 0.125 μg, 0.25 μg, 0.375 μg and 0.5 μg of Archaeoglobus fulgidus exonuclease III from example IV on native human genomic DNA as template using the 3-globin gene as target. The following primers were used:
(SEQ ID NO.: 10)
forward:
5′- TGG TTG AAT TCA TAT ATC TTA GAG GGA GGG C -3′
(SEQ ID NO.: 11)
reverse:
5′- TGT GTC TGC AGA AAA CAT CAA GGG TCC CAT A -3′
PCR was performed in 50 μl volume with the following cycle conditions:
1 × 94° C., 2 min;
40 × 94° C., 10 sec; 60° C., 30 sec; 72° C., 1 min;
1 × 72° C., 7 min;
Aliquots of the PCR reaction were separated on agarose gels. As shown in FIG. 7 with this template/primer system DNA synthesis in the presence of dUTP is possible with up to 375 ng of Afu exonuclease III. dUTP incorporation can further be proven by Uracil-DNA Glycosylase treatment (ROCHE Diagnostics GmbH, No. 1775367) of aliquotes from the PCR reaction products for 30 min at ambient temperature and subsequent incubation for 5 min at 95° C. to cleave the polynucleotides at the apurinic sites which leads to complete degradation of the fragments. The analysis of the reaction products by agarose gel electrophoresis is shown in FIG. 8 .
EXAMPLE X
Effect of Afu Exonuclease III on PCR Product Length
Taq polymerase is able to synthesize PCR products up to 3 kb in length on genomic templates. In order to estimate the capability of the Taq polymerase/Afu exonuclease mixture for the synthesis of longer products, the enzyme mixture was analyzed on human genomic DNA as template with three pairs of primers designed to amplifiy products of 9.3 kb, 12 kb and 15 kb length. The buffer systems used were from the Expand Long Template PCR System (Roche Molecular Biochemicals Cat. No 1 681 834). Reactions were performed in 50 μl volume with 250 ng of human genomic DNA, 220 ng of each primer, 350 μM of dNTPs and 2.5 units of Taq polymerase and 62,5 ng of Afu exonuclease with the conditions as outlined in Table 1:
TABLE 1
Expand
Long
Template
Product
buffer
length
Primers
No.:
PCR Programm
9.3 kb
forward 7
1
1 × denat. at 94° C. for 2 min
reverse 14
10 × denat. at 94° C. for 10 sec.
annealing at 65° C. for 30 sec
elogation at 68° C. for 8 min.
20 × denat. at 94° C. for 10 sec.
annealing at 65° C. for 30 sec
elogation at 68° C. for 8 min. plus
cycle elongation of 20 sec. per
cycle
1 × elongation at 68° C. for 7 min.
12 kb
forward 1
2
1 × denat. at 94° C. for 2 min
reverse 3
10 × denat. at 94° C. for 10 sec.
annealing at 62° C. for 30 sec
elogation at 68° C. for 12 min.
20 × denat. at 94° C. for 10 sec.
annealing at 62° C. for 30 sec
elogation at 68° C. for 12 min. plus
cycle elongation of 20 sec. per
cycle
1 × elongation at 68° C. for 7 min.
15 kb
forward 1
3
same as for 12 kb
reverse 2
The primer specific for amplification of the tPA genes used:
(SEQ ID NO.: 12)
Primer 7a forward:
5′- GGA AGT ACA GCT CAG AGT TCT GCA GCA CCC CTG
C-3′
(SEQ ID NO.: 13)
Primer 14a reverse:
5′- CAA AGT CAT GCG GCC ATC GTT CAG ACA CAC C-3′
(SEQ ID NO.: 14)
Primer 1 forward:
5′- CCT TCA CTG TCT GCC TAA CTC CTT CGT GTG TCC
C-3′
(SEQ ID NO.: 15)
Primer 2 reverse:
5′- ACT GTG CTT CCT GAC CCA TGG CAG AAG CGC CTT
C-3′
(SEQ ID NO.: 16)
Primer 3 reverse:
5′- CCT TCT AGA GTC AAC TCT AGA TGT GGA CTT AGA
G-3′
As shown in FIG. 9 it is possible to synthesize products of at least 15 kb in length with the Taq polymerase/Afu exonuclease mixture.
EXAMPLE XI
Thermostable Exonuclease III can be Replaced by a Polymerase Mutant with Reduced Polymerase Activity but Increased 3′ Exonuclease-activity
DNA polymerase from Thermococcuss aggregans (Tag) described from Niehaus F., Frey B. and Antranikian G. in WO97/35988 or Gene (1997) 204 (1-2), 153-8, with an amino acid exchange at position 385 in which tyrosine was replaced by asparagine (Boehlke at al. submitted for publication and European patent application 00105 155.6) shows only 6.4% of the polymerase activity but 205% of the exonuclease activity of the wild type DNA polymerase. This enzyme was used to demonstrate that the invention is not restricted to exonuclease III-type enzymes but also includes other types of enzymes contributing 3′ exonuclease activity.
Reactions were performed in 50 μl volume with 200 ng of human genomic DNA, 200 μM dNTP, 220 ng of each primer and Expand HiFi buffer incl. Mg ++ for reactions 1-4 or Expand Long Template buffer 1 for reactions 5-8 ( FIG. 10 ). In order to amplify a 4.8 kb fragment of the tPA gene, primer tPA 7a forward (5′-GGA AGT ACA GCT CAG AGT TCT GCA GCA CCC CTG C-3′, SEQ ID NO.: 12) and tPA 10a reverse (5′-GAT GCG AAA CTG AGG CTG GCT GTA CTG TCT C-3′, SEQ ID NO.: 17) were used in reactions 1-4. In order to amplify a 9.3 kb fragment of of the tPA gene, primer tPA 7a forward and tPA 14a reverse (5′-CAA AGT CAT GCG GCC ATC GTT CAG ACA CAC C-3′, SEQ ID NO.: 13) were used in reactions 5-8. 2.5 units Taq polymerase were added to reactions 1, 2, 4, 5, 6, and 8, not to reactions 3 and 7 which were used as negative controls. 11 ng of Tag polymerase mutant were added to reactions 2, 3, 6 and 7, 150 ng of Afu Exonuclease III were added to reactions 4 and 8.
The cycle programs used for reactions 1-4:
1 × 94° C., 2 min, 10 × 94° C., 10 sec 62° C., 30 sec 68° C., 4 min 20 × 94° C., 10 sec 62° C., 30 sec 68° C., 4 min, plus cycle elongation of 20 sec per cycle 1 × 68° C. for 7 min
for reactions 5-8:
1 ×
94° C., 2 min,
10 ×
94° C., 10 sec
65° C., 30 sec
68° C., 8 min
20 ×
94° C., 10 sec
65° C., 30 sec
68° C., 8 min, plus cycle elongation of 20 sec per cycle
1 ×
68° C. for 7 min
The PCR products were analysed on a 1% agarose gel containg ethidium bromide ( FIG. 10 ). The data show that Taq polymerase is able to amplify the 4.8 kb fragment but with low yield. The combination of Taq polymerase with Tag polymerase mutant or Afu Exo III results in a strong increase in product yield. The Tag polymerase mutant enzyme by itself is not able to synthesize this product.
Similar results were obtained with the 9.3 kb system. Using Taq polymerase alone no product is detectable. In combination with Tag polymerase mutant or Afu Exo III the expected PCR product is obtained in high yield.
These results show that Taq polymerase is not able to amplify DNA fragments of several kb from genomic DNA and support the hypothesis of Barnes (Barnes W. M. (1994) Proc. Natl. Acad. Sci . USA, 91:2216-2220) that the length limitation for PCR amplification is caused by low efficiency of extension at the sites of incorporation of mismatched base pairs. After removal of the mismatched nucleotide at the primer end, Taq polymerase is able to reassume DNA synthesis. The completed nucleic acid chain as a full length product can then serve as a template for primer binding in subsequent cycles.
EXAMPLE XII
Afu Exo III is not Active on Linear Single Stranded DNA
Reactions were performed in 50 μl volume with 270 ng of Afu Exo III, 5 μg of a 49-mer oligonucleotide in Expand HiFi PCR buffer with MgCl 2 and incubated for 0, 1, 2, 3, 4, and 5 hours at 65° C. After addition of 10 μl of Proteinase K solution (20 mg/ml) the samples were incubated for 20 min. at 37° C. The reaction products were analysed on a 3.5% Agarose gel containing ethidium bromide.
The result is depicted in FIG. 11 . It showes that the nucleic acid has the same size in all lanes. The product obtained after incubation for up to 5 hours (lane 6) with Afu Exo III has the same size as the controls (lanes 1, 7 and 8). Neither a significant reduction in intensity of the full length oligonucleotide nor a smear deriving from degraded products can be observed.
EXAMPLE XIII
Comparison of Afu Exonuclease III with a Thermostable B-Type Polymerase in Primer Degradating Activity
Thermostable B-type polymerases are reported to have single and double stranded nuclease activity (Kong H. et al. (1993) Journal Biol. Chem. 268:1965-1975). This activity is able to degrade primer molecules irrespective whether they are hybridized to the template or single stranded. The replacement of a thermostable B-type polymerase by a thermostable exonuclease in the reaction mixture might be of advantage with respect to stability of single stranded primer or other nuclei acids present in the reaction mixture.
In order to test for primer degrading activity, reaction mixtures without template DNA were incubated for 1 hour at 72° C., then DNA was added and PCR was performed. The results were compared with reactions containing Tgo polymerase as an example for a thermostable B-type polymerase (Angerer B. et al. WO 98/14590). As control the same mixtures were used without prior incubation. The results are summarized in Table 2.
TABLE 2
preincubation in
preinc. in the
second addition
reaction
the absence of
presence of
of primer after
#
enzyme (s)
template DNA
nucleotides
preincubaion
1
Tgo
yes
yes
2
Tgo
yes
yes
3
Tgo
no
4
Tgo
no
5
Tgo
yes
no
6
Tgo
yes
no
7
Tgo
no
8
Tgo
no
9
Tgo
yes
no
yes
10
Tgo
yes
no
yes
11
Taq
yes
yes
12
Taq plus
yes
yes
Afu Exo III
13
Taq plus
yes
yes
Afu Exo III
14
Taq
no
15
Taq plus
no
Afu Exo III
16
Taq plus
no
Afu Exo III
As target for amplification a fragment of the p53 gene was chosen, the primer used were: p53I 5′-GTC CCA AGC AAT GGA TGA T-3′ (SEQ ID NO.: 18) and p53II 5′-TGG AAA CTT TCC ACT TGA T-3′ (SEQ ID NO.: 19). PCR reactions were performed in 50 μl volume.
Reactions nos. 1-10 contained 200 ng of human genomic DNA, 40 pmole of each primer, 10 mM Tis-HCl, pH 8.5, 17.5 mM (NH4)2SO4, 1.25 mM MgCl 2 , 0.5% Tween, 2.5% DMSO, 250 μg/ml BSA and 1 unit (reactions number 1, 3, 5, 7 and 9) or 1.5 units (reactions number 2, 4, 6, 8 and 10) Tgo polymerase and 200 μM dNTPs.
Reactions number 11 to 16 contained 2.5 units Taq polymerase, Expand HiFi buffer+with Mg ++ , 40 pmoles of primer, 200 μM dNTPs, 100 ng human genomic DNA. Reactions number 12 and 15 contained 37.5 ng of Afu Exo III, reactions number 13 and 16 contained 75 ng of Afu Exo III.
As described in table 2 reactions 1, 2, 5, 6 and 11 to 13 were incubated for 1 hour at 72° C. in the absence of template DNA. The template DNA was added before PCR was started. Reactions 5, 6, 9 and 10 were preincubated in the absence of nucleotides, reactions 9 and 10 were supplemented with additional 40 pmoles of primer after the preincubation step. Because of the 5′-exonuclease activity of Taq polymerase, the enzyme was added after preincubation to reactions 11 to 13.
PCR Conditions:
1 ×
94° C., 2 min
35 ×
94° C., 10 sec
55° C., 30 sec
72° C., 4 min
1 ×
72° C. for 10 min
The reaction products were analysed on an agarose gel and stained with ethidium bromide ( FIG. 12 ).
When Tgo polymerase was incubated with the primer in the absence of template DNA (reactions 1,2,5 and 6) and compared with the corresponding reactions without preincubation (3,4,7 and 8) a clear difference was observed. The preincubation results in strongly reduced PCR product obviously affecting at least one essential component, most probably the PCR primer. Extra addition of 40 pmoles of PCR primer (reactions 9 and 10) after the preincubation step results in strong signals with intensities comparable to the control reaction which were not preincubated. This shows that Tgo polymerase, a thermostable B-type polymerase, degrades PCR primer in the absence of template no matter whether dNTPs are present or not.
The PCR products obtained with reactions 12 and 13, in which the primer were preincubated with Afu Exonuclease III before addition of template DNA and Taq polymerase gave similar bands as those obtained with reactions 15 and 16, in which no preincubation step was used. From the similar strong band intensities it can be concluded that little or no degradation of primer occured and that single stranded oligonucleotides are poor substrates for Afu Exonuclease III. From the strong band intensities or enhanced yields of PCR products it can be concluded that the enzyme enhances fidelity of an amplification process. | A purified thermostable enzyme is derived form the thermophilic archaebacterium Archaeoglobus fulgidus . The enzyme can be native or recombinant, is stable under PCR conditions and exhibits double strand specific exonuclease activity. It is a 3′-5′ exonuclease and cleaves to produce 5′-mononucleotides. Thermostable exonucleases are useful in many recombinant DNA techniques, in combination with a thermostable DNA polymerase like Taq especially for nucleic acid amplification by the polymerase chain reaction (PCR). | 2 |
This application is a continuation-in-part application of Ser. No. 08/855,833 filed May 12, 1997 and now abandoned.
BACKGROUND OF THE INVENTION
The present invention relates to an implantable device with a specific surface roughness that facilitates in vitro formation of a solution mediated coating, including calcium phosphate coatings, in which biologically active substances can be coprecipitated. The present invention further relates to a process of producing such a device and to the biomedical use of such a device.
U.S. Pat. No. 5,456,723 discloses an implant having a porous metallic surface which has been treated by sandblasting and reductive acid etching resulting in a surface micro-roughness having a maximum peak-to-valley height of about 20 to 30 μm and a roughness spacing of from 0.5 to 10 μm, preferably of about 1-5 μm. The extremely sharp, comb-like structure is necessary in order to achieve sufficient adhesion between the implant and the coating material (hydroxyapatite) formed on it by anchoring the hydroxyapatite in the implant.
A drawback of most hydroxyapatite-coated implants is that the anchoring of hydroxyapatite onto the implant requires high processing temperatures, which limit the choice of substrate materials and result in higher processing costs. The previously preferred technique for coating implant materials with hydroxyapatite is plasma deposition (for a review, see P. Serekian, in Hydroxylapatite Coatings in Orthopaedic Surgery, Ed. Geesink and Manley, Raven Press N.Y., 1993, p. 81-87). Another disadvantage of the plasma deposition technique, in addition to the high temperatures involved, resides in the relatively large particle size, in the order of 30-70 μm.
An aim of the present invention is to provide a coated implantable device that can be used in a wide variety of biomedical applications (surgery, bone-replacement, prosthodontics etc.). The device should give rise to effective bone formation and simultaneously result in a desired biological effect, such as assisting bone formation, preventing infection or rejection during or after implantation, induced by the presence of biologically active substances, such as proteins, growth-factors, lipids, (lipo)polysaccharides, cytostatic agents, hormones, antibiotics or other biological agents. In case a degradable coating is produced, degradation of said coating due to solution mediated processes or cell mediated processes should result in a further exposure or release of biologically active agents. The processing of the device and the temperature at which it is produced should not have an adverse effect on the biological activity of said agents.
SUMMARY OF THE INVENTION
The aim is achieved by a shaped article suitable as an implant of a solid, i.e. non-fluid, porous or non-porous material having a surface nano-roughness, giving rise to the formation of a composite coating when placed in certain solutions. Said solutions contain, but are not limited to calcium and phosphate ions, and biologically active agents (e.g. proteins, growth-factors, lipids, (lipo)polysaccharides, cytostatic agents, hormones, antibiotics) and may be saturated or supersaturated, but may also be relatively diluted. The coating can therefore be composed of both an organic phase, such as the biologically active agent and an inorganic (e.g. calcium phosphate) phase. The uniqueness about the present invention is that biologically active agents can be simultaneously co-precipitated during the formation of the solution mediated coating. As a result, a specified area in the coating or the whole thickness of said coating can be loaded with the biologically active agent(s), that expresses its use when exposed or released at the surface. Depending on the time at which the biologically active agent is added to the solution, said agent can be accurately co-precipitated anywhere throughout the thickness of the coating, as the coating formation is a time-dependent process and elimination of said agent from the solution results in the formation of an inorganic coating (i.e. a calcium phosphate coating). Utilizing such a co-precipitation technique where biologically active agents can either or not be co-precipitated at different time points and with different concentrations, can result in a wide variety of coatings, from relatively simple coatings in which a homogenous concentration of a co-precipitated biologically active agent is present, to a very complex coating containing, at different levels, different concentrations of different biologically active agents.
The surface roughness is an important factor of the device according to the invention. The surface roughness is defined herein by the average peak distance, i.e the average spacing between protrusions on the surface (Ra value). This average peak distance can be determined e.g. by means of Scanning Electron Microscopy (SEM). In general, the average peak distance may be 1,000 nm or less, down to 10 nm. The most suitable roughness depends on the nature of the material of the article. For articles made of titanium, the average peak distance can be e.g. from 10 to 200 nm, for polymeric material, the preferred peak distance is from 20 to 500 nm, whereas for stainless steel the peak distance is advantageously between 50 and 1,000 nm. In general, the preferred average peak distance range is between 2 and 500 nm.
The depth of the surface roughness of the article is less critical than the peak distance. However, a minimum depth is desirable, in particular a peak height--with respect to the deepest sites on the surface--of at least 20 nm, up to about 2,000 nm. The preferred average depth is of the same order of magnitude as the average peak distance, and is in particular from 50 nm to 1,000 nm. The average depth can also be determined by means of Scanning Electron Microscopy.
The substrate of the implant article can be of various materials. These include metals, in particular biocompatible metals such as titanium, tantalum, niobium, zirconium and alloys thereof, as well as stainless steel. Another useful class of biocompatible materials comprises organic natural and synthetic polymers such as polyethylene, polypropylene, polytetrafluoroethylene (Teflon®), which may also be biodegradable polymers such as polyglycolic acid, polylactic acid or certain polysaccharides. Ceramic materials such as calcium phosphate, alumina or bioglass, as well as composite materials, can also be used as an implant substrate. The material may be porous or non-porous. Where it is porous, the pores are distinguished from the valleys of the surface roughness by the depth: i.e. the pores have depths substantially greater than 2 μm, and the surface roughness may be superimposed on the pore walls.
The substrate having the desired surface roughness can efficiently be coated in vitro with a layer of a calcium phosphate and one or more biologically active agents. The composite coating can be relatively thin, on the order of from a a e.g. 50 nm to 200 μm, especially from 1 to 50 μm. The calcium phosphate preferably forms small crystals, producing an amorphous-like structure. The calcium phosphate can be any combination of calcium and phosphate ions, optionally together with e.g. hydroxide, chloride, sulphate, nitrate etc. anions or hydrogen, sodium, potassium, magnesium etc. cations. For a faster process, the deposition step can be preceded by a precalcification step using a solution of calcium and phosphate ions, or two solutions containing calcium ions and phosphate ions respectively and applied consecutively. The biologically active agent in the coating includes, but is not limited to, single or combinations of proteins, lipids, (lipo)polysaccharides, growth-factors, cytostatic agents, hormones, and antibiotics. Examples of such agents are bone morphogenetic proteins (BMP's), basic fibroblast growth factor (bFGF), transforming growth factor (TGF-β), osteogenic growth peptide (OGP), etcetera. The molecular weight of said biologically active agents can vary from several tens of Daltons, to thousands of kilo-Daltons.
The calcium coating can be applied from a solution containing calcium and phosphate ions and one or more dissolved biologically active agents. The solution may be saturated or even super-saturated, but it may also be relatively diluted. This is an important advantage of the present invention since it allows the formation of a calcium phosphate coating from practically any solution containing calcium and phosphate ions and the biologically active agent. The pH range of the calcium phosphate containing solution may be between 4 and 10, preferentially between 6 and 8. The loading rate of the coating with the biologically active agent(s) can vary from several promilles to 60 percent (in weight with respect to the coating) and depends on the concentration in which it expresses its biological activity. This can be established by varying the concentration of the biologically active agent in the solution. The composite coating can be produced to degrade due to solution mediated or cell mediated processes, or can be prepared as a stable coating that shows little or no degradation.
The implantable device with the calcium phosphate and biologically active agent composite coating can give rise to the acceleration, enhancement or induction of bone formation when implanted when the biologically active agent is composed of an osteoinductive protein, or growth factors.
The invention also provides a process of producing a device as described above, comprising subjecting a solid material to a surface treatment until a surface roughness with the required average peak distance (Ra value) is obtained, and subsequently coating the device with calcium phosphate, optionally together with a biologically active substance.
The surface treatment may e.g. be a sanding or scoring treatment using conventional sandpaper, emery paper or glass paper having an appropriate fineness, e.g. grade 4000, optionally in the presence of water or other fluids. Diamond paste can also be used in the mechanical surface treatment. The surface roughening can further be obtained by powder blasting, using suitable fine powders. The surface roughness may also be obtained by a chemical treatment with a strong, preferably mineral, acid solution, optionally followed by oxidising agents such as hydrogen peroxide, optionally followed by neutralising steps.
The coated implantable devices according to the invention are intended for biomedical use, i.e. as a bone substitute, a joint prosthesis, a dental implant (prosthodontics), a maxillofacial implant, a vertebral surgery aid, a transcutaneous device (stoma and the like) and other medical or cosmetic devices. Such implants can serve as a bone replacement or bone reinforcement, but also as a means of fixing a device to a particular bone.
BRIEF DESCRIPTION OF THE DRAWINGS
Some illustrative embodiments of the invention, and the best mode contemplated of carrying out the invention, are described in detail below with reference to the accompanying drawings in which:--
FIG. 1--Ca concentration as a function of time
FIG. 2--P concentration as a function of time
FIG. 3--SEM photomicrographs of the metal surfaces after immersion in HBSS, FIG. 3A Ti-6Al-4V 1200; FIG. 3B: Ti-6Al-4V 4000; FIG. 3C: Ti-6Al-4V 1 μm; FIG 3D: Ti-Al-2.5Fe 1 μm; FIG. 3E: Ti-Al-2.5Fe 4000; FIG. 3F--stainless steel 1200
FIG. 4--AFM photomicrograph of a Ti-Al-2.5Fe 1 μm sample after immersion in HBSS. Increasing magnification from field 0 to 3. Scanning length from field 3: 1.5 μm.
FIG. 5--XRMA spectra acquired on a Ti-6Al-4V 4000 sample before (A) and after immersion (B) in HBSS.
FIG. 6--XRD spectra acquired on a non-immersed (A) and immersed (B) Ti-6Al-4V 1 μm surface
FIG. 7. Surface chemical composition (in atomic percent) of the "as received" coating.
FIG. 8. Depth profile of the coating, from coating to substrate.
FIG. 9. Scanning electron micrograph of the Ca-P coating (CP) precipitated on cp.Ti (Ti) after 16 hours of immersion in FCS with Pre-Ca.
FIG. 10. EDX spectra of the cp.Ti surfaces non-treated, treated and immersed in FCS with Pre-Ca for different hours. The shoulder of 0 kα peak is clearly seen after the treatment. The Ca and P contents increased with the increase of immersion time.
FIG. 11. XRD patterns of the cp.Ti surfaces after different hours of immersion in FCS with Pre-Ca. The counts of apatite peaks get higher with increased immersion times. Octa-calcium phosphate (OCP) starts to be formed at around 8 hours.
FIG. 12. Scanning electron micrograph of a dense Ca-P coating (CP) precipitated on cp.Ti from HBSS after 1 week of immersion with Pre-Ca. The layer between coating and substrate is the titanium oxide layer (OL), formed as a result of the treatment. Note the surface roughness of the implant on which the calcium phosphate coating has been formed.
FIG. 13. Thin-film XRD pattern of a dense Ca-P coating deposited by immersion in HBSS with Pre-Ca for 1 week.
FIG. 14. Scanning electron micrograph of porous tantalum (Ta) after 2 days immersion in FCS with Pre-Ca. The coating is formed throughout the porous material.
FIG. 15. EDX spectra of (a) non-treated, (b) treated, and (c) Pre-Ca treated, 2 day, FCS immersed porous tantalum (Ta) sample.
FIG. 16. IR spectra of BSA (a) and cp.Ti surfaces after 2 days of immersion in FCS containing 0.2% wt. BSA (b) and FCS only (c). The existence of four absorption bands of BSA in spectrum (b) indicates the co-precipitation of BSA with the biomimetic calcium phosphate coating.
FIG. 17. The amount of BSA released into PBS as a result of the immersion time.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
EXAMPLE 1
Materials and Methods
Ti-6Al-4V and Ti-Al-2.5Fe samples, 9.15 mm and 5 mm in diameter respectively and 1.5 mm thick, were used. They were ground flat in SiC papers, 1200, 4000 grit and diamond polished down to 1 μm. 316L stainless steel samples, ca. 80 mm 2 , were also ground in SiC papers, 1200 and 4000 grit. All samples were ultrasonically cleaned in 90% ethanol for 20 minutes followed by a 20-minute double rinse with distilled water and dried under a flow of hot air. The surface roughnesses were measured with a laser profilometer (Perkin Elmer). Table 1 shows the results of the following roughness parameters: R a --arithmetic mean of the roughness height, R z --mean peak-to-valley height and R max --maximum roughness depth.
After surface polishing and cleaning, all samples were immersed in HBSS at 37° C. for 14 days in separate polyethylene containers. To allow a constant supply of solution this was changed every 48 hours. Empty polyethylene containers were used as reference. A sample of each retrieved solution was stored in 2 mL Eppendorf™ at 4° C. Ca and P concentrations in these solutions were later determined by atomic absorption spectrometry (Varian SpectAA 300) and spectrophotometry (Vitalab 21, Vitalab Scientific), respectively. All the results are the average of at least three measurements.
All surfaces were observed, before and after immersion, by scanning electron microscopy (Philips SEM 525M) and analysed by XRMA (Voyager XRMA system, NORAN Instruments). XRD (Philips Thin-film XRD) was used to determine the structure of the precipitate layer, and AFM was used to observe its morphology on polished titanium alloys.
Results and discussion
FIG. 1 shows the Ca concentrations as a function of time. In the solutions that were in contact with the alloys, a monotonic decrease of the concentrations of Ca was detected. The same phenomenon was also observed for the reference HBSS. Until day 5 all curves have similar forms but after day 5 a higher decrease for the Ti-6Al-4V 1 μm samples is apparent which reaches 123±1.5 ppm. For both Ti-6Al-4V 4000 and Ti-Al-2.5Fe 1 μm samples the Ca concentration decreased more rapidly after day 7 attaining similar final Ca uptake concentrations, 61±2.3 and 63±1.5 ppm, respectively. All other surfaces exhibited Ca uptake values between 5 and 20 ppm.
FIG. 2 shows the P concentration as a function of time. The P uptake curves, like the Ca determinations, also showed a decrease as a function of time. The Ti-6Al-4V 4000 and 1 μm and the Ti-Al-2.5Fe 1 μm showed the highest P uptake; 29±2.1, 34±1.5 and 58.5±2.2 ppm, respectively. These findings suggest that a Ca and P rich precipitate is formed on all the surfaces from the HBSS. In fact, it was possible to see a white film deposited on the polyethylene that contacted the HBSS. Ti-Al-2.5Fe 4000 and 1200 showed the lowest Ca and P uptake. The decrease in both Ca and P was attributed to the growth of precipitate nuclei on the surfaces from the HBSS solution. Similar behaviour was found by Li et al. [4] after immersion of silica-gel and gel-derived titania in a Simulated Body Fluid; Radin et al. [2] also reported a decrease in Ca and P concentration in Simulated Physiological Solution after the immersion of ceramic particles.
FIG. 3 shows SEM photomicrographs of the metal surfaces after immersion in HBSS. Comparing the photographs on FIG. 3 it can be seen that the precipitate layer has a plate morphology on which "globules" and/or crystals grow. XRMA revealed a higher quantity of Ca and P on these particles than in the plate precipitate. It was possible to observe that the plates fractured on some of the surfaces, namely Ti-6Al-4V 1200 and 1 μm, Ti-Al-2.5Fe 1 μm and stainless steel 1200. The orientation of the fractures does not seem to depend on the orientation of the grinding flaws as it is possible to observe a random cracking of the plates. The precipitate formed on Ti-6Al-4V 4000 shows a continuous texture at the same magnification as the other observations. It was only possible to detect fractures on these surfaces, on the Ca and P rich layer, at magnifications higher than 2400×.
Li et al. [4] performed a series of experiments in which silica-gel was immersed in SBF. They suggest that the regulation of apatite growth is related to the Ca/P molar ratio of the fluids. Fugishiro et al. [1] obtained different HA morphologies by immersing Fe and Ti in Ca(EDTA) 2- --NaH 2 PO 4 solution. Various concentrations of Ca(EDTA) 2- had a direct effect on the morphology of the hydroxyapatite film.
The SEM observations suggest that the morphology of the precipitate layer seems to be dependent both on material and surface finishing as the immersion fluid was the same in all experiments.
FIG. 4 shows an AFM photomicrograph from a Ti-Al-2.5Fe 1 μm sample. It is apparent that the calcium phosphate rich coating is constituted by the agglomeration of spherical particles. Similar results were obtained for the Ti-6Al-4V 1 μm surfaces. It seems that the formation of the coating starts with heterogeneous precipitation of nuclei which gather with time until all the surface is covered.
It was noticeable that the Ti-Al-2.5Fe alloy surfaces 4000 and 1200 did not exhibit plate precipitates. It was only possible to observe small scattered deposits which had a similar morphology to crystals. XRMA acquisition on the flat-ground surfaces showed the presence of no Ca or P. The same acquisition on the crystals showed the presence of the alloy elements, Ca and P, associated with Si. Si seems to act as a nucleus for the precipitation and growth of the crystals. This impurity is probably due to the SiC emery paper used during the surface preparation. Either the degreasing and cleaning of the surface was not sufficient, on these surfaces, to remove the SiC or some SiC particles might be anchored in the alloy's surface as Ti-Al-2.5Fe is a softer material than the other alloys.
FIG. 5 exhibits XRMA spectra acquired in a Ti-6Al-4V 4000 sample before and after immersion in HBSS. One can observe the presence of the alloy elements as well as very well defined Ca and P peaks on the after-immersion spectra. The calculated Ca/P ratio is 1.56±0.03 which indicates that the precipitate probably consists mainly of tricalcium phosphate.
FIG. 6 shows XRD spectra acquired on non-immersed (A) and immersed (B) Ti-6Al-4V 1 μm surfaces. On the immersed samples one can observe the appearance of a well defined [002] peak and a broader peak which seems to be constituted by the junction of peaks [211] and [112] indicating the amorphous characteristics of the calcium phosphate. These results suggest that the precipitate layer has an amorphous apatite-like structure. Similar results were obtained for the Ti-Al-2.5Fe 1 μm samples.
The thickness of this layer was previously determined by SEM observations and is ca. 5 μm. Li et al. [4] monitored the development of hydroxyapatite deposits on gel-derived titania, as a function of time, after immersion in Simulated Body Fluid. In the initial stages they detected scattered precipitates all over the surface which increased in number and size until, eventually, all the surface was covered by a 10 μm coating. Ducheyne et al. [5] reported the formation of small deposits on titanium discs after 1-day exposure to a Simulated Physiological Solution. Two weeks of differential immersion were needed to produce an apatite layer with a thickness of 1 μm.
Hanawa et al. [3] also reported that apatite is naturally formed on titanium when titanium is immersed in a solution whose pH is similar to that of the bioliquid. They reported a thickness of 7 nm of the apatite film grown on Ti-6Al-4V which makes it impossible for this layer to exhibit any properties of calcium phosphate in this environment.
The present results indicate that a calcium phosphate with an apatite-like structure is naturally formed on the surfaces of polished titanium alloys. The thickness of this layer makes it a suitable surface for bone induction. Thicknesses of at least 1 μm are needed for the calcium phosphate to show its properties and cause bone induction [5].
Conclusions
The morphology of calcium phosphate precipitates depends on the metal substrate and its surface characteristics. It is possible to produce a naturally formed calcium phosphate coating by immersing metals such as titanium alloys and stainless steel in HBSS. Ti-6Al-4V 4000 seems to be the surface that is most favourable to produce a continuous and more adherent apatite-like coating capable of bone induction.
EXAMPLE 2
Determination of calcium phosphate depth distribution on a titanium alloy substrate using x-ray photoelectron spectroscopy
This example illustrates the determination of the depth distributions of selected elements in a calcium, phosphorous and oxygen-containing coating on a titanium alloy sample using depth profiling X-ray Photoelectron Spectroscopy (XPS or ESCA).
Materials
The samples were titanium alloy plates that had been surface treated according to the procedure of Example 1 to produce a calcium phosphate coating when immersed in calcification solutions or simulated body fluids. The samples were mounted directly to a standard XPS sample holder using a spring clip arrangement, with no pre-treatment. The outer coating surface was sufficiently electrically conducting that no electrostatic charging problems were encountered during X-ray irradiation or ion beam etching. All analyses were carried out using a Surface Science Instruments (SSI) M-probe operating at a base pressure of 3×10 -9 torr.
Methods
A survey spectrum was recorded from the "as received" surface, to determine the surface composition of the coating and therefore determine the elements to be monitored for the depth profile. The XPS depth profile was obtained by alternating argon ion sputtering (over an area of approx. 2×2 mm) and data acquisition (from an area of approx. 300 μm diameter centred in the etched crater). Elements analysed were carbon, oxygen, calcium, phosphorus, magnesium and titanium. Etch time per step was variable from 15 to 120 seconds per cycle and the etch rate was 3 nm/min using a total sputter time of 4470 seconds.
Results
The surface chemical composition (in atomic percent) of the "as received" coating was: carbon 44.9%, oxygen 33.8%, calcium 10.5%, phosphorous 8.8%, magnesium 2.0% and titanium 0% (FIG. 7). The depth profile of the coating revealed a gradual transition of calcium and phosphorous from the coating to the substrate, indicating the incorporation of these elements in the surface (oxide layer), and thus a chemical bonding between coating and substrate (FIG. 8). The calcium-oxygen-phosphorous layer (calcium phosphate) is estimated as being approximately 90 nm, assuming a sputter rate of 3 nm per minute as calibrated on a tantalum pentoxide film on tantalum, and that the "interface" is defined as the point where the titanium reaches approx. 50% of its final value. A thin layer of titanium oxide separates the calcium phosphate layer from the titanium alloy substrate. The interface between the calcium phosphate and titanium shows changes in the oxygen, phosphorous, calcium and titanium chemistries. The XPS peak binding energies of calcium and phosphorous decrease at the interface with the titanium where a titanium oxide layer is found. An interphase region is likely to occur at the boundary and oxygen has been depleted from the calcium phosphate to form titanium dioxide at the interface. Metallic titanium is present below the interphase region. Magnesium is detected at 2-4 atomic percent throughout the calcium phosphate layer and increases slightly in concentration with depth towards the interface with the titanium (oxide). Carbon is found in the bulk of the titanium.
Conclusion
The calcium phosphate layer that is formed on the titanium alloy substrate is chemically bound to the substrate via its surface oxide layer.
EXAMPLE 3
Preparation of biomimetic calcium phosphate coatings on metallic implants and co-precipitation of proteins
This examples illustrates a new two-step chemical treatment for preparing an implant with a specific surface roughness, resulting in a metallic surface that allows fast precipitation of biomimetic calcium phosphate (Ca-P) coatings from in vitro supersaturated calcification solutions (SCS). The present method has the following advantages over the conventional techniques for the coating application: due to the specific surface roughness, (i) the biomimetic coatings directly induced from SCS are expected to be chemically bound to metallic substrates and to show higher bone-bonding ability, (ii) the coatings can be produced onto complex-shaped and/or macro-porous implants, and (iii) it is a controllable and cost-effective way to acquire Ca-P coatings. To examine the potential of biomimetic calcium phosphate coatings as drug-release carriers, bovine serum albumin (BSA) and Ca-P coatings were co-precipitated on the treated titanium surfaces by immersion in the SCS containing 0.2% wt. BSA. The BSA/Ca-P coatings are expected to serve as a potential drug-release system.
Materials and Methods
A newly developed two-step chemical treatment was performed on the metallic implant materials, i.e. commercially pure titanium (cp.Ti), annealed Ti6Al4V and porous tantalum (Ta), to produce a specific surface roughness. During this treatment, two series of chemical reagents were used for titanium (cp.Ti and Ti6Al4V) and tantalum implant materials, respectively, that resulted in the presence of the specific surface roughness necessary for the preparation of the coating. For the former, the samples were treated with a mixture of HCl and H 2 SO 4 , followed by immersion in a NaOH solution. The porous tantalum samples were treated with a mixture of HCl, H 2 SO 4 and HF, followed by immersion in H 2 O 2 .
Two kinds of SCSs with different Ca and P concentrations, fast calcification solution (FCS) and commercial Hanks' balanced salt solution (HBSS), were used for preparing biomimetic Ca-P coatings. To promote the Ca-P nucleation on the metallic surfaces, a precalcification (Pre-Ca) procedure was performed on half the treated samples before immersion in the SCS. The Pre-Ca was carried out by incubating the samples in 0.5N Na 2 HPO 4 overnight and then transferring them into saturated Ca(OH) 2 for 5 h. The solution for co-precipitation of BSA and Ca-P coatings was prepared by dissolving 0.2% wt. BSA into FCS. The untreated metals were also immersed as controls. The FCS solution volume used for immersion was 15 ml per cm 2 of sample surface area. The samples were immersed in sealed polystyrene vials at 37° C. in a calibrated water-bath. Scanning electron microscopy (SEM) together with energy disperse X-ray (EDX) analyses, X-ray diffraction (XRD) and infrared (IR) spectrophotometry were used to characterize the obtained Ca-P coatings.
Results
The biomimetic Ca-P coatings were fast precipitated on the treated cp.Ti and Ti6Al4V samples by immersion in both FCS and HBSS no matter whether the Pre-Ca procedure was performed or not. But the Pre-Ca treatments could dramatically speed-up the precipitation rate of the Ca-P coatings as listed in table 2.
FIG. 9 shows that a biomimetic Ca-P coating, approximately 16 μm thick, was formed on treated cp.Ti after 16 hours of immersion in FCS with Pre-Ca. The coating got thicker with immersion time as indicated by EDX (FIG. 10) and XRD (FIG. 11) results. The precipitation rate of the Ca-P coating in HBSS is slower than that in FCS. But the coating from HBSS (FIG. 12) was much denser than that from FCS. The coating from HBSS mainly consisted of apatite (FIG. 13). Biomimetic Ca-P coatings could also be precipitated on porous Ta samples (FIG. 14) after the treatment. The surface content change of the sample was detected by EDX as shown in FIG. 15. It is noteworthy that no precipitation was observed on any untreated samples after 2 weeks of immersion in FCS or HBSS, even with Pre-Ca. The formation of a specific titanium and tantalum oxide layer after their treatments is probably the main reason for the inductive precipitation of Ca-P coatings by means of in vitro immersion in SCS. The procedure of the treatments for titanium implants and tantalum could not be exchanged, otherwise no Ca-P coating was acquired. It is interesting to find that the results of co-precipitation of BSA and Ca-P coating were positive. The IR analyses (FIG. 16) indicated the obvious existence of BSA in the Ca-P coating on cp.Ti after immersion in FCS. Release experiments of BSA from BSA/Ca-P coatings are decribed in Example 4.
Conclusions
The results of this biomimetic calcium phosphate coating and protein co-precipitation study have shown that:--
The newly developed two-step chemical treatment is an effective method to prepare bioactive metallic implant surfaces allowing fast precipitation of adherent biomimetic Ca-P coatings by in vitro immersion in SCS. The chemical reagents needed for the treatment of titanium implant materials and tantalum are different from each other.
The precipitation of Ca-P coatings could be dramatically accelerated by means of pre-calcifying the treated samples before the immersions.
The precipitation rate and composition of the Ca-P coatings can be adjusted by controlling the components of the SCSs (FCS or HBSS) for immersion.
Some proteins like BSA can be co-precipitated with biomimetic Ca-P coatings. Such composite coatings, with other--bioactive-adsorbed organic molecules, are expected to be able to serve as potential drug-release systems.
EXAMPLE 4
Release of Bovine Serum Albumin (BSA) from calcium phosphate (Ca-P)/BSA coatings on surface-treated commercially pure titanium
Co-precipitation of BSA
Commercially rectangular blocks in size 10×10×2 mm were used as substrates. The two-step treatment and pre-calcification were performed on the metals as described in example 3. The supersaturated calcification solution used for immersion was prepared by dissolving 0.2% BSA into 0.8 ACS. All the samples were immersed in a 37° C. water-bath for two days.
Release experiments
The BSA content in solution was measured by means of the total organic carbon (TOC) method. Four blocks with Ca-P/BSA coatings were completely dissolved by 40 ml of 0.5 N HCl solution to detect the concentration of BSA in Ca-P/BSA coating. Four samples were immersed in 20 ml of 0.01 M PBS at pH 4 (adjusted using HCl) at 37° C. At certain intervals of time, 5 ml of the immersion solution was taken for TOC measurement at certain interval and then refilled to 20 ml with new PBS at pH 4 every time.
Results
BSA concentration in Ca-P/BSA coating
The Ca-P/BSA coatings on five samples were peeled off completely and then weighed using a balance. The weight of the Ca-P/BSA coating on each sample can be estimated to be a mean of 1.5 mg. The carbon concentration in the coating was calculated to be 15% and the BSA concentration was about 30% because the carbon concentration in BSA was detected to be around 50% by the same method.
BSA Release curve
The amount of BSA released into PBS was plotted against the immersion time as shown in FIG. 17. It is indicated that under these experimental conditions, BSA was released relatively fast in the first two days of the immersion and then the release rate levelled off somewhat. The main reason could be that the PBS was very acidic (pH=4) at the beginning stage and the coating was dissolved very fast. After certain time of immersion the pH became higher. The pH values of PBS at the 7th and 14th were measured to be 5.628 and 5.584, respectively. Relating these results to the actual in vivo situation, where the pH value will be around 7, these results indicate that a gradual, slow release system is obtained, assuming that the 48 hour incubation in an acidic medium is comparable to several weeks, if not months implantation in an organism.
Conclusion
This experiment shows that proteins such as BSA can be co-precipitated in a calcium phosphate coating and can subsequently be released from the coating. Although BSA was used to examine the feasibility of this technique, it is clear that a Ca-P/biologically active agent composite coating can be used as sort of a drug delivery system and has therefore potential in the medical field.
TABLE 1______________________________________Surface roughness measurements results Surface finish R.sub.a (μm) R.sub.Z (μm) R.sub.max (μm)______________________________________Ti--6Al--4V 1200 grit 0.47 ± 0.01 3.74 ± 0.04 5.13 ± 0.08 Ti--6Al--4V 4000 grit 0.24 ± 0.03 1.91 ± 0.31 2.46 ± 0.54 Ti--6Al--4V 1 μm 0.03 ± 0.00 0.35 ± 0.05 0.48 ± 0.03 Ti--Al--2.5Fe 1200 grit 0.42 ± 0.03 2.97 ± 0.35 3.47 ± 0.48 Ti--Al--2.5Fe 4000 grit 0.23 ± 0.01 1.97 ± 0.18 2.46 ± 0.34 Ti--Al--2.5Fe 1 μm 0.04 ± 0.01 0.28 ± 0.11 0.36 ± 0.19 316 L 1200 grit 0.3 ± 0.06 2.32 ± 0.47 2.96 ± 0.03 316 L 4000 grit 0.04 ± 0.01 0.35 ± 0.1 0.46 ± 0.1______________________________________
TABLE 2______________________________________List of Ca.sup.2+ and HPO.sub.4 .sup.2- concentrations, precipitationrate and composition of Ca--P coatings on cp.Ti and Ti6Al4V. FCS HBSS______________________________________Concentration (mM) Ca.sup.2+ 3.0 1.26 HPO.sub.4 .sup.2- 1.87 0.78 Precipitation rate of No Pre-Ca 0.5 μm/hr 1 μm/wk coating Pre-Ca 1 μm/hr 3 μm/wk Composition of coating apatite, OCP apatite______________________________________
Literature references
1. Y. Fujishiro, T. Sato and A. Okuwaki, "Coating of hydroxyapatite on metal plates using thermal dissociation of calcium -EDTA chelate in phosphate solutions under hydrothermal conditions", J. Mater. Sc: Mater in Med, 6, pp. 172-176, 1995
2. S. R. Radin and P. Ducheyne, J. Biom. Mater. Res., 27, pp. 35, 1993
3. T. Hanawa, "Titanium and its oxide film: a substrate for forming apatite", in Proc. of the Bone Biomaterial Interface Workshop, Toronto, Dec. 1990, J. E. Davies ed., Univ. Toronto Press, pp. 49-61, 1991
4. Li, P, PhD. thesis Leiden University (1993)
5. P. Ducheyne, S. Radin and K. Ishikawa, "The rate of calcium phosphate precipitation on metal and ceramics, and the relationship to bioactivity", in Bone Bonding Biomaterials, P. Ducheyne, T. Kokubo & C. A. van Blitterswijk (eds), Reed Heathcare Communications, pp. 213-218, 1992. | The invention provides an implantable device coated with a layer of calcium phosphate and optionally one or more biologically active substances such as growth factors, lipids, (lipo)polysaccharides, hormones, proteins, antibiotics or cytostatics. The device can be obtained by a nanotechnology process comprising subjecting a substrate to a surface treatment until a surface roughness with an average peak distance (Ra value) between 10 and 1,000 nm and subjecting the roughened surface to precipitation of calcium phosphate from a solution containing calcium and phosphate ions with optional coprecipitation of the biologically active substance. | 0 |
TECHNICAL FIELD OF THE INVENTION
The present invention relates to an improved silk screen frame, and more particularly, this invention relates to a retensionable screen frame that permits the user to quickly and easily substitute one screen for another, and properly tension each screen for effective, high-quality printing.
BACKGROUND OF THE INVENTION
Serigraphy, more commonly known as screen printing, is one of the most common and versatile printing processes in use today. Screen printing can be applied to a wide variety of surfaces including paper, cardboard, glass, wood, plastic, posters, bottles, electronic circuits, etc., and to an equally wide variety of shapes.
The screen printing process consists generally of forcing an ink, by pressure applied via a squeegee, through the mesh of a screen stretched on a frame and onto the object to which the desired image is intended to be transferred.
It is generally accepted in the screen-printing trade that the quality of a printed image is directly related to the tension of the printing screen. Particularly when printing detailed designs or multicolored images, it is imperative that the printing screen be secured in a very taut condition in order to ensure that the fine details or multitude of colors are accurately transferred onto the intended object.
Because a particular screen pattern may be in demand for an extended period of time, the printer may desire to store the screen so that the same pattern may be reproduced at some future time without the necessity of replacing the printing screen. Historically, the difficulty with removing and replacing the stretched screen meant that the screen was stored on the frame in a stretched condition. Storing the screen in this manner not only necessitated the need for an inventory of frames, but also increased the problem associated with the deterioration of the image produced by the screen, since screens under tension tend to relax somewhat with time.
Moreover, because the desired image may require the use of a number of different screens, an inventory of screens is needed unless the printer can quickly and easily substitute one screen for another in the particular frame.
To this end, a wide variety of solutions have been formulated and are generally represented throughout the prior art as adjustable tension silk screen frames employing floating bars or tension rollers that may be adjusted in some manner to exert a greater force on the silk screen secured thereto.
SUMMARY OF THE INVENTION
Heretofore invented and disclosed herein is an improved silk screen frame for tensioning a panel of screen material and for providing a means of quickly and easily integrating a screen panel with the frame or removing the panel therefrom.
The improved frame of the present invention employs two rotatable members adapted to grip a longitudinal strip to which is secured the screen panel material. The rotatable members are designed to exert a rotational force on the longitudinal strips in an off-center position relative to the member's axis of rotation. Rotation of the screen tensioning members in turn imparts a force on the attached screen panel material such that the material is stretched in a taut condition for effective use in the printing process. The rotated screen tensioning members are held in their rotated position by a locking mechanism that may be engaged or disengaged with the operator's fingers.
Other objects, advantages, and features of the present invention will be apparent to the reader from the foregoing and the appended claims, and as the ensuing detailed description and discussion of the invention proceeds in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE VARIOUS VIEWS OF THE DRAWINGS
In the drawings, like reference numerals refer to like parts throughout the various views unless indicate otherwise, and wherein:
FIG. 1 is a perspective view of a self-tensioning silk screen frame embodying the principles of the present invention, and wherein a silk screen panel is secured to the frame and the screen tensioning members have been rotated and locked into position;
FIG. 2 is a perspective view illustrating the self-tensioning silk screen frame of FIG. 1 and a silkscreen panel adapted to be secured to the frame;
FIG. 3 is a partial, enlarged perspective view of the self-tensioning silk screen frame of FIG. 2;
FIG. 4 is an enlarged cross-sectional view of a portion of the self-tensioning silk screen frame taken substantially along lines 4 — 4 of FIG. 3, illustrating the rotatable screen-tensioning member and the locking mechanism in a disengaged position; and
FIG. 5 is an enlarged cross-sectional view like FIG. 4 illustrating an engaged screen-tensioning member and locking mechanism.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the drawings, FIG. 1 depicts a self-tensioning silk screen frame of the present invention with a tensioned silk screen panel affixed thereto generally at 10 . The assembled silk screen panel 11 (FIGS. 1 and 2) is adapted to be secured and tensioned by the self-tensioning frame 14 thereby permitting the user to quickly and easily substitute one screen panel for another in the same frame.
Referring now primarily to FIGS. 2 and 3, self-tensioning frame 14 is composed of a first longitudinally extending rail 36 and a second longitudinally extending rail 38 interconnected by a pair of end rails 40 , 42 affixed at right angles thereto at each end of rails 36 , 38 . Each end rail 40 , 42 may be designed to secure frame 14 to a screen printing machine.
Self-tensioning frame 14 further comprises a pair of screen-tensioning holding members 44 , 46 which, along with first and second longitudinally extending rails 36 , 38 , are adapted to receive longitudinal strips 16 , 18 , 20 and 22 of assembled silk screen panel 11 . Screen-tensioning members 44 , 46 are positioned perpendicular to rails 36 , 38 and between end rails 40 , 42 and are connected to rails 36 , 38 via a pin 48 positioned therebetween which permits screen-tensioning members 44 , 46 to freely rotate about axis 50 for tensioning the silk screen frame panel material 12 . Strips 20 , 22 are herein also referred to as end members.
Rotatable lock members, e.g. finger locks 52 , 54 are positioned adjacent to screen tensioning members 44 , 46 along second longitudinally extending rail 38 such that they may be rotated into a position to engage the respective screen-tensioning member and thereby lock said screen-tensioning member into a position wherein the silk screen panel material 12 is stretched to a taut condition.
A variety of fabric types are available for use in the screen panel 12 , each of which will create a different overall impression of the particular print. Organdy and silk are the two most basic fabrics and were traditionally used in this form of printing. Monofilament nylon fabric and polyester are stronger and have replaced the traditional “silk” screen for many contemporary applications of this printing process. In addition, screens made from stainless steel and nickel-plated polyester may be used to achieve a grainier texture in the ink, but are more easily ripped or creased than are the nylon or polyester screens.
The screen panel 11 may be obtained in a pre-assembled form with four longitudinal strips 16 , 18 , 20 , and 22 affixed to the edges of the screen material and adapted for use in the self-tensioning frame 14 , or the user may assemble the screen panel individually.
Each longitudinal strip is composed of a three-sided channel member 24 , and a block 32 which is adapted to be received in channel member 24 and thereby secure an edge of the silk screen panel 12 to the particular longitudinal strip with which it is associated. The bottom side 26 of channel member 24 extends a particular length beyond a first vertical side 28 of channel member 24 to form extension 34 , while remaining flush with a second vertical side 30 (see FIGS. 4 and 5 ). This configuration is designed to securely fit within the first and second longitudinally extending rails 36 , 38 and screen-tensioning members 44 , 46 as illustrated in FIGS. 4 and 5.
Having observed the details of the various components of the self-tensioning frame and the adapted silk screen panel assembly, attention may now be given to the placement of the screen panel 11 into the self-tensioning frame 14 , and the tensioning of the silk screen panel material 12 .
Referring now primarily to FIGS. 2, 4 , and 5 , the assembled silk screen panel 11 may be connected to the self-tensioning frame 14 by first inserting either one of side longitudinal strips 16 , 18 into the corresponding first or second longitudinally extending rail 36 , 38 . Extension 34 is inserted first while the user holds the particular longitudinal strip at an angle. After having placed a first longitudinal strip into an associated longitudinally extending rail, the user then inserts the other strip in the same manner beginning at one end of the corresponding rail and moving toward the opposite end. The longitudinal strips are flexible and will bend as pressure is applied to them so that they may be snapped into place.
The next step in connecting the assemble silk screen panel 11 to frame 14 is similar to that just described, except that screen-tensioning members 44 , 46 may be rotated in a direction toward screen panel 11 (opposite from the tensioning direction illustrated by arrow 56 in FIG. 4) in order to more easily insert the corresponding longitudinal strips or end members 20 , 22 . With these strips in position, screen-tensioning members 44 , 46 are then rotated downwardly as indicated by the arrow referenced as numeral 56 in FIG. 4 . The off-center position of the pin 48 (illustrated by broken lines in FIGS. 4 and 5 ), about which each screen-tensioning member rotates, provides increased leverage for tensioning the silk screen panel material 12 .
Each screen-tensioning member is rotated to a position, as illustrated in FIG. 5, whereby the corresponding finger lock 52 , or 54 can be rotated in an upwardly direction, as indicated by the arrow referenced as numeral 58 in FIG. 4, to engage the screen-tensioning member and thereby hold said member in a tensioned position so that the silk screen panel material 12 remains taut.
Removal of the assembled screen panel 11 from the self-tensioning frame 14 is effected by disengaging the finger locks 52 , 54 from screen-tensioning members 44 , 46 , rotating said members in an upwardly direction opposite that of arrow 56 (see FIG. 4 ), and removing longitudinal strips 20 , 22 therefrom. Finally, either longitudinal strip 16 , or 18 may be removed by pushing the strip out of its rail via a specially adapted push tool (not shown) or similar instrument or device which is capable of being inserted through one of a plurality of small holes machined into the underside of each longitudinally extending rail 36 , 38 . Once one side longitudinal strip has been removed, the other can be easily slipped out of its position.
While the invention is described and illustrated here in the context of a particular embodiment, the invention may be embodied in many forms without departing from the spirit or essential characteristics of the invention. The present embodiment is therefore to be considered in all respects as illustrative and not restrictive. The scope of the invention is indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are intended to be embraced therein. | An improved silk screen frame for tensioning a panel of screen material via the rotation of a pair of screen-tensioning members adapted to grip a flexible strip secured to the edge of the screen material in an off-center position with respect to the axis of rotation of the tensioning member. Rotation of the screen-tensioning members imparts a force which thereby stretches the screen panel material to a taut condition, and places each tensioning member in position to be engaged by a pair of adjacent rotatable finger locks which maintain the screen-tensioning members in their rotated state. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
The present application is a continuation application from and claims priority to U.S. application Ser. No. 11/901,006 filed Sep. 14, 2007 now U.S. Pat. No. 8,075,602 which is a continuation of U.S. application Ser. No. 10/676,062 filed Oct. 1, 2003 now U.S. Pat. No. 7,273,481 which claims the benefit under 35 U.S.C. 119(e) of U.S. Provisional Application Ser. No. 60/421,819 filed Oct. 28, 2002. These applications are incorporated herein by reference in their entirety for all purposes.
FIELD OF THE INVENTION
One embodiment of the present invention is directed to a bone plate assembly that includes a bone plate, bone screw(s) received in aperture(s) in the bone plate, and screw fixation member(s). The screw fixation member(s) may, alone or in conjunction with the bone plate, fix the bone screw(s) in place when such bone screw(s) are inserted in the aperture(s) in the bone plate. In one example (which example is intended to be illustrative and not restrictive) when the bone screw(s) have been received by the bone plate and inserted into bone and/or tissue, the bone plate assembly can be used to fuse anatomical structures together (such as adjoining bones) and/or to heal a fracture in bone.
BACKGROUND OF THE INVENTION
Bone plate assemblies are employed in order to fuse bones or to repair fractures in bones. For example, U.S. Pat. No. 6,413,259, incorporated herein by reference, discloses embodiments for bone plates.
SUMMARY OF THE INVENTION
In one embodiment, the present invention is directed to an arrangement for fixing, in a vertebrate, a screw inserted through a plate. In one example (which example is intended to be illustrative and not restrictive) a bone plate assembly according to the present invention may have at least two bone screws, each received in at least two apertures in the bone plate. The bone plate assembly may also have screw fixation members provided for the bone screws. When the bone screws are inserted through the apertures in the bone plate, and installed in bone and/or tissue at a preselected angle, the presence of the screw fixation members may aid in fixing the bone screws in place. Each bone screw may have a head, sized so that the head does not pass through the bone plate, and a shank provided with threads (e.g., which threads may extend substantially to the tip of the bone screw). In yet another embodiment, the bone plate assembly may be provided with washers (e.g., for each screw employed in the assembly) that reside in the apertures in the bone plate. In yet another embodiment, each washer may be provided with an aperture in which the bone screw is received, when the bone screw is inserted into the bone plate. In yet another embodiment, after the bone screw is received in the aperture in the washer, and inserted in bone and/or tissue, the washer may be actuated to fix the angle at which the bone screw has been inserted (e.g., relative to the bone plate).
In a further embodiment, the washer may be provided with a sidewall, which sidewall defines the aperture though which the bone screw extends. The sidewall may have a thickness that varies with respect to the position along the washer's perimeter. In one embodiment, the washer may be provided with a first sidewall region on its perimeter that is relatively thicker than a second sidewall region.
In yet another embodiment, one or more apertures of the bone plate may be provided with a recess that is cut into the sidewall that defines the aperture in the bone plate. The depth to which the recess is cut may vary around the perimeter of the recess. In yet another embodiment, a first region of the recess may have a depth that is greater than a second region of the recess. In yet another embodiment, a washer may reside partially or fully within the recess.
In yet another embodiment, the washer may reside in the recess, aligned so that the first relatively thicker sidewall region of the washer is positioned within the first relatively deeper region of the recess, and the second relatively thinner sidewall region of the washer is positioned in the second relatively shallower region of the recess. After the bone screw is received in the aperture in the washer, and inserted in bone and/or tissue, the washer may be actuated to fix the angle at which the bone screw has been inserted (e.g., relative to the bone plate). The bone screw may be fixed by rotating the washer, thereby moving the first relatively thicker sidewall region of the washer into the second relatively shallower region of the recess, which effectively causes the first relatively thicker sidewall region to extend laterally, into the aperture in the bone plate, where the washer impinges against the bone screw (e.g., the head of the bone screw), applying a force thereto which wedges the bone screw between the washer and the opposite sidewall of the aperture. This operation thus fixes the bone screw in place, retaining it at a particular angle (e.g., the at which the bone screw is inserted).
In yet another embodiment, the present invention may allow for the bone screw(s) to toggle (i.e., move within a confined range) after being installed through the bone plate and being held by the washer. This can be arranged, for example, by actuating the washer to an intermediate position, which allows the screw to toggle.
In yet a further embodiment of the present invention, a bone plate assembly may be provided in which the bone plate assembly may include a bone plate, bone screw(s) received in aperture(s) in the bone plate, and washer(s). The washer(s) may, alone or in conjunction with the bone plate, fix the bone screw(s) in place when the bone screw(s) are inserted in the aperture(s) in the bone plate. Here the washer of the bone plate assembly may be adapted to reside over the bone screw and be joined therewith in a locking arrangement. In yet another embodiment, the head of the bone screw may be provided with a number of tangs, spaced apart from each other, mounted on the upper surface of the head. The tangs may be mounted upon wedges, which wedges extend up from the head of the screw. The wedges may be not as wide as the tangs, and may be narrowed by an undercut.
In a further embodiment, the washer may be provided with a washer body through which a central opening is provided. A number of lobes may be provided on the periphery of the central opening. In one example (which example is intended to be illustrative and not restrictive) three lobes are provided (it should be understood that other arrangements are, of course, possible). In yet another embodiment, the washer may also be provided with splays which are provided on the exterior of the washer. The splays may be separated from the remainder of the washer body by tracks, which tracks extend into the washer body.
In yet another embodiment, the washer and the wedges and/or tangs may be designed to engage with each other in a locking arrangement. Relative to each other, the wedges may be slightly wider than the width of at least a portion of the track.
In yet another embodiment, when the bone plate assembly is implanted in a person, the bone plate may be positioned on the bone, tissue and bone, or tissue to be joined by the bone plate. The bone screw may be inserted through the aperture in the bone plate and installed in bone and/or tissue by known techniques. The bone screw may be installed at a preselected angle, relative to the bone plate. To fix the screw at the angle at which it is installed, the washer may be placed over the head of the bone screw, and positioned so that the wedges are poised to enter the track portions. In yet another embodiment of the invention, a tool may be provided, the tool having a head adapted to fit within the central washer opening, which tool then engages with the central washer opening, to rotate the washer. The wedges may thereby enter the track portions. Since the wedges maybe wider than at least a portion of the tracks, the splays may be forced outward when the wedges enter the intermediate track portion(s). In this arrangement, the splays may be forced into an abutting arrangement with the sidewalls of the aperture in which the bone screw and washer reside. The abutting arrangement between the splays and the sidewalls of the aperture may fix the bone screw at a particular angle (e.g., the angle at which the bone screw was installed).
In yet another embodiment, a bone plate assembly may be generally provided with a bone plate, at least two bone screws received in apertures in the bone plate, and moveable doors that fix the bone screws in place when the bone screws are inserted in the apertures in the bone plate. The bone screw employed in this embodiment may have a head sized so that the head does not pass through the bone plate. The bone screw may further have a shank provided with threads (e.g., which threads may that extend to the tip of the bone screw). In another embodiment, the bone plate assembly may be provided with a cut out portion on its upper surface, to which the doors are slidably mounted. The cut out portion may be positioned adjacent the bone screw apertures, at a portion of the edge thereof.
In yet another embodiment, the sliding doors may be dimensioned to substantially not cover the apertures in the bone plate in a first position (in which first position the bone screws may be installed), yet slide and at least partially cover the apertures once the screws have been inserted (to thereby fix the bone screws in place). In yet another embodiment, the doors may be positioned in the cut out portion on the upper surface of the bone plate, and may be retained therein by a lip provided at the upper sidewall of the cut out portion. In yet another embodiment, the cut out portion may be sized slightly greater than the sliding doors. Thus, when a bone screw is positioned in the aperture of the bone plate, the sliding door can be slid in the direction of the hole, in order to cover the bone screw (and to fix the bone screw in place).
In yet another embodiment, a bone screw may be provided with a number of splays positioned around the periphery of the head of the bone screw. The splays may be mounted upon wedges that extend up from the head of the screw. In one embodiment, there is a space between at least a portion of the splay and the head of the bone screw. When the screw is installed in an aperture in the bone plate at a preselected angle, a tool may be employed to force the splays outward, into a locking and abutting arrangement with the sidewalls of the bone plate aperture. In yet another embodiment, a cam may be positioned in the interior space defined by the splays. When the cam is rotated, the cam may force the splays outward, into a locking and abutting arrangement with the sidewalls of the bone plate aperture. The presence of the cam may further provide a counterforce, which counterforce may maintain the splays in the locking and abutting arrangement.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of an embodiment of the present invention;
FIG. 2 is a top plan view of the embodiment of FIG. 1 ;
FIG. 3A is a cross sectional view of the embodiment of FIG. 1 ;
FIG. 3B is a cross sectional view showing in greater detail the circled portion of FIG. 3A ;
FIG. 4A is a cross sectional view of the bone plate of the embodiment of FIG. 1 (shown across the long side);
FIG. 4B is a cross sectional view showing in greater detail the circled portion of FIG. 4A ;
FIG. 5 is a side elevational view of a screw employed in the embodiment of FIG. 1 ;
FIG. 6 is a cross sectional view of the bone plate of the embodiment of FIG. 1 (shown across the short side);
FIG. 7A is a top plan view of a washer used in an embodiment of the present invention;
FIG. 7B is a perspective view of the washer of FIG. 7A ;
FIG. 8A is a cross-sectional view of a tool used in conjunction with the embodiment of FIG. 1 ;
FIG. 8B is a perspective view of a portion of the tool of FIG. 8A ;
FIG. 9 is a cross sectional view of the washer of FIG. 7A ;
FIG. 10 is a partially sectioned perspective view of a portion of the embodiment of FIG. 1 ;
FIG. 11 is a partially sectioned view showing an the undercut or recess in connection with the embodiment of FIG. 1 ;
FIG. 12A depicts the washer of FIG. 7A in the open or unactuated position;
FIG. 12B depicts the washer of FIG. 7A in the closed or actuated position;
FIG. 13 is a partially sectioned perspective view of another embodiment of the present invention;
FIG. 14 is a perspective view of a washer and screw of the embodiment of FIG. 13 ;
FIG. 15 is a perspective view of the washer of the embodiment of FIG. 13 ;
FIG. 16 is a top plan view showing in greater detail an aspect of the washer of the embodiment of FIG. 13 ;
FIG. 17 is a top plan view of the screw of the embodiment of FIG. 13 ;
FIG. 18 is a side elevational view of the screw of the embodiment of FIG. 13 ;
FIG. 19 is a perspective view of the screw of the embodiment of FIG. 13 ;
FIG. 20 is a cross sectional view of the washer and screw of the embodiment of FIG. 13 ;
FIG. 21 is a perspective view of the embodiment of FIG. 13 , where the washer has been opened;
FIG. 22A is a top plan view of another embodiment of the present invention;
FIG. 22B is a perspective view of the embodiment of FIG. 22A ;
FIG. 22C is cross sectional view of the embodiment of FIG. 22A ;
FIG. 23 is a perspective view of another embodiment of the present invention;
FIG. 24 is top plan view of the embodiment of FIG. 23 ;
FIG. 25 is a cross sectional view of the embodiment of FIG. 23 ;
FIG. 26 is a side elevational view of the embodiment of FIG. 23 ;
FIG. 27 is a perspective view of the embodiment of FIG. 23 ;
FIG. 28 depicts another embodiment of the present invention;
FIG. 29 depicts, in a perspective view, another embodiment in which a double lobed washer is employed;
FIG. 30 depicts, in a perspective view, another embodiment in which a tri-lobed washer is employed; and
FIG. 31 depicts, in a perspective view, a split-ring washer according to another embodiment of the present invention.
Among those benefits and improvements that have been disclosed, other objects and advantages of this invention will become apparent from the following description taken in conjunction with the accompanying figures. The figures constitute a part of this specification and include illustrative embodiments of the present invention and illustrate various objects and features thereof.
DETAILED DESCRIPTION OF THE INVENTION
Detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely illustrative of the invention that may be embodied in various forms. In addition, each of the examples given in connection with the various embodiments of the invention are intended to be illustrative, and not restrictive. Further, the figures are not necessarily to scale, some features may be exaggerated to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present invention.
Referring now generally to FIGS. 1-3 , it is seen that a bone plate assembly 10 is provided with bone plate 12 , bone screw(s) 14 received in aperture(s) 16 in the bone plate 12 , and washer(s) 18 that, alone or in conjunction with the bone plate 12 , fix the bone screw(s) 14 in place (e.g., when the bone screw(s) 14 are inserted in the aperture(s) 16 in the bone plate). Each bone screw 14 has a head 20 sized so that it does not pass through the bone plate 12 . Further, each bone screw 14 has a shank 22 provided with threads 24 (e.g., which threads 24 may extend to tip 26 ). The head 20 of bone screw 14 is further provided with an opening 15 that is dimensioned to mate with the head of a tool, so that the bone screw 14 can be installed in tissue and/or bone. In one embodiment, the head 20 of the bone screw 14 may be provided with grooves 21 (see, e.g., FIGS. 3B and 5 ). Bone plate assembly 10 is also provided with washer(s) 18 . Each washer 18 has an opening 19 though which a bone screw is received (see, e.g., FIG. 3B ).
Referring now generally to FIG. 3B , it is seen that each washer 18 is provided with a sidewall 28 (which sidewall 28 defines the aperture 19 though which the bone screw extends) and that the sidewall 28 has a varying thickness with respect to position along the washer's perimeter (see also, for example, FIG. 7A ). In one embodiment, the washer 18 is provided with a first sidewall region 28 a that is relatively thicker than a second sidewall region 28 b (i.e., in this embodiment dimension “a” is greater than dimension “b” (see FIG. 3B )).
Referring now to FIGS. 7A , 7 B, 8 A, 8 B, 9 and 31 , it is seen that in these examples (which examples are intended to be illustrative and not restrictive) the washer may be provided with a series of splines 31 that are spaced at intervals around the inside perimeter of the washer (the washer of FIG. 31 is similar to the washers of FIGS. 7A , 7 B, 8 A, 8 B and 9 , with the exception that the washer of FIG. 31 is a split-ring washer). As depicted in the Figures, the splines may be solid members (which may extend from the perimeter of the washer towards the aperture 19 of the washer), and may be spaced apart by openings 32 . The arrangement of the splines 31 and openings 32 may be complementary to a spline 41 and opening 42 arrangement provided on the head 44 of a tool 40 (see, e.g., FIGS. 8A and 8B ). In operation, when the splines of the washer are engaged with the spaces of the tool, and vice versa, the application of a rotational force to the tool is translated to the washer, thereby turning the washer. The tool may, for example, be operated manually by handle 43 , or by drill, in which case drill bit receiving channel 45 may be provided.
Referring once again to FIG. 7A , it is seen that in one example (which example is intended to be illustrative and not restrictive) the washer 18 may be provided with a detent 50 positioned on the outside of the sidewall 28 . In this example, the sidewall of the bone plate may be provided with an indentation 52 , which is sized to receive the detent provided on the washer 18 (see, e.g., FIG. 10 ). When the bone plate and washer are assembled, the washer can be aligned so that the detent 50 resides in the indentation 52 . This arrangement may inhibit unwanted rotation of the washer (e.g., until the time to actuate it, as described below).
As seen in FIG. 6 , bone plate 12 may be constructed with an arcuate shape. Of course, plates with other shapes and/or dimensions are possible.
In another example (which example is intended to be illustrative and not restrictive) bone plate 12 may be provided with one or more recesses 30 , positioned within the bone plate 12 (see FIGS. 4A , 4 B, 5 and 6 ). Each recess 30 may extend around the perimeter of each aperture 16 in the bone plate 12 . Each recess 30 may be cut into the sidewall of the apertures in the bone plate 12 . The lateral depth to which each recess 30 is cut may vary depending on the location on the perimeter of the recess 30 . In one example (which example is intended to be illustrative and not restrictive), a first region 30 a of the recess 30 may have a lateral depth that is greater than the lateral depth of a second region 30 b of the recess 30 (i.e., in this embodiment dimension “a” is greater than dimension “b” (see FIG. 4B )). In another example (which example is intended to be illustrative and not restrictive), the lower portion of aperture 16 may be provided with a tapered sidewall 16 a against which the bottom portion of the screw head 20 may rest (see FIG. 4B ). The washer 18 may reside within the recess, aligned so that the first relatively thicker sidewall region 28 a of the washer 18 is positioned within the first relatively deeper region 30 a of the recess, and the second relatively thinner sidewall region 28 b of the washer 18 is positioned in the second relatively shallower region 30 b of the recess. In one embodiment, when the bone screw 14 is inserted into the aperture 16 of the bone plate 12 , the washer 18 is substantially coplanar with the head 20 of the bone screw 14 .
Referring now to FIG. 11 , certain characteristics of the recess 30 as seen from the bottom of the bone plate 12 are shown. As shown here, the lateral depth of the second recess region 30 b may be minimal (and may not be present at all) and a lateral depth may be provided essentially only in the first recess region 30 a.
Referring now generally to FIGS. 12A and 12B , it is seen that when the bone plate assembly is implanted in a person, the bone plate is positioned over the bone, bones, and/or tissue to be joined by the bone plate 12 . The bone screw(s) are inserted through the aperture(s) in the washer(s) (which washer(s) may reside in the recess(s) provided in the aperture(s) of the bone plate) and the bone screw(s) are installed in bone and/or tissue by known techniques. Each bone screw may be installed at a preselected angle, relative to the bone plate. In the position in which a washer is unlocked, the bone screw may pass through the opening in the washer (e.g., so that the bone screw may be installed at a preselected angle) (see FIG. 12A ). To fix the bone screw (e.g., at the angle at which the bone screw is installed), the washer may be actuated by rotating the washer (e.g., with the tool, as described above). When the washer is rotated, the first relatively thicker sidewall region of the washer may move into the second relatively shallower region of the recess. Such movement may effectively cause the first relatively thicker sidewall region to extend laterally into the aperture in the bone plate (where the relatively thicker sidewall region impinges against the head of the bone screw, thereby applying a force thereto which wedges the bone screw between the washer and the opposite sidewall of the aperture) (see FIG. 12B ). Such wedging of the bone screw may fix the bone screw at an angle (e.g., the angle at which the bone screw was inserted). FIGS. 10 and 12B depict the condition where the bone screw is wedged after actuating the washer.
In yet another embodiment of the present invention, depicted in FIGS. 13-21 , another bone plate assembly is depicted. Shown here is a bone plate, bone screw, and a washer. With this arrangement, a bone plate that does not have a recess can be employed with this screw and washer pairing.
More particularly, FIG. 13 depicts a bone plate assembly 100 , generally provided with bone plate 102 , bone screw(s) 104 received in aperture(s) 106 in the bone plate 102 , and washer(s) 108 that, alone or in conjunction with the bone plate 102 , fix the bone screw(s) 104 in place (i.e., when the bone screw(s) 104 are inserted in the aperture(s) 106 in the bone plate 102 ). Each bone screw 104 has a head 110 sized so that it does not pass through the bone plate 102 . Further, each bone screw 104 has a shank 112 provided with threads 114 (e.g., which threads 114 extend to tip 116 ). In one embodiment, the head 110 of each bone screw 104 may be provided with grooves 118 (see, e.g., FIGS. 4 and 5C ). Bone plate assembly 100 is provided with washer(s) 108 , each of which (as described below) is adapted to reside over a bone screw 104 and be joined therewith in a locking arrangement.
As shown in FIGS. 13 and 17 - 19 , for example, in this embodiment the head 110 of bone screw 104 is provided with a number of tangs 120 , spaced apart from each other, mounted on the upper surface of the head 110 . The tangs 120 include wedges 122 , which wedges 122 are not as wide as the upper portions of the tangs 120 (the wedges 122 are 5 narrowed by an undercut). The head 110 is provided with an opening 107 in which a tool can be received to apply a rotational force, which rotational force permits the installation of the screw in tissue and/or bone.
Each washer 108 is sized and dimensioned to fit within one of the aperture(s) 106 in the bone plate 102 . Each washer 108 is provided with a washer body 124 through 10 which a central opening 125 is provided. A number of lobes 126 are provided on the periphery of the central opening 125 . As depicted in the embodiment of FIG. 14 , for example, three lobes are provided, though it should be understood that other arrangements are possible. Each washer 108 is also provided with splays 127 , which are provided on the exterior of the washer 108 . The splays 127 are separated from the remainder of the washer body 124 by tracks 128 , which tracks 128 extend into the washer body 124 . The tracks 128 are provided with an entrance portion 130 , an intermediate track portion 132 , and a terminus 134 . The entrance portion 130 and the terminus 134 are wider than the intermediate track portion 132 . The width of the intermediate track portion 132 is narrowed by the presence of nubs 136 that extend into the track (e.g., from the washer body 124 and/or the splays 128 ).
The washer 108 and the wedges 122 /tangs 120 are designed to engage with each other in a locking arrangement. Relative to each other, the wedges 122 are slightly wider than the width of at least the intermediate track portion 132 .
In operation, when the bone plate assembly is implanted in a person, the bone plate is positioned over the bone, bones, and/or tissue to be joined by/to the bone plate. The bone screw(s) are inserted through the aperture(s) in the bone plate and installed in bone and/or tissue by known techniques. Each bone screw may be installed at a preselected angle, relative to the bone plate. To fix the bone screw at a preselected angle (e.g., the angle at which the bone screw is installed), the washer is placed over the head of the bone screw, positioned so that the wedges 122 are poised to enter the track portions 128 . A tool, provided with a head adapted to fit within the central washer opening 125 and lobes 126 is inserted into the washer, which is then rotated. The wedges 122 thereby enter the track portions 128 . Since wedges 122 are wider than at least the intermediate track portions 132 , the splays 127 are forced outward when the wedges enter the intermediate track portions 132 (see, e.g., FIG. 21 ). The splays are forced into an abutting arrangement with the sidewalls of the aperture in which the bone screw 106 and washer reside 108 . The abutting arrangement between the splays 127 and the sidewalls of the bone plate 102 fixes the bone screw 104 (e.g., at the angle at which the bone screw 104 was installed).
In another example (which example is intended to be illustrative and not restrictive) the splays 127 may enter an undercut 140 in the aperture(s) 106 (see, e.g., FIG. 13 ).
In another embodiment FIG. 29 depicts, in a perspective view, a double lobed washer. The double lobed washer may be shaped differently than the recess and/or aperture in the bone plate which received the washer. When the washer is rotated, it is deformed, compressing it against the bone screw, fixing the angle of the bone screw (e.g., the angle at which the bone screw is inserted). The embodiment of FIG. 30 is similar. FIG. 30 depicts, in a perspective view, a tri-lobed washer. Again, the tri-lobed washer may be shaped differently than the recess and/or aperture in the bone plate. When the washer is rotated, it is deformed, compressing it against the bone screw and fixing the angle of the bone screw (e.g., the angle at which the bone screw is inserted). The embodiments of FIGS. 29 and 30 may thus operate without a recess.
In another embodiment, shown in FIGS. 22A , 22 B and 22 C, there is shown a bone plate assembly 150 , generally provided with bone plate 152 , bone screw(s) 154 (which bone screw(s) 154 are received in aperture(s) 156 in the bone plate 152 ), and 25 moveable doors 158 (which moveable doors 158 may slide and may fix the bone screw(s) 154 in place when the bone screw(s) 154 are inserted in the aperture(s) 156 in the bone plate 152 ). Each bone screw 154 has a head sized so that the head does not pass through the bone plate 152 . Further, each bone screw 154 has a shank provided with threads that extend to a tip. In one example (which example is intended to be illustrative and not restrictive), the head of the bone screw may be provided with grooves. Bone plate assembly 150 is provided with cut out portion(s) 164 , on an upper surface of the bone plate assembly 150 , to which the moving doors 158 are slidably mounted. The cut out portion(s) 164 are positioned adjacent the aperture(s) 156 , at a segment of the edge thereof.
In one example (which example is intended to be illustrative and not restrictive), each moveable door 158 is provided with two substantially flat sides 166 , 167 , cutouts of partial circles 168 , full cut out circle 169 , and arcuate side 172 . It should be apparent that other dimensional arrangements are possible. The moveable doors 158 are positioned in the cut out portion(s) 164 on the upper surfaced of the bone plate 152 , and are retained therein by lip 174 provided at the upper sidewall of the cut out portion 164 . Dovetail undercuts may also be present along other upper sidewalls to maintain the doors in place. The cut out portion(s) 164 are sized slightly greater than the moveable doors. Thus, when each bone screw is positioned in an aperture 156 of the bone plate 152 , the moveable door 158 can be slid in the direction of the aperture 156 , in order to cover the bone screw 154 (and thus fix the bone screw 154 in place).
Referring now to FIG. 22C , in one example (which example is intended to be illustrative and not restrictive) a channel 180 is fully or partially bored into the bone plate 152 at a location between the cut out portions(s) 164 . Still referring to FIG. 22C , in another example (which example is intended to be illustrative and not restrictive) the moveable doors 158 are provided with stops 182 that depend from the doors, into the channel 180 . When the door is moved into the locked position, as shown in the left hand side of FIG. 22C , the stop engages channel sidewall 184 , inhibiting further movement of the door. Detents 186 and indentations 188 may also be used if desired.
Another embodiment of the present invention is depicted in FIGS. 23-27 . In this embodiment a bone screw 200 is provided with a head 202 sized so that it does not pass through a bone plate (not shown) and shank 204 provided with threads (not shown) that extend to tip 208 .
In one example (which example is intended to be illustrative and not restrictive), the head 202 of the bone screw 200 may be provided with grooves (not shown).
As seen in these Figures, the head 202 of bone screw 200 is provided with a number of splays 212 , spaced apart from each other, and extending around the periphery of the head of the bone screw 200 . The splays 212 are mounted on the upper surface of the head 202 , and in one example (which example is intended to be illustrative and not restrictive), may have an arcuate shape. Each splay 212 extends around a portion of the periphery of the head of the bone screw 200 . Each splay 212 is mounted upon a wedge 214 , (wherein the wedges 214 extend up from the head of the screw). The wedges 214 join the splay 212 at the base of the splay 212 , elevating the splay 212 off of the head of the bone screw 200 . Spaces 215 are present between the portions of the splay 212 , which extend over the periphery of the head of the bone screw 200 , and the head of the bone screw 200 itself.
In this embodiment, after the bone screw 200 has been inserted into an aperture in a bone plate, and installed at a preselected angle, the angle can be fixed by forcing the splays outward (i.e., into a locking and abutting arrangement with the sidewalls of the aperture in the bone plate). In operation, a tool is inserted into the interior space 216 and rotated (to force the splays outward, into an abutting and locking arrangement with the sidewalls of the apertures).
In another embodiment, shown in FIG. 28 , a cam 218 may be utilized. In one example (which example is intended to be illustrative and not restrictive), the cam may be rotatably mounted to the head 202 of the bone screw 200 . In operation, the splays are forced outward, by rotating the cam 218 (which cam 218 moves against the interior walls of the splays). Here, the cam 218 provides a counterforce against the force applied by the sidewalls of the apertures (which counterforce facilitates the maintaining of the splays 212 in a locking and abutting arrangement with the sidewalls of the aperture in the bone plate). In another embodiment one or more of the washers may be a split-ring washer. While a number of embodiments of the present invention have been described, it is understood that these embodiments are illustrative only, and not restrictive, and that many modifications may become apparent to those of ordinary skill in the art. | One embodiment of the present invention is directed to a bone plate assembly that includes a bone plate, bone screw(s) received in aperture(s) in the bone plate, and screw fixation member(s). The screw fixation member(s) may, alone or in conjunction with the bone plate, fix the bone screw(s) in place when such bone screw(s) are inserted in the aperture(s) in the bone plate. In one example (which example is intended to be illustrative and not restrictive) when the bone screw(s) have been received by the bone plate and inserted into bone and/or tissue, the bone plate assembly can-be used to fuse anatomical structures together (such as adjoining bones) and/or to heal a fracture in bone. | 0 |
FIELD OF THE INVENTION
The invention involves the low-cost production of solubilized collagen having a high molecular weight. Solubilized collagen with high molecular weight is useful in the production of high strength paper, or as a binder for cellulosic products.
BACKGROUND OF THE INVENTION
The processing of animal hides to produce leather is an ancient art, and today it is a very mature industry. Excellent references to the chemistry of leather manufacture by McLauglin, G. D., et al, The Chemistry of Leather Manufacture, Reinhold Publishing Corp, N.Y. (1945), and collagen reactivity by Gustavson, K. H., The Chemistry and Reactivity of Collagen, Academic Press Inc., N.Y. (1956), date from the 1940's and 1950's, and are still basic descriptions of the art practiced today. The name "collagen" is derived from the Greek word for glue, as is the term "colloid" which means "gluelike" in Greek.
Skin is composed of four distinct layers, which are, proceeding from outside-in: (1) a thin outer layer of epithelium termed the "epidermis", which is rich in the protein keratin, not collagen; (2) a dense collagen-rich layer, termed the "dermal" or "grain" layer, also called in the older literature the "thermostat" layer; (3) a thicker layer of less-dense, collagen-rich connective tissues, termed the "corium" layer; and (4) an inner layer of "subcutaneous tissue", known to the tanner as "flesh", by which the skin is attached to the underlying tissue.
Although hides may merely be "cured" in salt and/or other biocidal solutions to stop microbial degradation, many hides that are intended for use in leather manufacture are "limed", that is, soaked in a saturated solution of hydrated lime (calcium hydroxide) and water. The liming process initiates the loosening of the epidermis and the subcutaneous layer, and is the first step in the dehairing process. After liming is complete, the hair, epidermis, and any residual flesh, fat and surface muscles are removed by mechanical scraping, and the dermal layer is mechanically cut, along with enough of the corium layer to give the final leather its required thickness, from the remaining inner corium layer.
In leather-making the primary interest is on the dense collagen-rich dermal layer, which is about 25% of the thickness of the corium layer. During the process of leather-making, the dermal tissue receives separate chemical and tanning treatments to stabilize the collagen structure.
The residual portion of the corium layer that is separated from the dermal layer is termed the "limed split" and is a by-product waste of the leather manufacturing process. It is these limed splits that become, for example, the collagen-rich feedstock for sausage casing production, and that have been used as the source of collagen for the examples herein.
During the liming process, the skin imbibes and binds water, and becomes highly swollen; in the process it acquires a very alkaline pH of about 12.5. The chemistry of the liming process is quite well understood. Prior to further leather processing, and in the collagen production process considered here, the skins must be "delimed" by soaking in acid or salt solutions.
Four U.S. Pat. Nos. (4,140,537, 4,233,360, 4,488,911, 4,655,980) all assigned to Collagen Corporation, describe enzymatic methods, including pepsin hydrolysis, for solubilizing collagen to produce a "non-immunogenic" soluble collagen, which is then converted to other forms for use as medical implants. In these patents, the initial soluble product is relatively low (for collagen) molecular weight aggregates (about 300,000 daltons); the objective is to remove all of the "telopeptides" which are found at the end of these chains. Higher molecular weight aggregates would not have the telopeptides completely removed, and would be more "immunogenic" by their standards.
A 1970 U.S. Pat. No. (3,532,593) describes a method for making collagen for use in papermaking. It describes a mechanical method for isolating preexisting gelled collagen fibers, not an enzymatic method for solubilizing the collagen as in the present invention. This patent describes a method for adjusting the pH of mechanically gelled collagen to promote flotation of fat and for skimming the floating fat from the collagen. The patent also refers to the partial "gelatinizing" of the collagen by heating to improve the bonding properties of the additive, although the primary objective is to produce a fibrous product.
SUMMARY OF THE INVENTION
A first embodiment of the invention is a method that typically produces an aqueous solution of high molecular weight solubilized collagen by the steps of: (a) providing an aqueous ground slurry of insoluble collagen; (b) adjusting the water or solid content of the wet ground slurry whereby the insoluble collagen is at a concentration that promotes substantially maximum solubilized collagen concentration and molecular weight in a final product; (c) adjusting the pH of the slurry from Step b to obtain activity for a proteolytic enzyme added in Step d; (d) adding the proteolytic enzyme to the pH adjusted slurry and reacting at a temperature, T, and for a time, t, effective for forming high molecular weight solubilized collagen from the insoluble collagen particles; (e) controlling the reaction conditions for obtaining a high concentration of soluble collagen and a high molecular weight of the solubilized collagen by simultaneously measuring the concentration of solubilized collagen and the molecular weight of the solubilized collagen, whereby the reaction is complete when the molecular weight and the concentration are substantially maximized; and (f) withdrawing the aqueous solution of high molecular weight solubilized collagen as product. The reaction is typically stopped by adjusting the pH to that where the proteolytic enzyme is substantially inactive; and/or reducing the temperature to that where the proteolytic enzyme is substantially inactive. The reaction is typically controlled by measuring solution viscosity at two different shear rates whereby the reaction is complete when a ratio of (viscosity at low shear)/(viscosity at high shear) is substantially maximized. The viscosity ratio is preferably at least 75% of maximum. Preferably at least 80 wt % of the insoluble collagen is converted to soluble collagen and the number average molecular weight is above 300,000 daltons or more preferably above 600,000 daltons; and most preferably at least 90 wt % of the insoluble collagen is converted to soluble collagen and the number average molecular weight is above 1,000,000 daltons. In a preferred embodiment the solids content of the wet ground slurry is adjusted to a concentration of about 0.1 to about 1.0 wt %, and the temperature, T, is about 5° C. to about 35° C., while more preferably the temperature, T, is between about 15° C. to about 30 ° C. In other typical embodiments in Step b, the solids concentration is between about 0.3 to 0.35 wt %; and in Step e. the reaction is controlled at a temperature of about 20 to about 30° C., and for time of 24 to 48 hours. Since many different sources of collagen can be used it is difficult to enumerate all of the proteolytic enzymes that can be used with the process of the invention, however, these can easily be selected by those skilled in the art. Some examples of proteolytic enzymes include those selected from the group consisting of porcine mucosal pepsin, bromelain, chymopapain, chymotrypsin, collagenase, ficin, papain, peptidase, proteinase A, proteinase K, trypsin, and similar enzymes or combinations of such enzymes. Typically the pH is adjusted to between about 1.5 to about 3.0 and the temperature to between about 26° to about 28° C., when porcine mucosal pepsin is selected.
Another typical embodiment of the method for producing an aqueous solution of high molecular weight solubilized collagen includes the steps of: (a) providing an aqueous ground slurry of insoluble collagen; (b) adjusting the water or solid content of the wet ground slurry whereby the insoluble collagen is at a concentration that promotes substantially maximum solubilized collagen concentration and molecular weight in a final product; (c) adjusting the pH of the slurry from Step b to obtain activity for a proteolytic enzyme added in Step d; (d) adding the proteolytic enzyme to the pH adjusted slurry and reacting at a temperature, T, and for a time, t, effective for forming a solution of high molecular weight solubilized collagen from the insoluble collagen particles; (e) controlling the reaction to obtain a high concentration of soluble collagen and a high molecular weight of the solubilized collagen by simultaneously measuring the concentration of solubilized collagen and the molecular weight of the solubilized collagen, whereby the reaction is complete when the molecular weight and the concentration are substantially maximized; (f) adding additional water and insoluble collagen to the solution containing high molecular weight solubilized collagen in Step d and mixing; (g) separating at least some of the solution containing high molecular weight solubilized collagen from the insoluble collagen and returning the insoluble collagen to Step b, whereby at least a portion of the proteolytic enzyme is recycled, and the separated solution containing high molecular weight solubilized collagen is withdrawn as product. The embodiment can include repeating Steps f and g one or more times. Alternatively, the recycling of proteolytic enzyme can be generally performed by extraction and recycle to earlier process steps by other methods generally known in the art. The reaction is typically stopped by adjusting the pH to that where the proteolytic enzyme is substantially inactive; and/or reducing the temperature to that where the proteolytic enzyme is substantially inactive. The reaction is typically controlled by measuring solution viscosity at two different shear rates whereby the reaction is complete when a ratio of (viscosity at low shear)/(viscosity at high shear) is substantially maximized. The viscosity ratio is preferably at least 75% of maximum. Preferably at least 80 wt % of the insoluble collagen is converted to soluble collagen and the number average molecular weight is above 300,000 daltons or more preferably above 600,000 daltons; and most preferably at least 90 wt % of the insoluble collagen is converted to soluble collagen and the number average molecular weight is above 1,000,000 daltons. In a preferred embodiment the solids content of the wet ground slurry is adjusted to a concentration of about 0.1 to about 1.0 wt %, and the temperature, T, is about 5° C. to about 35° C., while more preferably the temperature, T, is between about 15° C. to about 30° C. In other typical embodiments in Step b, the solids concentration is between about 0.3 to 0.35 wt %; and in Step e. the reaction is controlled at a temperature of about 20° to about 30° C., and for time of 24 to 48 hours. Since many different sources of collagen can be used it is difficult to enumerate all of the proteolytic enzymes that can be used with the process of the invention, however, these can easily be selected by those skilled in the art. Some examples of proteolytic enzymes include those selected from the group consisting of porcine mucosal pepsin, bromelain, chymopapain, chymotrypsin, collagenase, ficin, papain, peptidase, proteinase A, proteinase K, trypsin, and similar enzymes or combinations of such enzymes. Typically the pH is adjusted to between about 1.5 to about 3.0 and the temperature to between about 26° to about 28° C., when porcine mucosal pepsin is selected.
A yet further embodiment typically includes a method for producing an aqueous solution of high molecular weight solubilized collagen using the steps of: (a) providing an aqueous ground slurry of insoluble collagen; (b) adjusting the water or solid content of the wet ground slurry so that the solids are adjusted to a concentration of about 0.1 to about 1.0 wt %; (c) adjusting the pH of the slurry from Step b to obtain activity for a proteolytic enzyme added in Step d; (d) adding the proteolytic enzyme to the pH adjusted slurry and reacting at a temperature, between about 5° C. to about 35° C., and for a time, t, effective for forming high molecular weight solubilized collagen from the insoluble collagen particles; (e) controlling the reaction conditions for obtaining a high concentration of soluble collagen and a high molecular weight of the solubilized collagen by simultaneously measuring solution viscosity at two different shear rates whereby the reaction is complete when a ratio of (viscosity at low shear) divided by (viscosity at high shear) is substantially maximized; and (f) withdrawing the aqueous solution of high molecular weight solubilized collagen as product.
Feed material for the process can typically come from a variety of sources as long as the feed is relatively clean and has collagen containing material of relatively small particle size. One typical method for preparing the feed material of a wet ground slurry of insoluble collagen from animal tissues includes the steps: (a) providing soft animal tissues containing collagen; (b) cleaning the collagen containing tissues to remove hair, fat, carbohydrates, and other contaminants; (c) cutting the cleaned collagen containing tissues into small pieces; (d) mixing the small pieces with water to obtain a slurry; (e) adjusting the pH of the slurry substantially near the isoelectric point of collagen from the tissues; (f) wet grinding the resulting pH adjusted slurry to obtain a slurry of insoluble collagen. The pH of this method is typically about 3 to about 7.
The invention further encompasses the unique aqueous solutions of high molecular weight solubilized collagen produced by the above methods.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A is a plot showing the non-Newtonian behavior of the collagen solutions. Viscosity of diluted solutions of high molecular weight solubilized collagen of the invention (A) and BA-1 collagen solutions (B) at two shear rates (20 and 100 rpm).
FIG. 1B is a plot showing the ratio of the viscosity determined at 20 rpm to the viscosity at 100 rpm, termed here the "viscosity ratio". The data is calculated from the data in FIG. 1A for both the high molecular weight solubilized collagen (A) or the BA-1 collagen solutions (B).
FIG. 2 is a plot of the data for Example 1 showing the viscosity at 20 rpm and 100 rpm.
FIG. 3 is a plot of a small-scale batch collagen solubilizing reaction demonstrating the pepsin recycle of Example 3.
FIG. 4 is a plot of the development of viscosity ratios in Examples 5 (denoted by A) and 6 (denoted by B).
DETAILED DESCRIPTION OF THE INVENTION
It was recognized that a high-molecular-weight soluble collagen material, added to the pulp prior to the papermaking process (i.e, mixed with the pulp fibers in the machine chest), resulted in a significant increase in strength of the paper-collagen composite. There is no current large-scale use or commercial source for a collagen solution of this type. Small-scale applications for soluble collagen exist in the food, cosmetic and pharmaceutical industries, for which the products are much higher priced than will be economically acceptable in the subject paper application.
Therefore, the advantages of the invention are in: (1) minimizing the cost of preparing soluble collagen by processing directly from ground skin material to the maximum amount of soluble macromolecules; and (2) at the same time, maximizing soluble collagen material and the molecular weight of the soluble collagen material in order to enhance the binding effect to the pulp fibers, thereby maximizing the resulting tensile strength and/or other mechanical properties of the paper product.
Beef skin was selected as the collagen source in the examples described here because collagen preparation methods from skin have been widely reported, and the material is a high volume by-product of the major industries of beef production and leather manufacture; however, it is expected that collagen obtained from other sources (e.g. tendon) will work in the process also.
Collagen solubilization of skin has been accomplished by an enzymatic hydrolysis process with an animal stomach enzyme (pepsin) without any other purification steps. The process results in nearly complete solubilization of ground hide preparations in 20-30 hours at room temperature in acidic solutions. Other (untested) enzymes may yield faster or cheaper conversion of collagen-containing tissues, and the process has not necessarily been optimized to minimize enzyme requirements and production time. To date, the process has been scaled to produce approximately 500 gallons of 0.3-0.4% collagen solution, and it has been demonstrated to be relatively easy to control.
EXAMPLES
The following examples, illustrative of the novel compositions and the novel methods of preparing them, are given without any intention that the invention be limited thereto.
Materials
The pepsin used was a crude (relatively unpurified) powder from pig stomach mucosa (Cat. No. P7125) purchased from Sigma Chemical Company, St. Louis, Mo. Lot #070H0437 of this product, used in the examples, contains approximately 15% protein (by UV), with an activity of 91 pepsin units/mg solids and 620 units/mg protein. Residual solids in the preparation appear to be a combination of precipitation salts, buffer salts and/or carbohydrates. Crystallized pepsin has a maximum specific activity of about 3500 units/mg protein.
The collagen slurry used herein for all pepsin reactions was prepared from ground limed-splits of bovine skin. The collagen was supplied by Teepak's Sandy Run Plant, Columbia, S.C. Typical analyses for the material of Example 6 are pH=6.4; solids content=15.67%; gelatin content=2.62%; fat content=2.1%. A 1974 USDA report by Komanowsky, M., et al, "Production of Comminuted Collagen for Novel Applications", J. American Leather Chem. Assoc., 6, 410-422 (1974), describes techniques for pre-slicing, acidifying and wet-grinding of limed splits to produce five "comminuted" (ground) collagen products, classified by extent of grinding and the resulting particle size and texture. A subsequent 1978 paper by Turkot, et al, "Comminuted Collagen: Estimated Costs of Commercial Production", Food Tech., 48-57 (April, 1978), presents an economic analysis of the production costs for these same five products. The output from this plant closely approximates the ground limed-split material used as a source for collagen in the examples herein.
Control--A soluble control collagen solution ("BA-1"), used as a control solution in the examples, was supplied as the soluble skin product, Secolan BA-1, by Kensey Nash Biomaterials, Exton, Pa. The solution is typically a white milky color; pH=3.1-3.3; total solids=1% ±0.2%; active collagen >0.67% (nominally 1% in the examples). This product is sometimes found to be slightly gelled upon receipt. However, based on the pattern observed after electrophoretic analysis, it is believed that the BA-1 is produced by an acid-extraction process, not by an enzymatic reaction as practiced in the present invention.
It was found that the solubilization of collagen-containing solids can be effectively monitored by periodic measurement of the solution viscosity . Fluid viscosities can be conveniently measured by a variety of relatively simple methods, such as the Brookfield Model #RVT Viscometer (#3 Spindle) used with the examples. In this Brookfield system, the force exerted by a fluid upon a disk, which is rotated at constant rotational speed in the fluid, is used to estimate the fluid viscosity. In the collagen solutions described herein, the fluid viscosity will be strongly dependent on the concentration of dissolved collagen, the molecular weight distribution of the soluble collagen and the fluid temperature, and, to a lesser extent, fluid pH and ionic strength.
When the viscosity is independent of the applied force (shear), then the fluid is said to be "Newtonian". For solutions of many macromolecules, including the rod-like collagen molecules considered here, the solution viscosity is very dependent on the force applied to the liquid, and the liquid is said to be "non-Newtonian". When the dissolved macromolecules are highly elongated, and the shear rate (proportional to the rotational speed) is sufficiently high, the molecules tend to orient with the streamlines of the fluid and their effect on the fluid velocity tends to decrease in a manner that is strongly dependent on the shear rate.
The non-Newtonian behavior of collagen solutions is demonstrated in the experiments summarized in FIG. 1A, in which the viscosity of preparations of solubilized collagen and BA-1 were determined at room temperature as the solutions were progressively diluted with distilled water. Some uncorrected increase in solution pH may have occurred in this experiment as the samples were diluted; however, the trend for the data is valid.
For each solution, the viscosity was determined at two rotational speeds, 20 and 100 rpm. The open circles
and filled circles
represent data for solubilized collagen of the invention at 20 rpm and at 100 rpm, respectively. The open squares
and the filled squares
represent the data for the BA-1 collagen control at 20 rpm and 100 rpm respectively. Both solutions were more viscous at the lower rotational rate, as expected. The viscosities of the collagen produced in the examples and BA-1 preparations were substantially different, with the produced collagen solution having a much higher viscosity at lower collagen concentrations and a steeper slope. These effects appear to be primarily due to the difference in the average molecular weights of the collagen molecules in the two solutions, with the collagen solution of the invention having the larger average molecular size. The comparison shows that the method of the invention was successful in making a higher viscosity collagen material at a lower concentration thus showing the molecular weight was higher.
The ratio of the viscosity determined at 20 rpm to the viscosity at 100 rpm, termed here the "viscosity ratio", is a convenient measure of this non-Newtonian, molecular-weight-dependent effect. This is illustrated in FIG. 1B, in which the viscosity ratio is higher for collagen solutions of the invention than for BA-1. In FIG. 1B the open circles
represent data from the solubilized collagen of the invention and the open squares
represent data from the BA-1 collagen solution. The viscosity ratio is used herein is a measure of the "degree of conversion" of solid collagen materials to soluble collagen molecules and also a measure of molecular weight, where higher values of the viscosity ratio will correlate with the desired higher average molecular weights of the dissolved collagen. In FIG. 1B it is important to note that since the material is being diluted, an increase in viscosity ratio is measuring the increase in concentration of soluble collagen since the molecular weight of the material remains the same. In tests of the examples below, changes in the viscosity ratio will be measuring changes in concentration as well as molecular weight.
Analysis of collagen composition was routinely performed by SDS polyacrylamide gel electrophoresis (PAGE) that used a 3% stacking gel; 6% running gel, following denaturation by boiling with B-mercaptoethanol. Some irreversible precipitation occurs during the denaturation process. Gels were stained by Coomassie Blue dye and destained in staining buffer only.
PAGE demonstrates (results not shown here) that BA-1 solutions contain predominately tropocollagen monomer (300,000 daltons) aggregates. Collagen solutions produced by the present process that had viscosity ratios higher than 2.0 had much broader molecular weight distributions, with some components smaller than alpha chains but with predominately higher molecular weight components that appear to exist in solution in aggregates having molecular weights higher than 1,000,000 daltons.
In the examples below, it was determined that ground limed splits of beef hide can be nearly completely solubilized when they are subjected to pepsin hydrolysis at pH in the range of 2.0-2.2. Batch reaction times are typically 20-30 hours at room temperature (22°-26° C.). The maximum concentration of soluble collagen produced in this process is approximately 0.30-0.40% (3-4 mg dissolved collagen/ml). The process has been demonstrated at up to 2.0 liter-scale and, using essentially the same recipe, at approximately 500-gal scale, as discussed below.
EXAMPLE 1
Approximately 15 g of wet Teepak collagen solids were suspended by magnetic stirrer in 750 ml of Columbus, Ohio tap water at room temperature. The solution pH was adjusted to 2.1 with concentrated hydrochloric acid (HCl)--approximately 65-70 drops. Crude pepsin powder (0.38 g) was then added with stirring into the collagen suspension to initiate the reaction. The suspension was stirred overnight, during which heating of the solution to 26°-27° C. or higher sometimes occurred due to conduction from the stirrer plate. The viscosity of the solution was measured (20 & 100 rpm) periodically during the second day of the reaction until a maximum in the viscosity ratio was achieved, at which time the solution can be stabilized by increasing the pH to 3.0-3.5 and/or by placing the solution in the refrigerator. Increasing the pH above 4.0 may initiate irreversible gelation of the collagen solution.
Results for Example 1 are plotted in FIG. 2. FIG. 2 shows a plot of viscosity, (in centipoise) as a function of time reaction (in hours). Viscosity measurements were taken at 20 rpm (squares) and 100 rpm (circles). After completion of the reaction at pH 2.1, three samples were taken and the pH adjusted to 2.1,
2.8,
, and 3.5
Viscosity tests at 20 rpm taken several days later confirmed that the samples at pH=3.5 were indeed more stable and retained more of the original viscosity than those at pH=2.1.
EXAMPLE 2
Hydrolysis of Teepak collagen at temperatures between 30°-35° C. was investigated in a series of approximately 10 experiments to determine the potential for minimizing pepsin usage in the solubilization process. Typically, enzyme-catalyzed reaction rates will double with every 5°-10° C. increase in temperature. In these experiments, a 4-liter stainless steel beaker was wrapped with heating tape, then insulated with asbestos tape. The solution temperature was controlled by a Variac in line with the heating tape to about ±1°-2° C. The process above was scaled to 2 liters of reaction volume, and a range of lower pepsin concentrations and heating profiles was investigated. In nearly all cases, complete solubilization of the Teepak solids was accomplished in 10-15 hours, and in no case was substantial viscosity developed in the solubilized product.
Typical of the ten experiments is the following: 2 liters of water were added to a beaker, to which was added 40 g of Teepak collagen, then the pH was adjusted to 2.13 with concentrated HCl, and finally 1.0 g crude pepsin was added. Initially the bath temperature was 30.0° C., about 2.5 hours later the temperature was 33° C. and the viscosity at 100 rpm was 19 cps, and about 5.5 hours later the temperature was 36.5° C. with a viscosity of 8 cps. The sample was completely solubilized in less than 8 hours at 33°-36° C. with no increase in viscosity indicating the production of a higher molecular weight material. These experiments demonstrate that it is expected to be more difficult to conserve pepsin in this process by operating at higher reaction temperatures, even early during the hydrolysis process. The maximum feasible temperature for accumulating this particular large molecular weight collagen appears to be about 30° C.
EXAMPLE 3
Another approach for minimizing pepsin usage in the process is illustrated by the experiment summarized in FIG. 3. In this experiment, the recipe above (750 ml Columbus, Ohio tap water, 15.5 g teepak collagen, 0.38 g pepsin, pH=2.1) was mixed on Day 0 to initiate the reaction in a 2-liter flask at room temperature (Roman numeral I). After approximately 1 day, an additional 750 ml of water and another charge of Teepak collagen solids (16.1 g) were added, but no additional pepsin was added to the reactor (Roman numeral II). The flask was stirred for about 5 minutes to mix the contents and the pH was readjusted with 30 drops of concentrated HCl, then the stirrer was turned off and the solids were permitted to settle out. After approximately 30 minutes, 750 ml of supernatant, "Day 1" supernatant (D1), was decanted into another flask, and stirring of both flasks was resumed. The Day 1 Supernatant contained some fine collagen particles, but it contained a much lower suspended solids load than the bottom fraction. The same process of dilution (755 ml water), collagen solids addition (15.2 g Teepak collagen), pH adjustment with 30 drops concentrated HCl (Roman numeral III), and supernatant decanting of "Day 2" supernatant (D2) was repeated in the first flask after approximately 2 days of reaction.
The progression of the hydrolysis reaction is illustrated by the solid lines (-x-) in FIG. 3. The circles
show a plot of the progression hydrolysis reaction of the Day 1 supernatant while the squares
show a plot of the Day 2 supernatant. In this example three typical charges of Teepak collagen were hydrolyzed by a single charge of pepsin, although the rate of hydrolysis appears to be decreasing with each cycle. Because the viscosity ratios of both the Day 1 and Day 2 supernatants appeared to increase after they were decanted from the main reactor, it was apparent that some pepsin and insoluble collagen was transported along with the supernatant. However, it appears that the pepsin has a higher affinity for solid collagen particles than for soluble collagen, thus most of the enzyme can be recycled several times before it is removed from the system, thereby minimizing the cost of this reagent. Preferably better separation of liquid and solids is obtained if the supernatant is separated from the insoluble collagen by centrifugation.
EXAMPLE 4
An experiment was conducted in which 750 ml whitewater (recycle water from a papermaking process) was substituted for the tap water in the standard recipe of Example 3 above. Then 15.5 g Teepak collagen were added, the pH was adjusted to 2.14 with 40 drops of concentrated HCl, and 0.375 g of pepsin were added. Because the room temperature was elevated during this experiment, the reaction was conducted at 29°-31° C., and the solubilization appeared to proceed more quickly than standard reactions at 25°-26° C. In this single reaction, good viscosity was developed, the solids were nearly completely solubilized, and there appeared to be no problem with conducting the process in this solution (see the Table). Recycling whitewater from a papermaking process in this way will greatly diminish the amount of water introduced to the process.
TABLE______________________________________SOLUBILIZED HIGH-MOLECULAR-WEIGHTCOLLAGEN MADE IN WHITEWATER FROMPAPER MAKINGTime Viscosity Viscosity(hours) 20 rpm 100 rpm Ratio______________________________________0 -- -- --18.5 415 177 2.3422 440 186 2.3726.7 365 166 2.2042 280 136 2.06______________________________________
EXAMPLE 5
In this example, 500 gal of Savannah, Ga. tap water was delivered to a double-paddle, 600 gal. stainless steel tank, and 75# of Teepak collagen (13.5# solids @ 18% solids) was dispersed in the water. Approximately 1.4 liters of concentrated HCl was added to bring the pH to 2.14. Pepsin (1.01 kg; Sigma Lot #70H0437) was slowly added, then the tank was covered with polyethylene film and the tank was stirred overnight. After approximately 20 hours, hydrolysis was incomplete (viscosity ratio=1.32). Because the liquid and room temperatures were relatively low (approximately 20° C.), it was decided to attempt to raise the liquid temperature by putting live steam onto the outside bottom of the tank. The steam was used for about 2.5 hours, by which time the liquid temperature was 23° C., the viscosity ratio was 2.15, and the steam heating was discontinued.
At approximately 31 hours, the viscosity ratio was 2.43, which is relatively high for this reaction. It was decided to adjust the pH in the tank to approximately 3.0, by the addition of approximately 450 grams of NAOH flakes, in order to stabilize the solution (slow/stop the pepsin reaction) for use in paper the next day. Approximately 55 gal of the pH=2.1 solution were saved in 5-gal containers prior to the pH adjustment. Because the viscosity ratio dropped slightly overnight for the pH=2.1 solution (open circles,
,in FIG. 4 and denoted by A) compared to the pH=3.0 solution (closed circles,
, it is concluded that pH adjustment is helpful in maintaining the highest possible molecular weight in the product during storage at room temperature.
After approximately 24 hours of reaction, some floating solid material (presumed to be fat because of its low density) was observed on the upper surface of the collagen solution near the mixer shaft. Although no attempt was made in this experiment to remove this residue, it can be easily skimmed from the preparation if the residual fat was found to be detrimental to collagen performance.
Prior to using the collagen solution made in this example and in Example 6, described below, the solution was filtered by passing it through a knitted plastic screen with openings approximately 1×3 mm, in order to remove a small number of very slowly degrading skin particles. These particles are characteristically the last material to be dissolved by pepsin and can often be found in the 3-5 mm size range. A large sample of these residual particles and their dry weight was measured. Based on projecting this sample to the entire batch of collagen solution, it was estimated that more than 95% of the initial solids were solubilized in this process.
EXAMPLE 6
In this example, the same tank was filled with 500 gal of Savannah, Ga. tap water, which in January was very cold--about 11° C. Teepak collagen (79.5#; 12.5# of solids at 15.67% dry wt.) was dispersed in this water, then 1.5 liters of concentrated HCl was added to bring the pH to 2.18. Pepsin (1.01 kg; Sigma Lot #70H0437) was slowly added, then the tank was covered with polyethylene film. Live steam was placed on the outer bottom of the tank for approximately 4 hours to raise the liquid temperature from 11.5° to 25° C. At this time the pH was 2.40; an additional 0.4 liters of concentrated HCl was added to bring the pH down to 2.29. The tank was draped with polyethylene film to insulate the tank overnight. After approximately 28 hours the viscosity ratio was 2.51, with the temperature at about 22° C. at pH=2.46. Approximately 600 g of flaked NaOH was added to bring the tank contents to pH=2.98, the tank was covered as before and stirred overnight. The final viscosity ratio was 2.61. Results are shown in FIG. 4 at B (-x-).
Since the collagen solution in Example 6 was produced at about a 2°-3° C. higher reaction temperature during the first day than that in Example 5, the reaction appears to have progressed more rapidly, reaching completion about 4-5 hours sooner. When the pH was adjusted to about 3.0 the final solution appears to have slowed the enzymatic reaction so that little degradation of the soluble product was observed overnight.
The process is intended to produce nearly complete conversion of beef hides to a collagen solution using an enzymatic hydrolysis reaction. Objectives for the process are production of the highest possible molecular weight soluble product at the maximum yield, while conversion costs and fixed capital expenditures are minimized. The process is not intended to produce food- or medical-grade soluble collagen, and therefore requirements for production of clean solutions are minimal, and no purification of the soluble collagen is anticipated. No attempt has been made to remove the remnants of the other skin components (fat, proteoglycans, other proteins, salts, etc.), which are present in the ground-split feedstock at concentrations lower than collagen.
The process will require a series of cutters and grinders to reduce the feedstock limed splits to a shredded material that can be readily converted to soluble collagen. As cited above, the "front end" of the process will likely look similar to the USDA process for producing comminuted collagen. Depending on the pretreatment of the hides employed to prevent microbial growth, the hides may need to be delimed or acidified to remove residual calcium salts or other biocides. The ground solids are then mixed with process water (perhaps a reduced-solids whitewater stream from a paper plant), the pH is titrated to 2.0-2.2, and enzyme is added to begin the solubilization process. Following conversion, the soluble solids can be pumped directly to a paper making process and mixed with refined pulp solids or stabilized and stored.
In small-scale tests, maximum interaction between collagen and pulp solids appears to result if the pH of the solution is about 4.0 or less and the pulp consistency is 1.0% or lower. Therefore, adjustment of the pulp in the holding tank to about pH 4.0 or less appears to be beneficial.
Collagen solutions prepared by this process appear to be stable at room temperature for 12-24 hours, and stability can be enhanced by increasing solution pH to 3.0-3.5 and/or by reducing the solution temperature to 5°-10° C.
The process has demonstrated the feasibility of production of a low-cost high-molecular-weight soluble collagen product by the substantially complete solubilization of beef hide collagen (ground limed-splits). The process can be conducted at near-ambient conditions and is relatively easy to control.
While the forms of the invention herein disclosed constitute presently preferred embodiments, many others are possible. It is not intended herein to mention all of the possible equivalent forms or ramifications of the invention. It is to be understood that the terms used herein are merely descriptive, rather than limiting, and that various changes may be made without departing from the spirit of the scope of the invention. | The invention includes a method that produces a low cost aqueous solution of high molecular weight solubilized collagen by the steps of: (a) providing an aqueous ground slurry of insoluble collagen; (b) adjusting the water or solid content of the wet ground slurry whereby the insoluble collagen is at a concentration that promotes substantially maximum solubilized collagen concentration and molecular weight in a final product; (c) adjusting the pH of the slurry from Step b to obtain activity for a proteolytic enzyme added in Step d; (d) adding the proteolytic enzyme to the pH adjusted slurry and reacting at a temperature, T, and for a time, t, effective for forming high molecualr weight solubilized collagen from the insoluble collagen particles; (e) controlling the reaction conditions for obtaining a high concentration of soluble collagen and a high molecular weight of the solubilized collagen by simultaneously measuring the concentration of solubilized collagen and the molecular weight of the solubilized collagen, whereby the reaction is complete when the molecular weight and the concentration are substantially maximized; and (f) withdrawing the aqueous solution of high molecular weight solubilized collagen as product. Proteolytic enzyme recycle steps are disclosed that can be used to further reduce costs. | 3 |
CROSS REFERENCE TO RELATED APPLICATIONS
This is a continuation of copending application Ser. No. 09/556,026 filed on Apr. 20, 2000, now abandoned which is hereby incorporated by reference herein.
This invention is a continuation in part of U.S. patent application Ser. No. 09/430,534 filed on behalf of Marvin Wong, et al., on Oct. 29, 1999 now U.S. Pat. No. 6,188,414 entitled “Inkjet Printhead With Preformed Substrate” and assigned to the assignee of the present invention, the entire contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
This invention relates to inkjet printers, and more particularly to printing systems that include an inkjet printhead. Thermal inkjet printers have experienced a great deal of commercial success since their inception in the early 1980's. These printing systems have evolved from printing black text and graphics to full color, photo quality images. Inkjet printers are typically attached to an output device such as a computer. The output device provides printing instructions to the printer. These instructions typically are descriptions of text and images to be printed on a print media. A typical inkjet printer has a carriage that contains one or more printheads. The printhead and print media are moved relative to each other to accomplish printing.
The printhead typically consists of a fluid ejecting substrate which is electrically and fluidically coupled to the printing system. The fluid ejecting substrate has a plurality of heater resistors disposed therein which receive excitation signals from the printhead. The heater resistors are disposed adjacent a plurality of orifices formed in an orifice layer. Ink is supplied to the heater resistors from an ink source affixed to the printhead or from an ink source that is replaceable separate from the printhead. Ink supplied to the heater resistors is selectively ejected, in the form of ink droplets, through the orifices and onto the print media. The ink on the print media dries forming “dots” of ink that, when viewed together, create a printed image representative of the image description. The printed image is sometimes characterized by a print quality metric which may encompass dot placement, print resolution, color blending and overall appearance such as freedom from artifacts. Inkjet printer manufacturers are often challenged by an increasing need to improve print quality as well as increasing the reliability of the printhead.
The orifice layer and print media are ideally arranged in a parallel orientation to each other. An ink droplet ejected from an orifice in the orifice layer can be represented as a vector that is, ideally, directed orthogonal to the plane of the print media. Thus, when ink is ejected from the orifice layer of an “ideal printhead” the difference between where an ink droplet is placed on the print media and where it should have been placed is zero, thus the trajectory error is zero. In actuality, however, variations in the orifice layer manufacturing process result in ink droplets being ejected from an orifice at an angle which typically ranges between 0 and 2 degrees. These variations in the orifice layer are due to variation tolerances in the orifice formation as well as variation in the planarity of the orifice layer, to name a few.
The effect of trajectory error is exacerbated by separation distance between the printhead and print media. For example, a conventional printhead is separated from the print media by 1.5 mm. If ink is ejected from the orifice layer at an error angle of 2 degrees from the ideal or orthogonal direction, the ink droplet will be displaced 0.052 mm from where it should have been placed on the printing. If however, the printhead and print media are 0.7 mm apart and ink is ejected at the same 2 degree error angle, the ink droplet will be displaced by only 0.024 mm. This trajectory error tends to reduce or degrade the quality of the printed image because this error affects the positioning of ink on the print media.
The degradation in print quality resulting from trajectory error in conventional printheads is most prevalent where colors of ink are blended to produce “photographic” quality printed images. Here, displaced ink droplets will tend to cause the printed image to appear grainy and streaky. Furthermore, parasitic effects such as air current, tend to further influence trajectory error of the printing system. These parasitic effects tend to be reduced by lessening the printhead to print media spacing.
The printhead in a typical printing system is separated from the print media by a distance which may range from 1 millimeters to 1.5 millimeter (mm). This distance between the printhead and print media tends to be limited by the electrical coupling between the fluid ejecting substrate and the printhead body that supports the fluid ejecting substrate. For example, a disposable print cartridge includes a fluid ejecting substrate mounted in a pen body. An encapsulating material is often dispensed on top of the electrical coupling or interconnect to protect or shield the interconnect from ink. Inks used in thermal inkjet printheads tend to have salt constituents that tend to be corrosive and conductive. Once these inks leak into the electrical interface they tend to produce electrical shorts or corrosion that tend to reduce printhead life. The encapsulant disposed over the interconnect is commonly referred to as an encapsulant bead. The encapsulant bead protrudes beyond the orifice layer of the fluid ejecting substrate and tends to limit the spacing between the printhead and print media. Consequently, there tends to be a limit to the reduction of trajectory error.
In addition to print quality, the printing systems should have high reliability. Two common failure modes that may decrease the reliability of the printhead are: (1) exposure of the interconnect to ink and (2) ink leakage during the shelf life of the printhead. The encapsulant bead may be eroded thereby exposing the interconnect to ink if the printhead is positioned so close to the print media that the encapsulant bead rubs against the print media during printing. The ink tends to corrode the interconnect which ultimately leads to an electrical failure of the printhead thus, making the printhead less reliable.
Conventional inkjet printers employ a cleaning mechanism which includes a wiper that routinely wipes ink residue from the printhead orifice plate. This residue, if sufficient, can either clog the orifices thereby preventing drop ejection or cause misdirected drops. The cleaning mechanism has a predetermined tolerance so that the wiper does not damage the printhead during the cleaning process. However, the wiper tends to be less effective if it is obstructed by a protruding encapsulant bead and could possibly contribute to the erosion of the bead.
A second reliability factor that tends to reduce printhead life relates to environmental conditions that the printhead experiences. Printheads are often exposed to extreme environmental conditions before they are used in a printing system. For example, printheads are often stored in shipping warehouses where temperatures may range from 0-60 degrees Celsius. Or, printheads may be exposed to varying atmospheric pressures during shipping if the printheads are shipped via airplane. In general, conventional printheads are designed to accommodate these extreme conditions without leaking. However, under extreme environmental conditions as previously described, printheads may leak prior to being used in the printing system. In an attempt to remedy this problem, a tape-like material is placed over the orifice layer to further guard against ink leakage and drying of the ink in the orifices. Ideally, the tape-like material adheres evenly to the orifice layer. However, in conventional printheads, the encapsulant bead previously described may inhibit the tape-like material from uniformly adhering to the orifice layer. If the tape-like material does not uniformly adhere to the orifice layer, ink may leak through the orifice layer and damage surrounding objects. Additionally, ink leaking from the printhead may, over time, harden and clog the orifices as well as contaminate other colors of ink contained within the printhead. Furthermore, leaky printheads are perceived by consumers as being defective and inferior.
Accordingly, there is an ever present need for continued improvements to printing systems that are more reliable and capable of producing even higher quality images. These printing systems should be well suited for high volume manufacturing as well as have a low material cost thus further reducing per page printing cost.
SUMMARY OF THE INVENTION
The present invention is a printing system comprising an inkjet printhead responsive to activation signals for ejecting ink onto printing media. The printhead comprises a carrier having an upper surface that defines a recess and a fluid ejecting substrate disposed therein that is configured for establishing electrical and fluidic coupling with the carrier. The fluid ejecting substrate has a generally planar orifice layer disposed opposite the upper surface of carrier. The orifice layer defines a plurality of orifices disposed therein. The printhead has a generally planar contact surface positioned below the orifice layer and an encapsulant that at least partially encapsulates the fluid ejecting substrate and the carrier to form a substantially coplanar surface with the orifice layer.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of one exemplary embodiment of a printing system wherein a printhead is translated across a print media to accomplish printing.
FIG. 2 is a schematic representation of a printing system comprising the printhead and a fluid reservoir for replenishing the printhead.
FIG. 3 is a bottom perspective view of the preferred printhead of the present invention that includes a carrier and a fluid ejecting substrate mounted in the carrier.
FIG. 4 ( a ) is a bottom perspective view of the fluid ejecting substrate shown in FIG. 3 independent of the carrier.
FIG. 4 ( b ) is a cross section of the fluid ejecting substrate shown in FIG. 3 where the materials used to form the fluid ejecting substrate are shown.
FIG. 5 is a bottom perspective view in isolation of the carrier shown in FIG. 3 configured to receive a fluid ejecting substrate; the carrier receives ink from the fluid reservoir and channels ink to the fluid ejecting substrate.
FIG. 6 ( a ) is a perspective view of a carrier with the fluid ejecting substrate inserted therein; the fluid ejecting substrate is electrically and fluidically coupled to the carrier.
FIG. 6 ( b ) is a cross section of the carrier shown in FIG. 6 ( a ) where an interconnect formed between the fluid ejecting substrate and carrier is arched.
FIG. 7 ( a ) shows a perspective view of a mold configured to inject an encapsulant into selective regions of a countersunk recess formed in an upper surface of the carrier once the fluid ejecting substrate is inserted into the countersunk recess.
FIG. 7 ( b ) shows a perspective view of FIG. 7 ( a ) where a portion of the mold has been removed thereby revealing the planar surface formed between the upper surface of the fluid ejecting substrate and the upper surface of the carrier.
FIG. 8 ( a ) is a cross-section of FIG. 7 showing the mold, fluid ejecting substrate, and carrier as the encapsulant is injected into the carrier.
FIG. 8 ( b ) is a cross section of the present invention where the fluid ejecting substrate is encapsulated within the carrier thereby creating an upper substantially planner surface.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows an exemplary embodiment of a printing system 100 that includes a printhead 102 of the present invention. The printing system 100 includes a carriage 101 capable of supporting one or more printhead 102 . The carriage 101 is affixed to a carriage support member 104 which supports the printhead 102 as the printhead 102 is moved though a print zone. Collectively, the carriage 101 and carriage support member 104 are the printhead positioning member 105 . As the printhead 102 is moved though the print zone, print media 106 is simultaneously stepped through the print zone. The printhead 102 receives activation signals from the printing system 100 via interconnect 107 for selectively ejecting ink droplets onto the print media 106 while the printhead 102 is moved through the print zone. Alternatively, the printhead 102 may be stationary and the print media 106 moved relative to the printhead 102 to achieve printing. Whereas printing system 100 shown in FIG. 1 is formatted to print on 8½ by 11 inch print media, those skilled in the art will appreciate that printing system 100 and the printhead 102 are equally well suited to a wide variety of other printing environments, such as large format printing and textile printing to name a few.
FIG. 2 shows a schematic representation of a printing system incorporating a preferred embodiment of printhead 102 of the present invention. The printing system includes a fluid reservoir 202 that is fluidically coupled to a printhead 204 wherein ink is ejected from the bottom side (not shown) of printhead 204 . The printhead 204 is connected to the fluid reservoir 202 via a fluid conduit 206 . The fluid conduit 206 is formed of a flexible material that allows ink to continuously flow to the printhead 204 as the printhead 204 is moved across the print media. The printing system shown in FIG. 2 offers the advantage of having a separately replaceable fluid reservoir 202 . Thus, when ink contained in the fluid reservoir 202 is depleted, the fluid reservoir 202 can be replaced without replacing the printhead 204 . Alternatively, the printhead 204 can be replaced independent of the fluid reservoir 202 .
FIG. 3 shows a bottom perspective view of printhead 204 previously shown in FIG. 2 . The printhead 204 has been oriented such that the bottom portion of the printhead 204 from which ink is ejected is visible. The printhead 204 includes a carrier 300 and a fluid ejecting substrate 304 . The fluid ejecting substrate 304 is formed of a semiconductor material and has a plurality of orifices 306 defined in an orifice layer. Ink is ejected through the orifices 306 and onto a print media to accomplish printing. Additionally, the fluid ejecting substrate 304 is electrically coupled to the carrier 300 via electrical interconnect 308 which supplies excitation signals to the fluid ejecting substrate 304 . The electrical interconnect 308 electrically connects electrical connectors 307 formed in the carrier 300 to electrical contacts 309 formed on the fluid ejecting substrate 304 . In the present invention, electrical interconnect 308 is formed of gold wire however, other electrical conductors such as copper, aluminum, or silver to name a few, may also be used.
When the printhead 204 is inserted into the carriage 101 of printing system 100 , the electrical contact pads 310 contact adjacent electrical contact pads formed within the carriage 101 thereby forming an electrical connection between the printing system 100 and printhead 204 . Electrical interconnects 308 and a portion of fluid ejecting substrate 304 are encapsulated with an encapsulant 312 . The encapsulant 312 , as will be discussed in greater detail shortly, is configured to prevent ink from contaminating the electrical interconnect 308 .
FIG. 4 ( a ) is a perspective view of fluid ejecting substrate 304 shown in FIG. 3 independent of carrier 300 . The fluid ejecting substrate 304 has a first planar surface 400 , a second planar surface 402 and a bottom surface 403 . The first planar surface 400 has a plurality of orifices 306 defined in an orifice layer 401 . The second planar surface 402 , commonly referred to as a contact surface, has eight electrical contacts 309 although more or less electrical contacts 309 may be formed on second planar surface 402 depending on the particulars of the printhead. For example, the number of electrical contacts 309 tend to vary with the number of orifices 306 , number of signal lines, and multiplexing scheme of the printing system. The electrical contacts 309 are formed of an electrically conductive material such as aluminum or gold. The bottom surface 403 of the fluid ejecting substrate 304 contains a fluid channel 405 . Fluid from fluid channel 405 is channeled to the heater resistors (not shown) and selectively ejected through orifices 306 formed in the orifice layer 401 .
FIG. 4 ( b ) shows a greatly enlarged cross section of a preferred embodiment of fluid ejecting substrate 304 shown in FIG. 4 ( a ). The fluid ejecting substrate 304 further comprises an ink chamber 410 and heater resistors 412 . Ink received from carrier 300 flows into the fluid channel 405 of the fluid ejecting substrate 304 . The ink is then channeled into an ink chamber 410 where the ink resides on top of heater resistors 412 located at the base 413 of the ink chamber 410 . The heater resistors 412 receive excitation signals through electrical interconnects 308 (not shown) and subsequently eject ink through the orifice(s) 306 .
The fluid ejecting substrate 304 of FIG. 4 ( b ) is made of several materials that are sequentially layered to form a high quality, reliable printhead. Each layer has a predetermined thickness and a unique function. First, a semiconductor substrate 415 is provided that is approximately 0.6 mm thick. Next, a 1.2 μm thick oxide layer 414 is formed on top of the semiconductor substrate 415 to insulate the semiconductor substrate 415 from the forthcoming metal layers. The metal layers, formed on top of the oxide layer 414 consist of Aluminum (Al) 418 and Tantalum Aluminum (TaAl) 420 respectively. The metal layers are used to form the heater resistors 412 formed of a resistive material such as tantalum aluminum 420 and signal lines made of aluminum 418 . In the preferred embodiment, the combined thickness of the metal layers is 1.2 μm. Next, a 0.4 μm thick passivation layer 422 is formed on top of the metal layers. The passivation layer 422 prevents ink, being channeled to heater resistors 412 , from attacking the metal layers. An additional layer of protection, commonly referred to as a cavitation layer 424 , is formed on top of the passivation layer 422 . The cavitation layer 424 is made of Ta and ranges in thickness between 0.1 um and 0.8 um. An orifice layer 401 is then formed on top of the Ta layer 424 . The orifice layer 401 is typically 40 μm thick although a lesser or thicker orifice layer may be used.
FIG. 5 shows a perspective view of carrier 300 having an upper surface 500 and a countersunk recess 502 therein. The countersunk recess 502 is sized to accommodate the fluid ejecting substrate 304 . In a preferred embodiment, the countersunk recess 502 has a recess bevel depth indicated by reference character “d 1 ”. Recess bevel depth dl extends from upper surface 500 to inner lower surface 512 of carrier 300 . The counter sunk recess 502 contains electrical connectors 307 which receives excitation signals (not shown) from the printing system. The electrical connector 307 resides above the inner lower surface 512 by an electrical connector height designated by reference character “h 4 ”. The number of electrical connectors 307 typically correspond to the number of electrical contacts 309 on fluid ejecting substrate 304 . The carrier 300 also contains an aperture 506 that is coupled to fluid reservoir 202 shown in FIG. 2 . Ink flowing in aperture 506 inters a channel 510 on top of which fluid channel 405 of fluid ejecting substrate 304 resides. In a preferred embodiment of the present invention, carrier 300 is formed of molded plastic, however, other materials could be used to form the carrier 300 including ceramic, metal, and carbon composites.
FIG. 6 ( a ) shows carrier 300 having fluid ejecting substrate 304 inserted into the countersunk recess 502 . The second planar surface height designated by reference character “h 3 ” shown in FIG. 4 ( b ) is chosen such that when the fluid ejecting substrate 304 is inserted into the carrier 300 , second planar surface height h 2 and electrical connector height designated by reference character “h 4 ” align. Additionally, bevel height h 2 is chosen such that first planar surface 400 of fluid ejecting substrate 304 and upper surface 500 of carrier 300 align as well. Alternatively, first planar surface 400 of fluid ejecting substrate 304 may extend above upper surface 500 of carrier 300 . Next, the fluid ejecting substrate 304 is electrically coupled to the carrier 300 via electrical interconnect 308 . The electrical interconnect 308 is formed below the first planar surface 400 of the fluid ejecting substrate 304 and upper surface 500 of carrier 300 .
FIG. 6 ( b ) shows an enlarged cross section of one electrical interconnect 308 formed between the fluid ejecting substrate 304 and carrier 300 . The electrical interconnect 308 is wire bonded to the electrical connector 307 and electrical contact 309 such that the electrical interconnect 308 is arched at a radius indicated by reference character “R” shown in FIG. 6 ( b ). Positioning the electrical interconnect 308 as such is a common practice in the semiconductor industry. Forming an arch with the electrical interconnect tends to relieves stress which may otherwise lead to an electrical failure. The radius 602 is typically 100 μm and is less than the film stack height indicated by reference character h 1 shown in FIG. 4 ( b ) which typically equals 41 μm.
To ensure that the arched electrical interconnect 308 does not extend beyond the first planar surface 400 of the fluid ejecting substrate 304 , a bevel height indicated by reference character “h 2 ” shown in FIG. 6 ( b ) is increased. Increasing bevel height h 2 effectively lowers the electrical interconnect 308 relative to first planar surface 400 . Perhaps most significantly, the value of bevel height h 2 , which is typically 150 μm, can be chosen such that first planer surface 400 extends beyond the upper surface 500 of the carrier 300 while the arch of the electrical interconnect 308 resides below the upper surface 500 of carrier 300 . Alternatively, the value of bevel height h 2 may be chosen such that first planar surface 400 and upper surface 500 reside in the same plane while the arch of the electrical interconnect 308 resides below the upper surface 500 . Although in an embodiment of the present invention, a wire bond was used, a TAB circuit, which typically has a thickness greater than height h 1 may be used as well.
FIG. 7 ( a ) shows a mold 700 being used to dispose the encapsulant 312 in selected areas of carrier 300 . The encapsulant 312 is supplied to mold 700 in liquid form through inlet 704 . Additionally, a groove 702 is formed in mold 700 , thereby preventing the orifice layer 401 beneath mold 700 from being damaged when mold 700 is brought in contact with the carrier 300 . FIG. 7 ( b ) shows a perspective view of FIG. 7 ( a ) where a portion of mold 700 has been removed thereby revealing the planar surface formed between first planar surface 400 of fluid ejecting substrate 304 and upper surface 500 of carrier 300 . The encapsulant 312 is selectively disposed into two areas of carrier 300 . First, the encapsulant 312 is disposed in seams 706 created adjacent to the fluid ejecting substrate 304 and the countersunk recess 502 following the insertion of the fluid ejecting substrate 304 . Second, the encapsulant 312 is disposed in an interconnect region 708 of the fluid ejecting substrate 304 .
FIG. 8 ( a ) shows a cross section of FIG. 7 ( a ) where mold 700 is put in contact with carrier 300 . The encapsulant 312 is injected into the carrier 300 through channels 800 or alternatively, the encapsulant 312 is drawn into carrier 300 through channels 800 via capillary action. While the encapsulant 312 is dispensed onto the carrier 300 through mold 700 , the encapsulant 312 is isolated from the orifice layer 401 . Shielding the encapsulant 312 from the orifice layer 401 is important because the encapsulant 312 , if exposed to the orifice layer 401 , will permanently clog the orifices 306 formed therein. Once the encapsulant 312 has been dispensed, the encapsulant 312 dries at ambient temperature or is externally heated to accelerate the drying/curing process. Additionally, ultraviolet light may be used to cure the encapsulant as well. In a preferred embodiment of the present invention, the curing of the encapsulant 312 is accelerated by heating coils 802 formed within mold 700 .
FIG. 8 ( b ) shows a preferred embodiment of the present invention where the encapsulant 312 has been injected into the carrier 300 and mold 700 has been removed. The encapsulant 312 further planarizes the upper surface 500 of the carrier 300 and prevents ink on the orifice layer of the fluid ejecting substrate from reaching the electrical interconnect 308 . Consequently, damage to the electrical interconnect 308 by the ink is eliminated. Furthermore, since the electrical interconnect 308 is formed below the first planar surface of the fluid ejecting substrate 304 prior to the formation of the encapsulant 312 , the encapsulant bead prevalent in conventional printheads is eliminated. By eliminating the encapsulant bead, the printhead 204 of the present invention is operated in close proximity of the print media. In one embodiment, the encapsulant 312 allows the printhead positioning member 105 to position the orifice layer within 0.5 millimeters of the print media. Consequently, trajectory errors and parasitic effects inherent to the printing environment are minimized thereby improving print quality.
Previous attempts have been made to improve the reliability of printheads. For example, U.S. Pat. No. 4,873,622 to Komuro, et al., entitled “Liquid Jet Recording Head” describes a pressure transfer molding technique used to form a recording head. The recording head contains a discharge element having a membrane disposed thereon from which ink is ejected onto a print media. The discharge element is electrically coupled to a metal frame. The electrical connection is made on top of the discharge element and an epoxy is molded around the electrical connection and recording head. The membrane is recessed within the molded epoxy.
In the present invention, makes use of a stepped die so that the electrical connection is formed sufficiently below the orifice layer so that the encapsulant can be formed in the same plane as the orifice layer. The encapsulant of the present invention is in plane with the orifice layer in contrast to the Komuro reference where the membrane is recessed within the molded epoxy and therefore, the printhead of the present invention allows the orifice layer to be positioned closer to print media than the membrane of Komuro. Positioning the orifice layer closer to the print media allows trajectory error to be reduced. In addition, the printhead of the present invention provides a planar printhead surface that is readily cleaned in contrast to Komuro that has a recording head structure with a recess that tends to trap ink residue and debris and is harder to clean using conventional wiping technology. | A fluid ejection device capable of ejecting fluid onto media. The device includes a carrier having an upper surface that defines a recess. The device further includes a fluid ejecting substrate disposed therein that is configured for establishing electrical and fluidic coupling with the carrier. The fluid ejecting substrate has a generally planar orifice layer defining a plurality of orifices therein and a generally planar contact surface positioned below the orifice layer. The device further includes an encapsulant that at least partially encapsulates the fluid ejecting substrate and the carrier to form a substantially co-planar surface with the orifice layer. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. application Ser. No. 11/008,805, filed Dec. 9, 2004, entitled: Interproximal Dental Tool, from which U.S. Design Pat. D638127, issued May 17, 2011 entitled: Interproximal Dental Tool is a continuation, which is a continuation-in-part of U.S. Design Pat. D609341, issued Feb. 2, 2010 entitled: Interproximal Dental Tool, which is a divisional of U.S. Design Pat. D600810 issued Sep. 22, 2009 entitled: Interproximal Dental Tool. The entire disclosures of each patent/application are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to an interproximal dental tool, and more particularly, an interproximal dental tool for detaching unwanted material from teeth.
[0004] 2. Discussion of Prior Art
[0005] Interproximal dental tools which are currently in use for detaching unwanted material by and large are ineffective, are often difficult to use and far too often lead to injuries to the patient or dental practitioner. For example, interproximal dental tools in the form of dental saws currently are elongated, flexible, thin metal strips having a serrated edge which is inserted between the teeth to remove excess or unwanted material. This type of tool is operated by gripping each end and working the tool back and forth between the teeth in order to cut away the undesired material. As such, the dental practitioner must insert at least one hand into a patient's mouth which results in discomfort to the patient. Worse yet, in the event that the tool is used on teeth posterior to the incisors, it may be required that both of the dentist's hands are at least partially inserted into the patient's mouth which is even more uncomfortable.
[0006] Another perceived problem with the prior art dental saws is that far too often injury results at least in part due to the flexible nature of the thin metal strip material. Because it is difficult to control the depth of insertion between the teeth, particularly the teeth in the posterior region of the mouth, it is not uncommon to lacerate the gum tissue with this type of prior art device. Additionally, because the serrated edge of the tool extends virtually its entire length, far too often the dental practitioner's hands are injured when handling the device.
[0007] Still another perceived problem relates to the overall effectiveness of the prior art tool. Because the tool is highly flexible to allow for the insertion between the teeth, an inherent drawback is the difficulty in generating sufficient leverage on the tool when in use to effectively remove unwanted material.
[0008] In view of the foregoing it is readily apparent there is a need in the art for an improved interproximal dental tool which is effective at removing unwanted material, easier to use, and less likely to result in injury to the patient or dental practitioner during use.
SUMMARY OF THE INVENTION
[0009] In accordance with the present invention, there is provided an interproximal dental tool for detaching material from teeth comprising:
[0010] a housing, including a body, having spaced first and second ends; and
[0011] a blade fixedly attached to said housing and extending between the first and second ends, said blade including a leading portion having means for detaching material from teeth.
[0012] Examples of unwanted materials which can be detached from the teeth are materials used to repair teeth or used in cosmetic dental procedures. Such materials include by way of non-limiting example, cements, ceramics, composites, thermoplastics, and adhesives. Other unwanted materials may include calculus.
[0013] 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
[0014] The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein:
[0015] FIG. 1 is a perspective view of an interproximal dental tool in accordance with the teachings of the present invention;
[0016] FIG. 2 is a side view of the interproximal dental tool of FIG. 1 ;
[0017] FIG. 3 is an end view of interproximal dental tool of FIG. 1 ;
[0018] FIG. 4 is a cross sectional view taken along lines 4 - 4 of the interproximal dental tool of FIG. 1 ;
[0019] FIG. 5 is a side view of interproximal dental tool of FIG. 1 depicting a blade imbedded within the molded handle;
[0020] FIG. 6 is a top view of the interproximal dental tool of FIG. 1 ;
[0021] FIG. 7 is a perspective view of an alternative embodiment of an interproximal dental tool in accordance with the teachings of the present invention;
[0022] FIG. 8 is a perspective view of still another alternative embodiment of an interproximal dental tool in accordance with the teachings of the present invention;
[0023] FIG. 9A is a top view of the interproximal dental tool of claim 8 ;
[0024] FIG. 9B is a bottom view of the interproximal dental tool of claim 8 ; and
[0025] FIG. 10 is an end view of the interproximal dental tool of claim 8 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0026] The following description of various embodiments is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses.
[0027] Generally, the present invention describes a new and improved interproximal dental tool which is easy to use, effective and inexpensive to manufacture. Referring to FIGS. 1-6 , a first embodiment of an interproximal dental tool 10 contemplated under the present invention includes as its major components, a blade 12 which is fixedly attached to a housing 14 . The housing 14 which serves as a handle for gripping the tool along the outer edge 16 and/or along the respective opposing side walls 18 and 18 a depending upon which teeth are being worked on, has a substantially U-shaped body 20 which results in a recess 22 extending from a first end 24 of the housing 14 to a second end 24 a. Disposed within the recess 22 is blade 12 which extends from the first end 24 to the second end 24 a of the housing 14 . As will be described in greater detail below, the housing 14 is generally formed from a suitable injection moldable thermoplastic material which has a relatively high coefficient of friction to enhance gripping of the interproximal dental tool during use.
[0028] The housing is ergonomically sized to be conveniently used between the practitioner's index finger and thumb as shown in phantom in FIG. 1 . For example, the length of the tool from the first end 24 to the second end 24 a along the leading edge 42 is generally no more than about 1.25 inch. The height dimension of the dental tool as measured from the center point 34 of the housing base 26 to the leading edge 42 of the blade 12 along center line 4 - 4 is generally no more than about 0.75 inches. Likewise, the blade height as measured along the center line 4 - 4 from the terminal edge 50 of the housing to the leading edge 42 of the blade is generally no more that about 0.4 inches such that the blade can be fully inserted between the teeth. Thus, as should be appreciated, by ensuring that the blade height is no more than about 0.4 inches, the terminal edge 50 effectively serves as a stop mechanism to prevent undue penetration of the gum tissue. The width dimension at the widest point along the outer edge 16 is generally no more than about 0.5 inches. As should be appreciated by those skilled in the art, the dimensions set forth above may differ slightly for different oral care applications, provided the tool is small enough to be used between the thumb and fingers of the dental practitioner.
[0029] As shown most clearly in FIGS. 1 and 3 , respectively, the outer edge 16 may include enhanced gripping means for maintaining the dental practitioner's fingers along the tool during periods of use. Thus, by way of non-limiting example horizontally aligned ribs 30 are shown that rise above the face 32 of the outer edge along at least one of the first and second ends. The side walls 18 and 18 a of the housing may taper inwardly from the outer edge 16 of the housing 14 toward the blade 12 which assists in maintaining a grip when the user needs to grip the dental tool along the sides. In addition to the inward tapering, the housing material may be thinner at the center point 34 and thicker toward the ends 24 and 24 a respectively such that the housing is essentially concaved along either side as depicted most clearly in FIG. 6 . Likewise the outer edge 16 may be slightly concaved as indicated by reference numeral 36 in FIG. 4 to enhance gripping.
[0030] The blade 12 is generally formed from a thin, sterile metallic strip such as stainless steel. The blade as shown includes a first edge area 40 which is embedded within the housing 14 and thus is shaped to meet the molding requirements to obtain a substantially U-shaped housing as described above. The blade 12 also includes a second edge area 42 otherwise referred to herein as leading edge area extended proximate to the distal portions of the first and second ends 24 and 24 a of the housing. As shown in FIGS. 1-6 serrations 48 project from the leading edge area which are shaped to cut away material. The serrations 48 can vary in shape and size as is known in the art.
[0031] The average width of the blade should be no more than about 0.1 mm, and preferably no more than about 0.05 mm to effectively fit between the teeth. Widths of about 0.05 mm allow the blade to flex during use which is helpful in accessing hard to reach areas.
[0032] Referring to FIG. 7 , an alternative embodiment is depicted. Under this embodiment, the leading edge area 42 includes a band of abrasive material 52 along at least one blade side 28 and 28 a which are referenced in FIG. 6 . By providing an abrasive, the dental tool of the present invention can be used when a sanding or smoothing activity is called for to detach unwanted material. As demonstrated, typically the band of abrasive will be discontinuous thereby providing an abrasive free gap 54 . The abrasive free gap 54 allows for the blade to be inserted between the teeth and to avoid undesired abrasion of the teeth. The width of the abrasive band can vary according to need but typically will be less than about 0.25 inches. Additionally, the grit of the abrasive can be varied along the band such that a first section 56 has a first grit and a second section 56 a has a second grit. This may allow a dental practitioner to perform both sanding (course to medium grit) and smoothing (medium to fine grit) with a single dental tool. The abrasive materials employed are considered a matter of design choice.
[0033] Referring to FIGS. 8-10 , still another alternative embodiment is depicted. For ease in description, the reference manual designations will be increased by 100 for previously described elements. According to this embodiment, the interproximal dental tool 110 includes two blades 112 , 112 a provided on opposite ends on the same tool. The body 120 of the housing 114 includes first and second opposing substantially U-shaped portions thereby resulting in an overall dog bone shape. By providing multiple blades 112 , 112 a the dental practitioner could optionally performing multiple tasks with a single tool. For example, as depicted in FIG. 8 , the bottom half 160 of the tool 110 may include a blade 112 having serrations 148 along the edge 140 and the other half 160 a of the tool may include a blade 112 a having a band of abrasive material dispersed in proximity to the leading edge. As should be appreciated, such an embodiment would allow the dental practitioner the option of cutting away unwanted material with the serrated portion and optionally smoothing and sanding away unwanted material with the abrasive portion. Again, it is beneficial to include an abrasive free gap 154 . Still, other combinations are anticipated with the embodiment of FIG. 8 such as both blades 112 , 112 a including serrations, optionally with different size and/or shaped serrations. Likewise, both blades 112 , 112 a could have different abrasive materials, e.g. different grits, to carry-out differing functions as described above.
[0034] The housing would also generally include of the features described with reference to the embodiments of FIGS. 1-7 . For example, the sidewalls 118 , 118 a can be tapered inwardly from the dot and dash center-line 162 toward each of the perspective blades 112 , 112 a. Likewise, the housing material may be thinner at the center point 134 than along the ends 124 , 124 a as depicted in FIG. 9 . The outer edge of the tool 116 may be concaved and may include ribs 130 as shown in FIG. 9 .
[0035] Regarding the manufacture of the interproximal dental tools depicted with reference to FIGS. 1-6 and 7 , a preferred method involves the steps of positioning the blade 12 within an injection molding cavity and injection molding the housing 14 relative to the blade(s). Upon molding, the blade becomes fixed to the housing and projects from the housing to substantially occupy the recess 22 leaving the leading edge area and sides 28 and 28 a freely exposed. Thus, the first edge area 40 of the blade 12 which is depicted with dot and dash lines is embedded in the housing. To enhance fixation of the blade 12 to the housing, the blade 12 may include a plurality of apertures 46 , as shown in FIGS. 4 and 5 , disposed near the first edge area 40 through which the thermoplastic material flows. Thus after injection and upon curing the thermoplastic material, an effective dynamic interproximal dental tool is achieved.
[0036] Similarly, the interproximal dental tool of FIG. 8 involves the steps of positioning a single blade having dual blade portions 112 , 112 a, or dual blades within an injection molding cavity and injection molding the housing 114 relative to the blades. Again, edge areas of the respective blades are captured by the thermoplastic and may include apertures such as those shown in FIG. 5 , disposed therealong for enhancing fixation of the blades within the housing. Optimally, a hole 162 may be provided along the housing or extending from the housing (not shown) for application of a suitable tether.
[0037] 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. | The present invention relates to a hand held interproximal dental tool for detaching unwanted materials from a patient's teeth and to methods of manufacturing such tools. The interproximal dental tool includes a compact, ergonomically designed housing which is gripped by a dental practitioner during use and a blade extending from and structurally supported by the housing which includes serrations for cutting or abrasive materials for sanding unwanted material. | 0 |
FIELD OF THE INVENTION
This invention is a portable door-securing device which can be readily attached by an occupant of a room from the inside to hold the door securely closed and yet be readily and quickly removed to open the door. It is used in addition to conventional deadbolt locks and requires no modification to conventional doors, door frames or jambs.
DESCRIPTION OF THE PRIOR ART
The closest prior art is a commercially available device. The instant invention is an improvement over this prior art.
SUMMARY OF THE INVENTION
Similar to the prior art, an elongated rigid strip has a stud near one end for engaging the striker plate hole in a door jamb and extends from the striker plate hole into the interior of the room through the gap between the closed door and the door jamb. The extended portion has a series of equally dimensioned through holes which are spaced apart in a staggered fashion. A generally rectangular rigid locking plate has a center slot to enable it to slide over and along the extended end of the strip orthogonal to the strip to press up against the closed door and the jamb. A locking pin inserted in one of the through holes in the strip holds the locking plate firmly and securely in place against the door and the door frame. Resilient pads are attached to the side of the locking plate facing the door and the door frame or jamb to prevent marring of the door and door frame surfaces and to permit the locking plate to be pushed firmly against the door and door jamb or frame so that when the locking pin is in place, the door is held firmly closed. The pads may differ in thicknesses to compensate for unevenness between the door and frame, e.g., if the door is not flush with the door frame, i.e., if the inner surface of the door and the inner surface of the door frame are not in the same plane when the door is closed, or if there is a molding on the door jamb. Also, at its inner end the strip is angled away from the door to make it easier to place the locking device in position when closing the door.
As one feature of the instant invention, the locking stud is machine pressed onto the strip to insure that it will not break loose if excess pressure is applied to the door. Another feature is that about one-half the length of the locking pin is knurled or otherwise roughened so that the pin will enter only half its length into the hole. In this fashion any force applied by the door to the locking plate is equally distributed over the full length of the locking pin. Also, the locking pin can be slightly twisted while being inserted in the hole so that the edge of the roughened surface will make a firm frictional fit within the hole to lessen the chance that the pin could be jiggled loose. Another feature is that the pads are made of different durometer material for reasons described later.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the prior art;
FIG. 2 is a cross-section showing a portion of the door and the door jamb with the invention in use to secure the closed door; and
FIG. 3 illustrates attachment of the locking stud to the locking strip.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Since the prior art and the instant invention are similar, the same reference numerals are used for corresponding component parts in the prior art and the instant invention with reference to FIGS. 1 and 2. An elongated strip 10 made of a material having a suitable strength, preferably thirteen gauge sheet steel, has a stud 11 attached at one end which extends out orthogonally from one of the major surfaces of the strip 10 and engages a conventional striker plate opening 12 in a door jamb 13 for door 14. Conventionally, a spring-biased latch in the door normally engages the striker plate opening when the door is closed but with this invention the latch is recessed back into the door and is not shown for clarity. Strip 10 extends from the striker plate opening 12 through the space between the edge of the closed door 14 and jamb 13 into the interior of the room. The inner extending portion of strip 10 has a number of equally dimensioned through holes 15 which are spaced apart in a staggered fashion. At its furthest interior end 10A strip 10 is angled away from the door to make it easier to hold the strip in place after the stud has been inserted and while the door is being closed. A rigid generally rectangular locking plate member 16, also made out of a material of suitable strength, such as thirteen gauge sheet steel, has a central slot 17 for accommodating strip 10 so that locking plate 16 can be slid back and forth along strip 10. On the surface of locking plate 16 facing door 14 is an adhesively attached resilient pad 18 and facing door jamb or frame 13 is a thinner adhesively attached resilient pad 19. In the prior art (FIG. 1) a rigid locking pin 20 (FIG. 1) is suitably dimensioned and smoothly finished to snugly yet slidably engage holes 15 over its entire length and is tapered at one end 20A so it can be easily guided into the hole. One end of a chain 21 is attached to the other end of pin 20 and the other end of chain 21 is attached to strip 10 for convenience in keeping the two pieces joined together.
In use, door 14 is first held partially ajar to enable the stud 11 to be inserted into the striker hole 12 and door 14 is then closed and, if necessary, the strip 10 is pulled so that stud 11 rests against an edge of the striker hole 12. Locking plate 16 engaged with strip 10 via slot 17 is then pushed firmly against the door and the door jamb compressing pads 18 and 19 to make firm pressing contact against the door and the door jamb and then the locking pin 20 is inserted in a suitable hole 15 to hold the locking plate 16 secure. Essentially, the instant invention functions in the same fashion but with some differences.
As mentioned earlier, pads 18 and 19 may be of different thickness to accommodate any offset between the door jamb and the door. Typically, for example, the door jamb may have a molding around it so when the thicker pad 18 is pressed against the door the thinner pad 19 rests on the molding. As part of the instant invention the thicker pad 18 is made out of a relatively hard, slightly compressible rubber having in the order of about forty to fifty durometer while the thinner pad 19 is made out of a foam-like rubber having a high degree of compressibility as compared to the thicker pad 18. The low compressibility pad 18 is located on locking plate 16 opposite the door so when locking plate 16 is secured in place any force applied against the door will produce little or no movement of the door so that pin 30 (FIG. 2) cannot be jiggled out of hole 15 in strip 10. The higher compressible pad 19 also serves the function of allowing the locking pin 30 to be set into the best hole for holding the door tightly closed. For example, when locking plate 16 has been manually pushed firmly against the door, a hole 15 adjacent the locking plate 16 may be only partly open. By manually pushing locking plate 16 forcibly against the softer pad 19 to somewhat skew plate 16, the hole can be opened somewhat further so that pin 30 can then be inserted into the hole where it will then be holding the door closed as tightly as possible. To unsecure the door pin 30 can be removed in similar fashion.
As a further feature of the invention, one-half the length of pin 30, designated 30A, is smooth-surfaced and dimensioned so that it snugly yet slidably engages hole 15 similar to pin 20 while the other half, 30B, has a knurled or otherwise roughened surface so that pin 30 can be inserted only about half way into the appropriate hole. This distributes any force on the locking plate 16 equally over the length of pin 30 thereby minimizing the likelihood that pin 30 can be bent so that pin 30 would only give way by being sheared, which is highly unlikely. As an added feature, as the smooth length 30A of pin 30 is inserted into the appropriate locking hole 15 when the roughened or knurled surface 30B is reached the pin can be pushed and rotated so that the edge of the knurled section 30B will bite into the interior surface of hole 15 to help hold pin 30 securely in place and make it unlikely that the pin would fall or be jiggled loose out of the hole.
Another feature of the invention, as illustrated in FIG. 3, is the manner in which stud 11 is attached to strip 10. Initially strip 10 has a through hole 21 which is beveled at one end 22. Stud 11 is made out of the same round bar stock as an undercut smaller diameter rod 23 which is snugly pushed into hole 21 until the underside of stud 11 rests against the topside of strap 10 (as viewed in the drawing). An axial force is applied by a machine press to stud 11 and rod 23 to compress the latter so that it fills in the beveled area 22 and thereby firmly locks stud 11 onto strip 10 almost as a single integral unit. | A press fitted stud on one end of a metal strip is hooked into the opening of a striker plate in a door jamb and the strip extends in the space between the jamb and the edge of the door past the jamb and closed door. The extended end of the plate has holes for receiving a knurled locking pin which holds a locking plate tightly against the closed door and the door jamb to keep the door securely closed. Resilient pads of different thickness and compressibility on the locking plate facing the door keep the door tightly closed. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention pertains to the art of laundry appliances and, more specifically, to the incorporation of a versatile programming control arrangement in a laundry appliance.
2. Discussion of the Prior Art
In a laundry appliance, such as a clothes washer or dryer, it is necessary for a consumer to establish a certain operating cycle, as well as a desired operating time for the cycle. For example, in a washing machine, either before or after loading a tub of the machine with clothes to be laundered, the user must establish both a desired cycle and to establish an operating time for the cycle. Typically, a rotatable control knob is provided on a control panel of the appliance, with the knob having associated graphic zones thereabout to signify different, selectable cycles. For instance, a conventional washing machine would incorporate a knob which can rotate through 360° for use in selecting between the washing of whites, delicates or colors. The knob would have associated therewith an indicator which generally functions as a pointer to provide feedback to the user of the selected operation.
The time needed to perform the selected operation depends on the positioning of the knob within a given cycle range. For example, the consumer can set the appliance to perform a light, normal or heavy washing operation, with each of these settings functioning to establish the length of time needed to perform the selected washing cycle. Additionally, the consumer could simply select a rinse mode, along with the time for the rinse mode.
In such a commonly known cycle and time setting arrangement utilizing a rotatable control knob, the knob can only be rotated in one direction. As the cycles for whites, delicates and colors are sequentially arranged about the knob, the knob often has to be rotated through a significant angular range to reach a desired position. In addition, since the knob can only be rotated in one direction, if the user even slightly over-rotates the knob, the user must then rotate the knob through slightly less than 360° to finally reach the desired setting. Obviously, this overall control setting arrangement is quite inefficient.
A similar rotatable control knob arrangement for use in selecting both cycle and operating times can also be found in many clothes dryers. That is, it is known to provide a rotatable knob on a clothes dryer wherein the knob is used to select both the drying cycle, generally based on the type of clothing articles to be dried, and the drying time. Therefore, the same type of disadvantages discussed above with respect to the known washing machine control arrangements can also pertain to clothes dryers. In any event, there exists a need in the art of laundry appliances for an improved operation cycle and time setting control device wherein operation cycles and times can be easily and efficiently established.
SUMMARY OF THE INVENTION
The present invention pertains to a control device including a member which need only be manually shifted through a limited range of travel to establish a desired cycle and to adjust an operational time for the cycle in a laundry appliance. In accordance with a preferred embodiment of the invention, the control member has associated therewith four movable contacts which are arranged in pairs and interposed between three fixed contacts. Shifting of the control member a small amount in a first direction will function to engage a single pair of the contacts which, in accordance with a preferred embodiment of the invention, will cause a slow increase in the cycle time for the appliance. A larger shift of the control member causes another one of the movable contacts to engage another fixed contact to cause a change in the operation cycle for the appliance, preferably towards a previous cycle.
The control member is preferably biased to a center or neutral position. In a corresponding manner, a small shift of the control member from the neutral position in a second direction, opposite the first direction, causes a slow decrease in the cycle time. A larger shift of the control member in the second direction causes the system to advance to the next cycle. In any event, with this system, contacts which move with the control member can cooperate with fixed contacts to enable both time and cycle adjustments by the user through only a very limited range of travel of the control member.
In accordance with the most preferred form of the invention, the control member constitutes a rotary knob which need only be rotated a few degrees in order to complete a programming operation in a quick and convenient manner. In one embodiment of the invention, the control knob can only be rotated through approximately 15° either direction from the neutral position. Around the rotary control knob is provided an annular graphic zone and an indicator is utilized to reflect the programmed information to the user. Most preferably, a light is provided in the annular zone to indicate both the cycle selected by the user and also the established cycle time. Therefore, the appliance control provides immediate feedback, in a consumer friendly manner, by lighting up a specified portion of an illumination track. When a rotary control member is utilized, the illumination track generally simulates a dial skirt.
Additional objects, features and advantages of the present invention will become more fully apparent from the following detailed description of a preferred embodiment, when taken in conjunction with the drawings wherein like reference numeral refer to corresponding parts in the several views.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front perspective view of a top loading washing machine incorporating the programming control device of the present invention;
FIG. 2 is enlarged, front view of a control dial incorporated in the programming control device of FIG. 1; and
FIG. 3 depicts an electrical contact and rotary control arrangement according to a preferred embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
With initial reference to FIG. 1, a laundry appliance constructed in accordance with the present invention is generally indicated at 2 . For exemplary purposes, laundry appliance 2 is shown to be constituted by a clothes washer. However, as will become more fully evident below, the invention is also applicable to clothes dryers as well. As shown, laundry appliance 2 includes an outer cabinet 5 provided with an upper opening 8 that can be selectively closed by means of a pivotable lid 12 . In a manner widely known in the art, lid 12 can be raised to provide access to a rotatable basket (not shown) mounted within cabinet 5 , with clothes to be laundered being adapted to be placed in the basket. In the preferred embodiment shown, lid 12 includes an angled front portion 15 to enhance access to within cabinet 5 .
At a rear portion of cabinet 5 is arranged a control panel 20 that includes various control units which can be used to program a desired laundering operation for appliance 2 . In the preferred embodiment shown, control panel 2 includes a first control unit 30 having a vertically shiftable knob 32 . Knob 32 is adapted to be shifted between raised and lowered positions in order to enable a user of appliance 2 to select a desired load size. For instance, knob 32 can be shifted between mini, medium, large and super load capacity positions, as well as potential reset position. Control panel 20 also includes a second control unit 35 that is defined by a plurality of buttons 38 - 41 . Second control unit 35 is provided in accordance with the exemplary embodiment of the invention of a washer machine in connection with establishing wash and rinse temperatures. Therefore, button 38 is used to establish hot/cold wash/rinse temperatures; button 39 is used to establish warm/warm wash/rinse temperatures; button 40 is used to establish warm/cold wash/rinse temperatures; and button 41 is used to establish cold/cold wash/rinse temperatures respectively.
Adjacent second control unit 35 is a third control unit 45 which is defined, in the preferred embodiment shown, by buttons 48 - 50 . Third control unit 45 can be used by a consumer to selectively establish a super wash operation through the use of button 48 , the application of a second rinse through button 49 , and to cancel either of these control features through button 50 .
In addition to these operating parameters, it is also necessary to establish both a desired cycle and operational time for a laundry operation to be performed within appliance 2 . To this point, it should be recognized that first, second and third control units 30 , 35 and 45 are dedicated for use in connection with the preferred embodiment of laundry appliance 2 being a washing machine. Obviously, the need for this number of control units and/or the functions performed thereby would change when utilizing the invention in connection with a clothes dryer. In general, the structure described above with respect to laundry appliance 2 is already known in the art and does not constitute part of the present invention. Therefore, this structure has only been described for the sake of completeness. Instead, the present invention is particularly directed to the structure and function of a fourth control unit 55 formed as part of control panel 20 .
As shown in both FIGS. 1 and 2, fourth control unit 55 includes a control member 59 that preferably takes the form of a rotatable knob. About control member 59 is provided graphic indicia generally indicated at 63 which, in the preferred embodiment shown, is essentially divided into first, second and third graphic zones 66 , 70 and 74 respectively. First graphic zone 66 is used in connection with the preferred embodiment of the invention to represent a washing cycle for whites; second graphic zone 70 represents a washing zone for delicate clothing articles; and third graphic zone 74 represents a washing cycle selection zone for colored garments. As will be readily evident to the reader of this disclosure, the provision of indicia defined within zones around a rotatable knob within a washing machine is also quite prevalent in the art. However, it is particularly the manner in which control member 59 is shifted to establish a particular operation cycle as represented by the various zones, along with the operational time for the selected cycle, that is of particular concern as will be more detailed more fully below.
Disposed annularly about control member 59 and radially positioned between control member 59 and graphic indicia 63 is an annular illumination track 80 as clearly shown in FIG. 2 . Disposed within annular illumination track 80 is an indicator 84 which is preferably constituted by a light element such as an LED or diode. Indicator 4 is used to convey to the user of appliance 2 an established desired cycle and operational time for a laundry operation. For example, in the position shown in FIG. 2, indicator 84 represents a selected cycle for whites, with the operation being established for a relatively short cycle due to light clothes soiling.
FIG. 3 illustrates details of control member 59 . More specifically, control member 59 includes an inner body portion 90 that is rotatable about an axis 92 . As will be detailed fully below, body portion 90 is only rotatable about a limited angular range in opposing directions. That is, body portion 90 is biased to a neutral position as shown in FIG. 3 and can be rotated either clockwise or counterclockwise. In the most preferred embodiment, body portion 90 is biased by means of a torsion spring 95 including a first end 98 attached to body portion 90 adjacent axis 92 and a second end 99 that is fixed at 100 . As shown, body portion 90 includes angled side portions 104 and 105 which are adapted to cooperate with stop abutments 106 and 107 respectively for limiting the rotational angle or shifting of control member 59 . In a preferred embodiment of the invention, this angular movement is limited to a range of no more than 45°. In the most preferred embodiment, body portion can only be shifted from the neutral position through approximately 15° in either the clockwise or counterclockwise rotational directions.
Extending from body portion 90 are a plurality of spaced contact members 108 - 111 . Most preferably, each contact member 108 - 111 has arranged on a tip thereof an electrical contact, such as that indicated at 114 . Control member 59 also has associated therewith a plurality of fixed contact elements 121 - 123 . In a manner similar to contact members 108 - 111 , fixed contact elements 121 - 123 also have associated electrical contacts on tips thereof, such as indicated at 127 . As will be detailed further below, contact members 108 - 111 are adapted to be electrically interconnected with respective ones of fixed contact elements 121 - 123 through the engagement of electrical contacts 114 and 127 in order to complete an electrical circuit through body portion 90 in order to direct signals to a program module 133 of control panel 20 through various wires 136 .
In the most preferred embodiment depicted in FIG. 3, contact members 108 and 109 are interposed between contact elements 121 and 122 , while contact members 110 and 111 are interposed between contact elements 122 and 123 . More specifically, while body portion 90 and, commensurately, overall control member 59 , is in a neutral position, contact member 108 is preferably spaced a distance X from contact element 121 . Contact member 111 is similarly distanced from contact element 123 . On the other hand, contact members 109 and 110 are spaced a greater distance than distance X from contact element 122 . In the most preferred form of the invention, contact members 109 and 110 are each spaced a distance equivalent to 2X from contact element 122 .
With this arrangement, rotation of control member 59 in a first direction, such as a counterclockwise direction, will always initially cause contact member 108 to engage contact element 121 . That is, after body portion 90 has been shifted through an arcuate distance equal to X, the electrical contact 114 of contact member 108 will engage the electrical contact 127 of contact element 121 in order to send a signal through a respective wire 136 to program module 133 . Continued rotation of control member 59 in the counterclockwise direction will cause contact member 110 to engage contact element 122 . Of course, this engagement requires some flexing of either or both of contact member 108 and contact element 121 . In the most preferred form of the invention, each of contact members 108 - 111 and contact elements 121 - 123 can be elastically deflected. As indicated above, the distance X only represents a minimal angular shifting of body portion 90 , most preferably through approximately 15°.
In a similar fashion, control member 59 can be rotated in the clockwise direction from the neutral position shown in FIG. 3 in order to initially engage contact member 111 with contact element 123 and, upon further rotation in the clockwise direction, to cause contact member 109 to engage contact element 122 . Again, each of these interengagements function to complete an electrical circuit whereby control signals are forwarded through wires 136 to program module 133 for appliance 2 .
In the most preferred form of the invention, the engagement of contact member 108 with contact element 121 functions to slowly increase the cycle time for a laundry operation. Therefore, with the engagement of contact member 108 and contact element 121 , indicator 84 shown in FIG. 2 would slowly shift toward the “light” setting and, if maintained in engagement, further toward the “normal” and “heavy” settings. Further rotation of control member 59 will also cause the abutment of contact member 110 and contact element 122 . In accordance with the most preferred embodiment, this functions to shift the overall selected cycle for appliance 2 to a previous cycle. Therefore, if this momentary switch contact was made, indicator 84 would jump from the WHITES cycle setting to the COLORS cycle setting.
On the other hand, rotation of body portion 90 in the clockwise direction will cause contact 111 to engage contact element 123 to slowly decrease the cycle time established for the particular laundry operation. Further rotation in the clockwise direction also causes engagement between contact member 109 and contact element 122 which functions to shift the overall selected cycle to the next cycle, i.e., in a clockwise direction about the illustrated graphic indicia 63 .
With this arrangement, only limited rotational movement of control member 59 is required to easily establish and adjust desired cycle and operational times for a particular laundry operation to be performed within appliance 2 . If the desired setting position as represented to the user through indicator 84 is passed, it would not be necessary to rotate main selector knob through nearly 360° as with conventional, rotatable control knob arrangements. Instead, only a limited degree of rotation of control member 59 in a predetermined direction is required.
Although described with respect to a preferred embodiment of the invention, it should be readily understood that various changes and/or modifications can be made to the invention without departing from the spirit thereof. For instance, although the engagement between the various contact members 108 - 111 and contact elements 121 - 123 have been disclosed with respect to performing particular setting functions, it should be readily understood that the arrangement of the functions could be readily altered. In addition, such a setting control arrangement could be employed for use in connection with other parameters needing to be set for appliance 2 . Furthermore, control member 59 could also be linearly shifted, instead of rotated in opposing directions from a neutral position to perform corresponding functions. Therefore, it is only important that limited shifting is required which enhances the ability for appliance 2 to be efficiently programmed in a quick and convenient manner. The use of indicator 84 and annular illumination track or zone 80 provides immediate feedback, in a consumer friendly manner, to the user. When control member 59 is rotary in accordance with the preferred embodiment, graphic indicia 63 generally simulates a conventional dial skirt which will be readily recognized by the user. In any event, the invention is only intended to be limited by the scope of the following claims. | A control device for a laundry appliance includes a member which need only be manually shifted through a limited range of travel, from a neutral position to which the control member is biased, in either of first and second opposing directions, to establish a desired cycle and to adjust an operational time for the cycle. The control member is provided with numerous movable contacts which are interposed between fixed contacts. Shifting of the control member a limited amount in either direction will function to engage a single pair of the contacts, while shifting the control member a further amount in the same direction causes another pair of the contacts to become engaged. In this manner, the contacts are paired to slowly increase or decrease the operational time and to also select either the next or previous operational cycle. User feedback of the selected setting is preferably provided through the use of a illuminated indicator that shifts around a track adjacent operational indicia. | 3 |
This application is a divisional applaication of application Ser. No. 09/223,964 filed Dec. 31, 1998 now U.S. Pat. No. 6,001,304.
FIELD AND HISTORICAL BACKGROUND OF THE INVENTION
The present invention is directed to bonding particle materials, and more particularly to reactive or nonreactive synthesis, consolidation, or joining of metallic, ceramic, intermetallic, or composite materials to near-net shapes by application of high shear high current (1-20 kA), and high pressure (about 1 to 2,000 MPa).
Pressure-assisted consolidation or sintering generally involves heating a particle powder compact, while applying pressure simultaneously. The powder compacts are typically heated externally using graphite or molybdenum heating elements and the pressure is applied hydraulically, pneumatically or isostatically depending on the type of the process. Conventional pressure assisted consolidation techniques include hot pressing, hot isostatic pressing, hot forging, and hot extrusion. The conventional techniques require long processing time and high chamber temperature in order to produce high-density parts. In addition, several preparatory steps are required, such as powder heat treatment, precompaction, canning, welding, and machining.
The field of powder consolidation includes powder particles with average particle sizes ranging from about 100 microns to less than 0.01 microns. In any powder consolidation process, the objective is to have minimum grain boundary contamination, maximum density and minimum grain growth. However, powder particles with large surface area, due to their surface charge distribution, readily react with the atmosphere and form a stable oxide phase, which significantly affects the consolidation process. The presence of these oxides, moisture and other contaminants on the surface of the particles, limits the final density that can be achieved and degrades the mechanical properties of the consolidated parts. Thus, it is important to reduce the surface impurities, such as oxygen and other contaminants present on the particle surfaces.
The consolidation of powders to near theoretical density, without significant grain growth has been a difficult task because of the tendency for the grains to coarsen at elevated temperature. Attempts have been made to consolidate powders with average particle size less than 0.01 microns by many techniques, such as furnace sintering, hot pressing, and hot isostatic pressing. However, the drawback is that the total time required for consolidation at the elevated temperature, is very long (several hours) which leads to significant grain growth, and poor mechanical and thermal properties.
Most refractory metals, ceramics, intermetallics and certain composite materials, are extremely hard and require diamond-tipped tools to machine them to final dimensions. In order to minimize expensive machining, the powder densification process must be capable of near-net shaping. The development of a novel process that consolidates the difficult-to-sinter materials into near-net shaped parts has been the goal of many powder metallurgy industries.
As application opportunities continue to emerge that require materials to perform at higher temperatures for sustained periods of time, joining of ceramic and intermetallic materials becomes necessary to enable advanced structure to be produced. Sinter bonding, sinter-HIP bonding, diffusion bonding are typically employed to join these advanced materials. However, long preparation and processing times are required in the conventional techniques that result in high manufacturing cost.
Ultrafine particle materials (with average particle size less than 0.01 micron) have great potential in structural, electronic, thermal management and optical applications since these materials exhibit superior performance characteristics.
Various techniques relating to compacting or sintering of powder materials are disclosed in U.S. Pat. Nos. 3,250,892; 3,340,052; 3,598,566; 3,670,137; 4,005,956; 5,084,088; 5,427,660; and 5,529,746; and in publications—F. V. Lenel, “Resistance Sintering Under Pressure”, Journal of Metal, Vol. 7, No. 1, pp 158-167 (1955), and M. J. Tracey et al., “Consolidation of Nanocrystalline Nb—Al Powders by Plasma Activated Sintering”, NanoStructured Materials, Vol. 2, pp. 441-449 (1993).
The prior art techniques are also not considered effective at least for the reasons that they: are limited to producing smaller size parts, result in nonuniform distribution of temperature throughout the powder compact, result in lower than near theoretical densities, result in undesirable grain growth, do not reactively consolidate or join the materials, do not consolidate or join precursor particle materials, require pretreatment or presynthesis of the particle material, do not apply to ultrafine particles (<1 micron), etc.
In view of the above, there is a need in the industry for a technique that can rapidly consolidate, bond or join precursor or elemental particle material to near theoretical density without requiring complicated preparatory steps.
OBJECTS AND SUMMARY OF THE INVENTION
The principal object of the present invention is to provide a method of rapidly bonding a particle material to near theoretical density with minimum grain growth and to join or bond with high interface integrity and minimum microstructural distortion in the bulk material.
An object of the present invention is to provide a method of bonding a particle material to near theoretical density and near net shape using pulsed plasma, pressure and current.
Another object of the present invention is to provide a method in which a particle material can be reactively or nonreactively consolidated or joined to near-net shape and near theoretical density in a short period of time (less than 10 minutes) with minimum grain growth.
Yet another object of the present invention is to provide a method of bonding a particle material to near theoretical density in which oxygen and other contaminants are removed during the bonding step without any additional preparatory steps.
Still yet another object of the present invention is to provide a method of bonding particle material to near theoretical density which produces bonded material or desired articles economically at reduced processing temperature and ID time while maintaining nanometer dimensions.
An additional object of the present invention is to provide a method of bonding a particle material to near theoretical density which produces dense near-net shape parts or articles without expensive machining.
Yet an additional object of the present invention is to provide a rapid bonding technique that can join ceramic, intermetallic, and other dissimilar materials in a short period of time without any complicated preparation.
Still yet an additional object of the present invention is to provide a method of bonding a particle material to near theoretical density which can produce near-net shape parts or articles directly from precursors or elemental particle material without the complicated synthesis steps.
Another object of the present invention is to provide a method of bonding a particle material to near theoretical density by simultaneously applying high shear or high pressure, and high current directly to the particle material resulting in high heating rate (less than 100° C.-1,500° C. per minute), improved particle surface activation, enhanced densification, uniform distribution of heat, and strong bonding.
Yet another object of the present invention is to provide a method of bonding a particle material to near theoretical density which can be used to bond powders with average particle size ranging from 100 microns to 0.01 microns, without significant grain growth, by rapidly processing at lower temperature and duration.
Still yet another object of the present invention is to provide a method of bonding a particle material to near theoretical density which does not require the use of any binders or additives for producing desired shapes.
An additional object of the present invention is to provide a method of bonding a particle material to near theoretical density which produces near-net shape, high density ceramic or other material parts by using a combination of “sol-gel” precursor and a reactive gas in the presence of pulsed and steady electric field.
Yet an additional object of the present invention is to provide a method of bonding a particle material, such as B 4 C/SiC, Ti B 2 / BN, and Al 2 O 3 /AIN.
An additional object of the present invention is to provide a method of rapidly bonding diamond and coated diamond powders into near-net shaped parts or articles.
Yet an additional object of the present invention is to provide a method of bonding a particle material to near theoretical density which can produce near-net shape parts of any desired geometry, such as cylindrical, cubic, rectangular, hemispherical, tubular, or any combination thereof.
Still yet additional object of the present invention is to provide a method of bonding a particle material to near theoretical density by creating interparticle plasma which controls the undesirable grain growth, reduces the densification temperatures, and significantly improves the properties of the bonded material.
A further object of the present invention is to provide a method of producing an article having a near-net shape and near theoretical density and a length of less than one-half inch to six inches or more, or a diameter of less than one-half inch to six inches or more.
Yet a further object of the present invention is to provide a method of producing near-net shaped articles having improved properties, rapidly and at significantly lower manufacturing costs.
Still yet a further object of the present invention is to provide a method of bonding a particle material by producing interparticle plasma that controls particle grain growth, reduces densification temperatures and improves the overall properties of the bonded material.
An additional object of the present invention is to provide a method of bonding a particle material which can be used to restore or repair damaged parts or articles.
Yet an additional object of the present invention is to provide a method of bonding a particle material which can be used to coat or clad a particle material to a surface.
Still yet an additional object of the present invention is to provide a method of bonding a particle material which can be used to grow single crystals of a particle material.
In summary, the invention relates to reactive and non-reactive synthesis, consolidation, sintering, joining, or bonding process of particle material into near-net shape and near theoretical density using high shear, high pressure (less than 1-2,000 MPa) and high current (1-20 kA).
In the process of the invention, the materials to be consolidated or joined, are placed preferably in a graphite die and punch assembly. The driving force for densification and joining is provided by passing current directly through the particle material, while simultaneously applying high shear and high pressure in separate steps. High shear force in combination with pulsed electric power is initially applied to the particle material to generate electrical discharge that activates the particle surface by evaporation of oxide film, impurities, and moisture. Subsequently, bonding is accomplished by resistance heating at the contact points between the activated particles in the presence of high pressure. The time and temperature required for consolidation or joining is lowered as high current density is applied in addition to high shear and high pressure (up to 2,000 MPa), which leads to localized heating and plastic deformation at interparticle contact areas. The rapid sintering, which preferably lasts for less than ten minutes, prevents grain growth and allows the particles to retain their initial microstructure.
The unique feature of the present process is the simultaneous application of pulsed current and high shear on the particle material resulting in surface heating of the particles to very high temperatures for short periods of time resulting in a localized plasma which enhances the rupturing of the surface oxide layers and facilitates rapid diffusion at the surface of the particles. The temperature of the particle material remains low, thereby minimizing the grain growth and the processing temperature. Application of the shear forces during surface heating of the particles results in an abrasive action between the particles to further facilitate rupturing of the surface oxide layer and redistribution of the particles. High shear causes deformation of the powder particles, agglomeration of the particles and since they are in intimate contact it reduces the consolidation temperature. Reduced consolidation temperature results in reduced grain growth and improved performance.
It is noted herewith that, as used herein, the term “bonding” includes, but is not limited to, reactive or nonreactive joining of generally solid materials, and reactive or nonreactive consolidation, sintering or synthesis of particles or powder materials. Likewise, the term “particle material”, includes, but is not limited to, particle material in any form, such as solid, liquid, powder, gas, fluid, etc. Preferably, the particle material includes metallic, ceramic, intermetallic, alloy, composite, coated or uncoated powders, porous materials, partially dense, and fully dense substrates.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objects, novel features and advantages of the present invention will become apparent from the accompanying detailed description of the invention as illustrated in the drawings, in which;
FIG. 1 is a schematic representation of an apparatus that is utilized in carrying out the method of the present invention;
FIG. 2 is a schematic representation of the pulsed, alternating pulsed, alternating DC and steady DC current flow pattern of the output from the power supply; and
FIGS. 3-5 are schematic illustrations of the steps in carrying out the method of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
As best shown in FIGS. 1 and 3, the particle material PM, to be consolidated or joined, is placed in a chamber, such as a punch and die assembly D, preferably a graphite or carbon-carbon composite die assembly, and the plungers 10 and 12 are inserted on both sides.
The particle material is preferably a coated or uncoated particle powder, or a solid substrate. The assembly D is then placed in a chamber C with controlled atmosphere and pressure. In particular, a vacuum is preferably created in chamber C via conduits 14 and 16 . The treatment of the particle material PM in the vacuum causes improved removal of oxide, moisture and other contaminants from the particle or solid substrate surface, and results in a product with improved and better properties, such as substantially enhanced purity. The conduits 14 and 16 also permit injection of reactive gases, such as nitrogen, ammonia, methane, oxygen, hydrogen, etc., for ‘in situ’ reactive consolidation or joining of various materials. Inert gases, such as helium, argon, etc., may also be injected into the chamber C.
A hydraulic piston (not shown) is lowered on the top graphite plunger 10 to hold the entire assembly together and to provide a path for the current to flow. Once sufficient particle contacts have been established, pulsed current is applied using a power supply PS. The voltage varies from about 1V-100V and the current from about 1-20 kA. Preferably, the voltage varies from about 1-30V and the current from about 1-8,000 amps. The voltage depends on the electrical resistively of the die, plunger, and the materials to be consolidated or joined, and the current depends largely on the size of the powder compact. The pulsing rate can vary from about 1 to 1000 Hz, and preferably from about 10-100 Hz, and the pulsing duration from about less than 1-600 minutes, and preferably from about 5-30 minutes.
As pulsed current is applied, the top graphite plunger 10 is rotated in a clockwise direction (see arrow X in FIG. 4) and the bottom plunger 12 is rotated in a counterclockwise direction (see arrow Y in FIG. 4 ), to generate high shear between the particles. The rotation of the plungers is preferably controlled from 1 to 10 revolutions per minute, and the pressure from about less than 1-2.000 MPa, and preferably from about 10-200 MPa. The surface activation of the particles results in the outgassing of volatile species via conduits 4 and 16 .
Subsequently, as shown in FIG. 5, a steady DC current in combination with axial pressure (see arrows Z in FIG. 5) is applied to achieve rapid consolidation or joining of the particle material to form particle compact PC. The direct current value varies from about 1-20 kA, and preferably 1-8 kA, depending on the material and the size. The duration of direct DC current varies from about 5 to 60 minutes. The temperature attained during resistance heating varies from about less than 500° C. to over 2500° C., and is controlled by the amount of current flowing through the sample. A DC voltage may be applied in an alternating manner to provide uniform heating of the sample from top to bottom. Pressures of up to 2,000 MPa may be applied using the hydraulic cylinder and piston. The shape of the die and punches determines the shape of the part. For example, it can be cylindrical, cubic, rectangular, hemispherical, tubular or any combination of standard geometrical objects.
It is noted herewith that the shear and axial pressures may be applied by using one or combination of hydraulic means, pneumatic means, electric field and magnetic field.
Since the shape of the dies and punches determine the final shape of the consolidated or joined part dies and punches are designed according to the required specifications for rapid near-net shape fabrication. The technique of the invention has been used to reactively consolidate metallic particle material, such as iron, cobalt, nickel, tungsten, rhenium; ceramics, such as silicon carbide, aluminum nitride, titanium dioxide, titanium diboride and aluminum dioxide; intermetallics, such as iron aluminides and molybdenum disilicide; and composite particle material, such as tungsten carbide cobalt, tungsten-copper, molybdenum-copper, and iron cobalt-silicon carbide.
The process has also been used to reactively join ceramics, such as silicon carbide/silicon carbide (SiC/SiC) and silicon carbide/alumina (SiC/Al 2 O 3 ); intermetallics, such as molybdenum-disilicide (MoSi 2 /MoSi 2 ) and iron aluminide/iron (FeAl/Fe); and dissimilar metals, such as iron/nickel (Fe/Ni), copper/boron nitride (Cu/BN), and tungsten/molybdenum (W/Mo). The technique of the invention provides a rapid near-net shape process that is capable of reactively or nonreactively consolidating or joining various particle materials to near theoretical density with minimum grain growth.
The method of the invention may be applied to produce near-net, high density samples or articles having a length of from about less than one-half to six inches or more, and a diameter of from about less than one-half to six inches or more.
The following Table 1 summarizes various parameters for carrying out the method of the invention.
TABLE 1
Parameter
Operating Range
Preferred Range
Temperature
Room temperature to
Room temperature to 2500° C.
3000° C. (25° C.)
(25° C.)
Pressure
<1 MPa to 2000 Mpa
10 to 200 MPa
Cycle Time
<1 minute to 600 minutes
5 to 30 minutes
Pulsing
1 to 1000 Hz
10-100 Hz
Frequency
Peak Current
5 A to 20 kA
200 A to 20 kA
Base Line
0 to 14000 A
0-4000 A
Current
1 to 20 kA
1 to 8 kA
Heating Rate
1-1500°C./minute
100-1500° C./minute
Voltage
1-100 V
1-30 V
The technique of the invention may also be applied to repair metallic. ceramic, intermetallic, alloy, single crystal and composite parts by localized surface modification. In service, most blade tips used in turbines and compressors, cutting tool edges get damaged. It will be more economical if the damaged part can be repaired and restored to the original dimension. The part to be repaired is cleaned, depending on the size or area of damage, powder particles or surface can be used. The part to be repaired and the particle material are placed in a chamber and pulsed electric current with shear, followed by steady current and high pressure are applied, as noted above. Bonding is ensured by localized diffusion of heat.
The technique of the invention may also be applied to clad powders on to metallic, ceramic, intermetallic, alloy, single crystal and composite parts. Ceramic materials in general have high wear resistance and low thermal conductivity. Certain applications, such as high temperature engines, turbines, will have an increase in efficiency by coating these parts with, for example, ceramic materials. Currently, there are only two methods of accomplishing this coating, plasma spray technique and physical and chemical vapor deposition (PVD/CVD) technique. In plasma spray, the coating is porous and the adhesion is poor. In the PVD/CVD technique, not all materials can be deposited and the coating develops a particular orientation. In accordance with the present invention, the part to be coated with a particular or a combination of particle materials is dip coated in a slurry and placed inside a vacuum chamber between the two plungers. The part is then heated using the pulsing and steady current technique of the present invention. This results in interparticle diffusion and bonding of particle material to the substrate. Thus, cladding the surface with the desired material. The thickness and density of the coating can be controlled by controlling the slurry concentration and the number of coating cycles.
Finally, the technique of this invention may be used to grow single crystals by using a combination of particle material and seed crystal. As one of ordinary skill in the art would be aware, applications of single crystals are steadily increasing and new techniques are being developed to produce single crystals. The present techniques of growing single crystals from vapor deposition or from molten metals are expensive and very sensitive to contamination and process parameters. Single crystals exhibits certain properties which cannot be attained by any other densification or processing techniques of the same material. Using the process of the invention, ultrafine powders can be packed along with a seed is single crystal and placed preferably in a graphite die. Using a combination of pulsed power and steady current, as noted above, it is possible to grow single crystals.
The following Examples are provided to illustrate the invention, but it is understood that the invention is not limited thereto.
EXAMPLE 1
Rhenium powders (average particle size 25 microns) were consolidated to near theoretical density (96-99%) without significant grain growth by processing at 1100-1400° C. and 400-600 MPa with isothermal holding time of 1-10 minutes.
The sample size ranged from ½ to 2″ in length and ½ to 1″ in diameter.
EXAMPLE 2
Tungsten powders (average particle size 0.2 to 4 microns) were consolidated to near theoretical density (96-99%) without significant grain growth by processing at 1100-1600° C. and at 10-900 MPa for 1-10 minutes. The sample size ranged from ½ to 2″ in length and ½ to 1″ in diameter.
EXAMPLE 3
Ultrafine iron powders (average particle size <0.1 microns) were consolidated to near theoretical density (96-99%) without significant grain growth by processing at 500-950° C. and 50-900 MPa for 1-5 minutes. The sample size ranged from ½ to 2″ in length and ½ to 1″ in diameter.
EXAMPLE 4
Molybdenum-Copper composite powders (average particle size 1-3 micron) were consolidated to near theoretical density (95-97%) at 900-1150° C. and at 50-900 MPa in less than 20 minutes. The sample size ranged from ½ to 2″ in length and ½ to 1″ in diameter.
EXAMPLE 5
Tungsten-carbide cobalt powders (with average particle size <1.0 micron to up to 12 microns) were consolidated to near theoretical density (96-99%) at 1300° C and at 700 MPa in less than 5 minutes. The sample size ranged from ½ to 2″ in length and ½ to 1″ in diameter.
EXAMPLE 6
Aluminum nitride powders (<20 microns) were consolidated to near theoretical density (91-99%) without significant grain growth by processing at 1500-1600° C. and at 30-70 MPa for 1-5 minutes. The sample size ranged from ½ to 2″ in length and ½ to 1″ in diameter.
EXAMPLE 7
Aluminum powders (<30 microns) were consolidated to near theoretical density (96-99%) without significant grain growth by processing at 500-600° C. and at 30-70 MPa for 1-5 minutes. The sample size ranged from ½ to 2″ in length and ½ to 1″ in diameter. Hollow tubes were also consolidated with an internal diameter of ¼″ and an outer diameter of 1 inch. The length of the tube was 1 inch.
EXAMPLE 8
Molybdenum disilicide powders (<10 microns) were consolidated to near theoretical density (92-96%) without significant grain growth by processing at 1700-1900° C. and at 30-70 MPa for 1-5 minutes. The sample size ranged from ½ to 2″ in length and ½ to 1″ in diameter.
EXAMPLE 9
Sol-gel precursor consisting of organometallic polymer of Si—C—O—H was decomposed to SiC by applying pulsed DC for 15 minutes at 200 amps followed by final consolidation to near theoretical density (95-96%) at 2100° C. and at 70 MPa for 30 minutes. The sample size was ½-1″ in length and 1″ in diameter.
EXAMPLE 10
Tantalum powders (<45 microns) were consolidated to near theoretical density (92-98%) without significant grain growth by processing at 1400-1600° C. and at 30-70 MPa for 1-8 minutes. The sample size ranged from ½ to 2″ in length and ½ to 1″ in diameter. Hollow tubes were also consolidated with an internal diameter of ¼″ and an outer diameter of 1 inch. The length of the tube was 1 inch.
EXAMPLE 11
Joining of SiC/Al 2 O 3 was achieved directly from SiC and Al 2 O 3 powders by placing 0.5″ long Al 2 O 3 green compact on top of 0.5″ long SiC green compact, and consolidating them at 2000° C. and 65 MPa for 20 minutes. Dense (98% of theoretical) and strongly bonded compact was produced without the use of additives and binders.
EXAMPLE 12
Titanium and boron powders were mixed in the ratio of 1.2 and combustion synthesized to form TiB and TiB 2 by applying pulsed DC current for <5 minutes at 2000 amps. The powders were then consolidated to hollow cylinders (¼ inch inner diameter, 1 inch outer diameter and 1 inch long) at 2000° C. and 50 MPa for minutes. The density of the final consolidated part was 95% of the theoretical density.
EXAMPLE 13
Diamond powders were consolidated at 800-1 300° C. and under a pressure of 30-70 MPa with a hold time less than 5 minutes. The sample size ranged from ½ to 1″ in length and ½ to 1″ in diameter. Coated diamond powders such as cobalt coated diamond and nickel coated diamond powders were also consolidated under similar conditions.
EXAMPLE 14
Nickel aluminide powders were consolidated at 1000-1300° C. and under a pressure of 30-70 MPa for 1-5 minutes. The sample size ranged from ½ to 2″ in length and ½ to 2″ in diameter.
While this invention has been described as having preferred ranges, steps, materials, or designs, it is understood that it is capable of further modifications, uses and/or adaptations of the invention following in general the principle of the invention and including such departures from the present disclosure as those come within the known or customary practice in the art to which the invention pertains and as may be applied to the central features hereinbefore set forth, and fall within the scope of the invention and of the limits of the appended claims. | A method of bonding a particle material to near theoretical density, includes placing a particle material in a die. In the first stage, a pulsed current of about 1 to 20,000 amps., is applied to the particle material for a predetermined time period, and substantially simultaneously therewith, a shear force of about 5-50 MPa is applied. In the second stage, an axial pressure of about less than 1 to 2,000 MPa is applied to the particle material for a predetermined time period, and substantially simultaneously therewith, a steady current of about 1 to 20,000 amps. is applied. The method can be used to bond metallic, ceramic, intermetallic and composite materials to near-net shape, directly from precursors or elemental particle material without the need for synthesizing the material. The method may also be applied to perform combustion synthesis of a reactive material, followed by consolidation or joining to near-net shaped articles or parts. The method may further be applied to repair a damaged or worn substrate or part, coat a particle onto a substrate, and grow single crystals of a particle material. | 8 |
TECHNICAL FIELD
[0001] The field to which the disclosure generally relates includes thermo-reversible dry adhesives.
BACKGROUND
[0002] Gecko feet pads, with nanohair structures on them, are examples of smart dry adhesives. The working principle of the Gecko adhesion is that the nanohair structure allows the foot pad to make maximum contact with a counter surface regardless of its roughness and chemical composition. This is accomplished by nanohairs that are relatively long and protruding from the foot pad at an angle so that adjacent nanohairs can contact the counter surface regardless of its topography. The maximum contact further allows for accumulation of millions of small van der Waals (in the range of microNewtons) interactions between the Gecko foot pad and the counter surface, leading to an overall adhesion force (pull-off force) of about 10 N/cm 2 . When the detaching force is employed in a peel-off mode, however, the complete detachment is achieved gradually by overcoming small adhesion forces corresponding to very small areas. Thus, the adhesion is easily reversed. Overall, the attractiveness of the Gecko adhesion lies in the combination of adhesive strength (10 N/cm 2 ), reversibility, and the ability to adapt to a variety of surfaces in terms of both the surface roughness and composition. The above unique features of the Gecko adhesion has stimulated scientific research efforts to produce synthetic smart dry adhesives that work using the same principle as the Gecko feet. Up to now, the two best synthetic Gecko adhesives show maximum pull-off strength of 3 and 10 N/cm 2 towards glass. Both adhesives suffer from severe adhesion loss after only one or two attaching/detaching cycles, as a result of breakdown of the nano structures or lateral collapse of the nano structures, with the latter referring to the bonding of adjacent nano-hairs. In addition, typical synthetic Gecko adhesives are expensive to produce and large-scale manufacturing is practically too difficult.
SUMMARY OF EXEMPLARY EMBODIMENTS OF THE INVENTION
[0003] One embodiment of the invention includes a method of joining two substrates with multilayer thermo-reversible dry adhesives and separating the two bonded substrates by completely thermally reversing the adhesion via heating.
[0004] Other exemplary embodiments of the invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while disclosing exemplary embodiments 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
[0005] Exemplary embodiments of the invention will become more fully understood from the detailed description and the accompanying drawings, wherein:
[0006] FIG. 1 illustrates a product according to one embodiment of the invention.
[0007] FIG. 2 illustrates a product according to one embodiment of the invention.
[0008] FIG. 3 illustrates a product according to one embodiment of the invention.
[0009] FIG. 4 illustrates a product according to one embodiment of the invention.
[0010] FIG. 5 illustrates a product according to one embodiment of the invention.
[0011] FIG. 6 illustrates a product according to one embodiment of the invention.
[0012] FIG. 7 illustrates a product according to one embodiment of the invention.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0013] The following description of the embodiment(s) is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses.
[0014] Referring to FIG. 1 , one embodiment includes a multilayer thermo-reversible dry adhesive 11 . In one embodiment, the multilayer thermo-reversible dry adhesive 11 may be a double layer adhesive (DLA) 10 . The DLA 10 may include an elastomeric dry adhesive layer 12 and a shape memory polymer (SMP) layer 14 .
[0015] In various embodiments, the dry adhesive layers may be an epoxy elastomeric dry adhesive. In various embodiments, the shape memory polymer may be an epoxy. In various embodiments, the components of the dry adhesive or the components of the shape memory polymer may include a rigid epoxy and a flexible epoxy. The range of possible crosslinking chemistries which may be used to achieve a dry adhesive or shape memory polymer may include alpha, omega-diaminoalkanes, organic multi-caroxylic acid, anhydride, or catalytic (as in imidazole type) crosslinking reactions. There are many different ways to achieve the appropriate relationships between the molecular properties. For example, the dry adhesives or shape memory polymers may include a rigid epoxy, an epoxy extender, and a crosslinking agent; or a rigid epoxy, a flexible crosslinking agent, and a flexible epoxy; or a rigid epoxy, a rigid crosslinking agent, and a flexible epoxy; or a rigid epoxy, a flexible epoxy, and a catalytic curing agent; or a rigid epoxy, a crosslinking agent, and a diluent; or a flexible epoxy, a crosslinking agent, and a diluent; or a rigid epoxy and a flexible crosslinking agent; or a flexible epoxy and a catalytic curing agent; or a flexible epoxy and a crosslinking agent; and wherein the rigid epoxy is an aromatic epoxy having at least two epoxide groups, the flexible epoxy is an aliphatic epoxy having at least two epoxide groups, the epoxy extender has one epoxide group, and the crosslinking agent is one of a multi-amine, an organic multi-carboxylic acid, or an anhydride, and the diluent is a monoamine or a mono-carboxylic acid. In various embodiments, the catalytic curing agent (or catalytic cure) promotes epoxy-to-epoxy or epoxy-to-hydroxyl reactions. The catalytic curing agent may include, but is not limited to, tertiary amines, amine salts, boron trifluoride complexes, or amine borates. In one embodiment, the components of the dry adhesive may be present in an amount sufficient to provide, upon curing of the composition, a dry adhesive having a glass transition temperature (T g ) of −90° C. to 200° C. and having a pull-off strength of 1-200 N/cm 2 from a substrate. In another embodiment, the dry adhesive may have a glass transition temperature of −90° C. to 25° C. In one embodiment, the components of the shape memory polymer composition may be present in an amount sufficient to provide, upon curing of the composition, an epoxy shape memory polymer having a change in storage modulus of 2 to 3 orders of magnitude before and after its glass transition. In one embodiment, the shape memory polymer has a T g of 25° C. to 200° C.
[0016] FIG. 1 shows the original curvature of the DLA 10 including the dry adhesive layer 12 and the SMP layer 14 , according to one embodiment of the invention. In FIG. 1 , the DLA 10 is positioned on a flat substrate 18 . In various embodiments, the substrate 18 may be, for example but not limited to, stainless steel alloy 304, glass, aluminum alloy 5657, polypropylene, or Teflon (polytetrafluoroethylene). FIG. 2 shows the DLA of FIG. 1 from another angle. As shown in FIG. 2 , a contact area 16 between the dry adhesive layer 12 and the substrate 18 is small due to the curvature of the DLA. In one embodiment shown in FIG. 3 , the DLA 10 includes a non-adhesive portion 20 formed in the dry adhesive layer 12 . In one embodiment, the non-adhesive portion 20 may be formed at approximately the center of the dry adhesive layer 12 . In various embodiments, the non-adhesive portion 20 may be introduced by molding or coating methods. The non-adhesive portion 20 may comprise a non-adhesive material, for example but not limited to, glass, metal, or Teflon (polytetrafluoroethylene). In one embodiment, the non-adhesive portion 20 may be an opening in the dry adhesive layer 12 . In another embodiment the non-adhesive portion 20 may be a non-adhesive material over the dry adhesive layer 12 or the non-adhesive material may be received in an opening or recess in the dry adhesive layer 12 .
[0017] In one embodiment, a method is provided for reversible adhesion of the DLA 10 . The DLA 10 is positioned on the substrate 18 . Then the DLA 10 with the non-adhesive portion 20 is heated to a temperature higher than the glass transition temperature of the SMP layer 14 . Then a load is imposed on the DLA 10 while the DLA 10 is cooled. In one embodiment, the load pressure may be about 0.1 N/cm 2 to about 20 N/cm 2 . In one embodiment, the DLA 10 may be cooled to about 25° C. The DLA 10 deforms and complies with the substrate 18 , as shown in FIG. 4 (side view of the DLA) and in FIG. 5 (top view of the DLA). A strong adhesive bond is formed between the DLA 10 and the substrate 18 . In one embodiment, adhesive strength of 60 N/cm 2 may be achieved. As shown in FIG. 5 , the DLA 10 may not adhere to the substrate 18 at the location of the non-adhesive portion 20 .
[0018] According to the method of one embodiment, the DLA 10 is then released from the substrate 18 by heating the DLA 10 to a temperature above the glass transition temperature of the SMP of the SMP layer 14 , and not applying a load. The DLA 10 recovers to its original curvature and the residue adhesion is approximately zero, or complete adhesion reversal. FIG. 1 shows a side view of the recovered DLA 10 that has been released from the substrate 18 .
[0019] Referring to FIG. 6 , in another embodiment, the multi-layer thermo-reversible dry adhesive 11 may be a quadruple dry adhesive 26 , including two layers or portions of an elastomeric dry adhesive and two layers or portions of a shape memory polymer. The quadruple dry adhesive 26 may include a first dry adhesive layer 28 and a second dry adhesive layer 30 , wherein the curvatures of the layers 28 , 30 point in the opposite directions. At least one of the first adhesive layer 28 or the second adhesive layer 30 may include the non-adhesive portion 20 , as shown in FIG. 6 . The outer surface of each of the layers 28 , 30 may have a generally convex shape. The first and second dry adhesive layers 28 , 30 meet each other at the outer edges 32 and 34 . The quadruple dry adhesive 26 may also include a first shape memory polymer portion 36 and a second shape memory polymer portion 38 . The first shape memory polymer portion 36 may be positioned adjacent to the first adhesive layer 28 . The second shape memory polymer portion 38 may be positioned adjacent to the second adhesive layer 30 . A cavity 40 may be formed between the first and second shape memory polymer portions 36 , 38 .
[0020] In one embodiment, the quadruple dry adhesive 26 is positioned between a first substrate 42 and a second substrate 44 and heated to a temperature above the glass transition temperature of the SMP of the first and second shape memory polymer portions 36 , 38 .
[0021] Then a load is imposed on the quadruple dry adhesive 26 while is cooled to attach the first substrate 42 to the second substrate 44 , as shown in FIG. 7 . The quadruple dry adhesive 26 may be cooled to about 25° C. The quadruple dry adhesive 26 deforms and complies with the substrates 42 and 44 . Upon cooling under the load, the cavity 40 may become very small or may disappear altogether. A good contact and thus strong adhesive bond is formed between the quadruple dry adhesive 26 and the substrates 42 and 44 . The quadruple dry adhesive 26 may not adhere to the first substrate 42 or the second substrate 44 at the non-adhesive portion(s) 20 .
[0022] Then the quadruple dry adhesive 26 may be released from the first and second substrates 42 and 44 by heating the quadruple dry adhesive 26 to a temperature above the glass transition temperature of the SMP of the first and second shape memory polymer portions 36 , 38 , and not applying a load. Upon heating, each of the first and second dry adhesive layers 28 and 30 peel from the substrates 42 , 44 respectively, first from near the outer edges 32 and 34 , and progressing towards a center 46 . Upon heating, the cavity 40 forms in between the first and second polymer layers 36 and 38 . The quadruple dry adhesive 26 recovers to its original curvature. In an embodiment where the first and second adhesive layers 28 , 30 include the non-adhesive portion 20 , the residue adhesion is approximately zero, or complete adhesion reversal.
[0023] One embodiment of the invention includes a method of making a multilayer thermo-reversible dry adhesive 11 comprising heating 3.6 g of EPON 826 (a Bisphenol A based epoxy resin) to about 75° C. and mixing the same with 2.16 g of neopentyl glycol diglycidyl ether (NGDE) and 2.3 g of a diamine such as Jeffamine D-230. Jeffamine D-230 is a polyetheramine that is difunctional, primary amine with an average molecular weight of about 230. The primary amine groups are located on secondary carbons at the end of the aliphatic polyether chain. Jeffamine is available from Huntsman.
[0024] The mixture may then be poured into an aluminum pan and cured in an oven at about 100° C. for 1.5 hours. Then a mixture of 2.16 g of NGDE and 1.15 g of an amine such as Jeffamine D-230 may be poured into the aluminum pan on top of the first cured epoxy layer and cured for 1.5 hours at 100° C. In a third step, the oven temperature may be raised to 130° C. for post-curing for about one hour. At the end of the post-curing, the cured double layer epoxy may be demolded and cut into small pieces, if desired. A double layer epoxy may be obtained with the first layer which had a thickness of about 2 mm and functioned as a shaped memory polymer with a glass transition of about 50° C. and second layer as a dry adhesive having a thickness of about 1 mm. The non-adhesive portion 20 can be formed by selectively depositing a non-adhesive metal coating such as aluminum.
[0025] Another embodiment of the invention includes a method of making a dry adhesive layer 12 comprising mixing 4.32 g of neopentyl glycol diglycidyl ether (NGDE) with 2.3 g of an amine such as Jeffamin D-230. The liquid mixture was then poured into an aluminum mold. Curing was conducted in an oven for about 1.5 hours at 100° C. and then for about one hour at 130° C. The cured epoxy may then be demolded and cut into small pieces, if desired.
[0026] Another embodiment of the invention includes a method of making an SMP layer 14 comprising mixing 3.6 g of EPON 826 with 2.16 g of NGDE and 2.3 g of Jeffamine D-230. The mixture was poured into a circular aluminum pan and cured at 100° C. for 1.5 hours and postcured at 130° C. for 1 hour. The cured epoxy may then be demolded and cut into small pieces, if desired.
[0027] The dry adhesive layer 12 may provide a continuous contact surface or the dry adhesive layer may include a plurality of spaced apart fingers each providing a relative small contact surface so the overall contact surface of the adhesive layer is not continuous.
[0028] Numerous shaped memory polymers may be utilized in various embodiments of the invention. For example, staring with a typical aromatic diepoxy/diamine system with a T g of about 90° C., the aromatic epoxy component is replaced systematically with an aliphatic diepoxy to yield a series of epoxy shape memory polymers with T g 's ranging from 3° C. to 90° C. As such, a shape memory polymer may be tailored for use with a dry adhesive as desired for a particular application operated within certain temperature ranges.
[0029] The following is another embodiment of the invention providing a method of making a shape memory polymer layer 14 with T g 's ranging from 3° C. to 90° C. EPON 826 was weighed into a glass bottle and placed into an oven preset at 70° C. to melt. The melting took about 1 hour. Immediately after the bottle containing the EPON 826 was taken out of the oven, weighed Jeffamine D-230 and NGDE were added to the bottle. The bottle was then shaken vigorously by hand for about ten seconds to mix the components. The detailed formulations of the five epoxy SMP samples prepared according to the method are summarized in Table 1.
[0000]
TABLE 1
Formulations of epoxy samples 1-5
Sample
EPON 826
NGDE
Jeffamine D-230
#
(mole)
(mole)
(mole)
1
0
0.02
0.01
2
0.005
0.015
0.01
3
0.01
0.01
0.01
4
0.015
0.005
0.01
5
0.02
0
0.01
[0030] Next, the mixture was poured into an aluminum pan. The epoxy samples were thermally cured at 100° C. for 1.5 hours and postcured at 130° C. for 1 hour. Upon the completion of the cure, the epoxy samples were demolded and cut into desirable shapes.
[0031] In another embodiment, a series of epoxy amine shape memory polymers with various crosslink densities were synthesized in the following manner. The epoxy formulations for samples 6-11 are given in Table 2 below. For each sample, 0.02 mole of EPON 826 was weighed into a glass bottle, which was placed into an oven preset at 75° C. and kept there for half an hour. Immediately after the bottle containing EPON 826 was taken out of the oven, Jeffamine D-230 and decylamine were introduced into the bottle according to the amounts specified in Table 2. The bottle was then shaken vigorously by hand for about ten seconds to mix the components and the mixture was poured into an aluminum pan. All epoxy samples were thermally cured at 100° C. for 1.5 hours and postcured at 130° C. for 1 hour. Upon the completion of the cure, the epoxy samples were demolded and cut into desirable shapes.
[0000]
TABLE 2
Formulations of epoxy samples 6-11
Sample
EPON 826
Jeffamine D-230
decylamine
#
(mole)
(mole)
(mole)
6
0.02
0.01
0
7
0.02
0.0075
0.005
8
0.02
0.005
0.01
9
0.02
0.0025
0.015
10
0.02
0.0005
0.019
11
0.02
0
0.02
[0032] In one embodiment, the system consists of EPON 826, Jeffamine D-230 as the crosslinker, and decylamine as the monoamine. As shown in Table 2, from sample 6 to 11, the fraction of the crosslinker is systematically reduced, while the total amounts of epoxy functionality and active hydrogen functionality on the amines are maintained equal. Among these samples, sample 11 was used as a reference sample because it contains no crosslinker and is not expected to possess shape memory properties.
[0033] In one embodiment, the substrate(s) may be flat and the multilayer thermo-reversible dry adhesive 11 may be curved. In another embodiment, the substrate(s) may be curved and the multilayer thermo-reversible dry adhesive 11 may be flat.
[0034] The above description of embodiments of the invention is merely exemplary in nature and, thus, variations thereof are not to be regarded as a departure from the spirit and scope of the invention. | One embodiment of the invention includes a method of joining two substrates with multilayer thermo-reversible dry adhesives and separating the two bonded substrates by completely thermally reversing the adhesion via heating. | 2 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority under Title 35, U.S.C. §119(e) to U.S. Provisional Patent Application Ser. No. 61/316,586, filed Mar. 23, 2010, the entire disclosure of which is hereby expressly incorporated by reference herein.
BACKGROUND OF THE INVENTION
[0002] 1. Technical Field
[0003] The present disclosure relates to an expandable seal arrangement, and associated method, for sealing a gasket to an annular wall of a rigid structure.
[0004] 2. Description of the Related Art
[0005] Manhole access ports are often assemblies of various components placed adjacent one another, and have joints which may also need to be sealed from leakage. For example, it may be desirable to provide a seal across a manhole frame, optionally one or more grade rings, and a manhole chimney to prevent moisture infiltration into the fluid passageway accessed by the manhole access port.
[0006] In underground pipe systems, it is often necessary to connect a pipe in a sealed manner within an opening in the wall of a rigid structure, such as a manhole riser or monolithic base, for example. Typically, a flexible elastomeric gasket is placed within the opening in the wall, followed by fitting an expansion ring against the interior surface of the gasket. Thereafter, a suitable expansion mechanism is used to radially expand the expansion ring and lock same in an expanded condition in which the gasket is sealingly compressed between the expansion ring and the opening in the wall of the structure. Thereafter, a pipe is inserted through the gasket, and one or more clamps are installed around a portion of the gasket which extends from the wall to sealingly compress the extending portion of the gasket between the clamps and the outer surface of the pipe. In this manner, a sealed connection is made between the pipe and the structure.
[0007] Similarly, sealed connections between two pipes are frequently made. Underground pipes which are used in municipal water and sewer systems, for example, typically include bell and spigot ends that are attached to one another in a sealed manner. Typically, either the spigot end or the bell end of such pipes includes a rubber seal which is compressed between the ends of the pipes to provide a sealed joint when the spigot end of one pipe is inserted into the bell end of another pipe. Occasionally, these primary joint seals between adjacent pipes may leak after installation in the field, requiring a secondary sealing assembly to seal the connection.
[0008] Yet another application for a pipe seal is the fixing of a leak within a pipe structure. Where a pipe has begun allowing ingress of moisture, such as through a hole or crack in the wall of the pipe, a gasket may be placed within the wall of the pipe spanning the structure, and each side of the gasket may be sealed to prevent further leakage into the pipe.
[0009] To make the above seals, a flexible elastomeric gasket may be placed against the pipe or manhole wall, followed by fitting an expansion ring against the interior surface of the gasket. Thereafter, a suitable expansion mechanism is used to radially expand the expansion ring and lock same in an expanded condition so that the gasket is sealingly compressed between the expansion ring and the wall of the pipe or manhole at the joint. Thereafter, a pipe is inserted through the gasket, and one or more clamps are installed around a portion of the gasket which extends from the wall to sealingly compress the extending portion of the gasket between the clamps and the outer surface of the pipe. In this manner, a sealed connection is made between the pipe and the structure.
[0010] What is needed is an improved expansion ring mechanism and sealing assembly for sealing joints in fluid-carrying structures such as manhole access ports, underground pipes, and underground pipe junction points, for example.
SUMMARY
[0011] The present disclosure provides an expansion ring assembly for sealing a gasket with respect to an annular wall of a rigid structure. The expansion ring assembly includes two arcuate expansion ring bands that cooperate to define a generally circular profile. At one side of the expansion ring assembly, a first pair of ends of the expansion ring bands overlap and include a ratcheting mechanism which allows the ring to incrementally expand but not to contract. At another location of the expansion ring assembly, a second pair of ends are joined by a drive mechanism for engaging and driving apart the opposing ends of an expansion ring to thereby non-incrementally expand the ring. The ratchet mechanism may be used to initially set and hold the expansion ring against a gasket in a desired position and to provide an initial expansion pressure, i.e., for a coarse adjustment. The drive mechanism may then be used to provide a final expansion pressure of the gasket, i.e., for a fine adjustment. Advantageously, the coarse adjustment followed by the final adjustment allows a user to quickly and precisely achieve a desired gasket pressure by manipulating the torque applied to the drive mechanism.
[0012] The ratchet mechanism includes a tooth formed on the first ring band which cooperates with a series or rack of slots or apertures formed in the second, overlapping ring band, each of the apertures sized to receive the tooth therein. As the first and second ring bands are moved apart from one another to incrementally expand the overall size of the expansion ring, the tooth advances along the series of slots. Movement of the tooth in the other direction is prevented by the ratchet mechanism, so that contraction of the band is prevented from occurring once the band has been expanded.
[0013] The drive mechanism generally includes a pair of block members having threaded bores therethrough, and a bolt having oppositely-threaded ends which are threaded within respective bores of the block members. The bolt additionally includes a tool-receiving structure, such as a nut portion, which may be engaged by a suitable tool to rotate the bolt. The block members are respectively engaged with opposite ends of the expansion ring. Rotation of the bolt in a first direction simultaneously drives the block members apart from one another along the bolt to radially expand the expansion ring, and rotation of the bolt in a an opposite, second direction simultaneously drives the block members toward one another along the bolt to allow the expansion ring to radially contract.
[0014] Expansion of the expansion ring compresses the gasket between the expansion ring and the opening of the structure to provide a fluid tight seal between the gasket and the structure. Subsequently, a gasket may be sealed about the interface between a manhole base and a manhole frame to prevent water infiltration into a manhole.
[0015] The present expansion ring assembly may also be used in other applications, such as, for example, for sealing an internal coupling gasket within one or more pipes to prevent water infiltration into a pipeline. Alternatively, a pipe may be coupled to a structure by coupling a gasket to an annular opening in the wall of a structure and inserting a pipe through a second portion of the gasket which extends outwardly of the structure, and then securing the extending portion of the gasket to the outer surface of the pipe using conventional hose clamps or take-up clamps, for example.
[0016] Advantageously, the ratchet mechanism allows rapid expansion of a contracted expansion ring to a size nearly large enough to form a fluid-tight seal. An initial expansion is rapidly accomplished utilizing the ratchet mechanism. The substantial overlap of the expansion ring bands at the ratchet mechanism allow a large expansion from a contracted state, so that the expansion ring assembly may easily be placed within a manhole or pipe assembly prior to expansion. The ratcheting mechanism is then used to expand the expansion ring assembly to fit the annular surface of the manhole or pipe, with overlap remaining at the ratcheting mechanism to provide a continuous annular surface for an effective gasket seal.
[0017] For the final expansion of the expansion ring, the oppositely-threaded ends of the bolt may be rotated in one direction to simultaneously drive the block members apart from each other to expand the expansion ring, such that only one tool need be used to actuate the drive mechanism to expand the expansion ring. Additionally, the screw threaded engagement between the bolt and the block members allows the block members to be driven away from one another along the bolt to an infinitely variable extent based upon the rotational position of the bolt. Therefore, after the initial rapid expansion of the ring with the ratchet mechanism, the expansion ring may be further expanded by applying a known amount of torque to the drive mechanism. A precise pressure in the expansion ring assembly is achieved, and the gasket is firmly and sufficiently compressed between the expansion ring and the opening of the structure to provide a fluid tight seal.
[0018] A further advantage of the expansion ring assembly is the ability to remove the assembly from the structure if needed, followed by re-installing the assembly in a different position, or by re-using the assembly by installing same in a different structure or using same in a different application. The expansion ring may be collapsed to a contracted position by rotating the bolt of the drive mechanism in the opposite direction, and/or by disengaging the ratcheting mechanism.
[0019] The disclosure, in one form thereof, comprises an expansion ring assembly for sealing a gasket against an annular surface, the expansion ring assembly, including a ring having a circumference, the ring including first and second ring band each having opposite ends, a ratcheting mechanism joining respective first ends of the ring band, the ratcheting mechanism allowing incremental expansion of the circumference of the ring by a first distance and preventing contraction of the circumference of the ring, and a drive mechanism joining respective second ends of the ring band, the drive mechanism including a pair of first threaded members joined to the respective second ends of the ring band, and a second threaded member disposed between and threadingly connecting the pair of first threaded members, the drive mechanism allowing non-incremental expansion of the circumference of the ring by a second distance to a fully expanded configuration, the drive mechanism also allowing non-incremental contraction of the circumference of the ring by a third distance, whereby the expansion ring assembly cooperates with the gasket to form a fluid type seal at the annular surface and a fully expanded configuration.
[0020] The disclosure, in another form thereof, comprises an expansion ring assembly for sealing the gasket against an annular surface, the expansion ring assembly comprising a ring having a circumference, the ring including first and second ring bands each having opposite ends, means for providing incremental expansion of the circumference of the rings by a first distance, the means for providing incremental expansion preventing contraction of the circumference of the ring, and means for providing non-incremental expansion of the circumference of the ring by a second distance to a fully expanded configuration, the means for providing non-incremental expansion also allowing non-incremental contraction of the circumference of the ring by a third distance, whereby the expansion ring assembly cooperates with the gasket to form a fluid type seal at the annular surface and the fully expanded configuration.
[0021] The disclosure, in a further form thereof, comprises a method of installing a gasket against annular surface, the method including placing an expansion ring assembly in a contracted configuration approximate to gasket so that gasket is disposed between the expansion ring assembly and the annular surface, actuating a first, ratcheting mechanism to incrementally expand the expansion ring assembly to a partially expanded configuration, and actuating a second mechanism having a pair of threaded members, where an actuation of the second mechanism simultaneously drives the pair of threaded members away from one another to non-incrementally expand the expansion ring assembly to a fully expanded configuration, the expansion ring assembly cooperating with the gasket to form a fluid type seal at the annular surface in the fully expanded configuration.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] The above-mentioned and other features and advantages of this disclosure, and the manner of attaining them, will become more apparent and the invention itself will be better understood by reference to the following description of embodiments of the invention taken in conjunction with the accompanying drawings, wherein:
[0023] FIG. 1 is a perspective view of an expansion ring assembly in accordance with the present disclosure;
[0024] FIG. 2 is another perspective view of the expansion ring assembly shown in FIG. 1 ;
[0025] FIG. 3 is a partial perspective view of a portion of the expansion ring assembly shown in FIG. 2 , illustrating a ratcheting mechanism series of slots;
[0026] FIG. 4 is a partial perspective view of the expansion ring assembly shown in FIG. 1 , illustrating a ratcheting mechanism tooth;
[0027] FIG. 5 is a perspective view of an expansion ring ratcheting tool usable with the ratcheting mechanism shown in FIGS. 3 and 4 ;
[0028] FIG. 6 is a partial sectional view of a connection between a concrete structure and a pipe, wherein a wall of the concrete structure includes an opening into which a gasket is sealingly fitted with an expansion ring assembly according to the present disclosure, and further showing a pipe sealingly connected to the gasket;
[0029] FIG. 7 is a partial sectional view of a connection between a manhole frame and a manhole base disposed beneath a pavement surface, showing a gasket sealingly connecting the manhole base and the manhole frame using a pair of expansion ring assemblies according to the present disclosure to prevent water infiltration into the manhole;
[0030] FIG. 8 is a partially exploded view of a pipe-to-pipe connection which includes an internal pipe coupler therebetween, the internal pipe coupler including a pair of expansion ring assemblies according to the present disclosure to prevent water infiltration into the pipes;
[0031] FIG. 9 is an exploded, fragmentary view of the expansion ring assembly of FIG. 1A , showing the expansion ring ends, the drive mechanism, and the oversleeve; and
[0032] FIG. 10 is a fragmentary perspective view of the pipe connection of FIG. 1A , showing the actuation of the drive mechanism to expand the expansion ring.
[0033] Corresponding reference characters indicate corresponding parts throughout the several views. The exemplifications set out herein illustrate embodiments of the disclosure, and such exemplifications are not to be construed as limiting the scope of the invention any manner.
DETAILED DESCRIPTION
[0034] Referring to FIGS. 1 and 2 , expansion ring assembly 34 includes first ring band 36 a having opposite ends 48 a , and second ring band 36 b having opposite ends 48 b . At one side of expansion ring mechanism 34 , ends 48 a , 48 b of ring bands 36 a , 36 b are joined by drive mechanism 38 , which can be used to continuously non-incrementally expand or non-incrementally contract the overall size of expansion ring assembly 34 as discussed in detail below. At the other end of expansion ring assembly 34 , ends 48 a , 48 b of ring bands 36 a , 36 b are joined by ratchet mechanism 100 , which can be used to quickly incrementally expand expansion ring assembly 34 by discrete amounts. Ratchet mechanism 100 can be used to make a “macro” or large-scale expansion of expansion ring assembly 34 , such as upon initial installation at a manhole assembly, pipe connection, or the like. With this large scale adjustment made, drive mechanism 38 may be used to make “micro” or small-scale adjustments to either expand or contract expansion ring assembly 34 to provide a desired or appropriate amount of expansion force or pressure, such as may be required for a particular gasket arrangement. The expansion force may be inferred from the amount of torque applied to drive mechanism, so that a known torque indicates the desired amount of expansion pressure.
[0035] FIG. 2 illustrates ratchet mechanism 100 joining ends 48 a , 48 b of ring bands 36 a , 36 b . Ratchet mechanism 100 allows first ring band 36 a to move relative to second ring band 36 b in direction A. Direction A corresponds to the direction of a first distance along which ratchet mechanism 100 allows incremental expansion of the circumference of ring assembly 34 . FIG. 2 also illustrates drive mechanism 38 joining opposite ends 48 a , 48 b of ring bands 36 a , 36 b . Drive mechanism 38 allows first ring band 36 a to move in direction B 1 and second ring band 36 b to move in direction B 2 such that first ring band 36 a and second ring band 36 b simultaneously move away from one another. Direction B 1 and direction B 2 correspond to the direction of a second distance along which drive mechanism 38 allows non-incremental expansion of the circumference of ring assembly 34 to a fully expanded configuration. Drive mechanism 38 also allows first ring band 36 a to move in direction C 1 and second ring band 36 b to move in direction C 2 such that first ring band 36 a and second ring band 36 b simultaneously move toward one another. Direction C 1 and direction C 2 correspond to the direction of a third distance along which drive mechanism 38 allows non-incremental contraction of the circumference of ring assembly 34 . In one embodiment, the first distance that ratchet mechanism 100 allows incremental expansion of the circumference of ring assembly 34 is greater than the second distance that drive mechanism 38 allows non-incremental expansion of the circumference of ring assembly 34 .
[0036] 1. Expansion Ring Assembly Uses and Environments
[0037] In use, expansion ring assembly 34 may be used to seal a gasket at a connection or junction between two or more fluid-carrying structures. For example, referring to FIG. 6 , expansion ring assembly may be used to seal gasket 26 at pipe connection 20 . Pipe connection 20 is shown in the context of an underground pipe system, in which a pipe is connected to a structure, such as a manhole riser or monolithic base, for example. The structure may be formed of concrete, fiberglass, or any other suitable rigid material. The structure includes wall 22 having interior side 22 a defining the interior of the structure, and exterior side 22 b defining the exterior of the structure. Additionally, wall 22 includes opening 24 therein. An annular gasket 26 includes a first portion 28 disposed within opening 24 of wall 22 , and a second portion 30 extending from first portion 28 . Gasket 26 may be made from a flexible, elastomeric material such as rubber or neoprene, for example, and provides a sealing connection between opening 24 in wall 22 of the structure and a pipe 32 . First portion 28 of gasket 26 is sealingly engaged with opening 24 of wall 22 by expansion ring assembly 34 , which generally includes first and second expansion ring bands 36 a , 36 b , drive mechanism 38 , oversleeve 40 , and ratchet mechanism 100 . As discussed in detail below, expansion ring assembly 34 is radially expandable to compress gasket 26 into sealing engagement with opening 24 in wall 22 to provide a fluid tight seal therebetween.
[0038] After first portion 28 of gasket 26 is sealingly engaged with opening 24 of wall 22 by expansion ring assembly 34 , second portion 30 of gasket 26 is connected to pipe 32 by inserting pipe 32 therethrough, followed by installing one or more clamps 42 around second portion 30 of gasket 26 and tightening clamps 42 to compress second portion 28 of gasket 26 into sealing engagement with outer surface 44 of pipe 32 to provide a fluid tight seal therebetween. Second portion 30 of gasket 26 may include annular recessed seats 46 for receipt of clamps 42 to locate clamps 42 on second portion 30 of gasket 26 .
[0039] In FIG. 6 , only a portion of the length of pipe 32 is shown for clarity, it being understood that pipe 32 typically extends past expansion ring assembly 34 through opening 24 in wall 22 , past inner surface 22 a of wall 22 , and into the interior of the structure. Also, expansion ring assembly 34 is shown in FIG. 6 with drive mechanism 38 disposed in a nine o'clock position with respect to opening 24 for clarity, and with ratcheting mechanism 100 not shown, it being understood that ratcheting mechanism 100 is disposed generally opposite drive mechanism 38 . However, expansion ring assembly 34 may be selectively configured with drive mechanism 38 and ratcheting mechanism 100 oriented in any desired position around the circumference of opening 24 , it being noted that a configuration with drive mechanism 38 disposed in a twelve o'clock position is favored in many applications. Further, the pipe connection of FIG. 6 may installed in a manner in which second portion 30 of gasket 26 extends inward of wall 22 , in essentially the opposite manner shown in FIG. 6 , such that clamps 42 are disposed within the structure.
[0040] Although expansion ring assembly 34 is shown in FIG. 6 in an application in which expansion ring assembly 34 is used to seal a gasket within an opening in the wall of a structure, expansion ring assembly 34 may also be used in many other applications. For example, in FIG. 7 , a pair of expansion ring assemblies 34 a and 34 b are used to seal gasket 27 about an interface between manhole base 29 and a manhole frame 31 disposed beneath pavement surface 33 . Specifically, an upper expansion ring assembly 34 a is used to press an upper portion of gasket 27 into sealing engagement with manhole frame 31 , and a lower expansion ring assembly 34 b is used to press a lower portion of gasket 27 into sealing engagement with manhole base 29 . In this manner, water infiltration into manhole base 29 is prevented, regardless of whether relative movement occurs between manhole frame 31 and manhole base 29 .
[0041] In FIG. 8 , a pair of expansion ring assemblies 34 a and 34 b are used with an internal coupling gasket 35 for sealing a connection between the female or bell end 37 of a first pipe 32 a and the male or spigot end 39 of a second pipe 32 b . Specifically, a first expansion ring mechanism 34 a presses one end of gasket 35 into sealing engagement with bell end 37 of pipe 32 a , and a second expansion ring assembly presses an opposite end of gasket 35 into sealing engagement with spigot end 39 of pipe 32 b to prevent water infiltration into the pipes if or when the primary bell-spigot connection between pipes 32 a and 32 b fails. Alternatively, expansion ring assemblies 34 a and 34 b may be used with an internal coupling gasket 35 to bridge and seal a crack or leak disposed anywhere along a single pipe 32 within a pipeline.
[0042] Thus, expansion ring assembly 34 may be used in any application which generally involves the radial expansion of a flexible gasket into sealing engagement with a rigid structure. The details and operation of expansion ring assembly 34 are discussed below.
[0043] 2. Expansion Ring Construction
[0044] Referring to FIGS. 1 , 2 and 9 , a first embodiment of expansion ring assembly 34 is shown. Expansion ring bands 36 a , 36 b are made of a continuous strip of material, such as stainless steel, other metals, or a plastic, for example, and include opposite ends 48 a , 48 b , respectively. Expansion ring bands 36 a , 36 b may include a generally planar base wall 50 ( FIG. 9 ) having outer surface 52 for engaging the interior surface of a gasket. Expansion ring bands 36 a , 36 b may form substantially flat annular surfaces, as shown in FIGS. 1-4 , 6 , 7 and 10 , or may have side walls 54 projecting inwardly from base wall 50 , as shown in FIG. 9 . Where bands 36 a , 36 b have side walls, 54 , base wall 50 and side walls 54 together define a generally U-shaped cross-sectional profile; however, the overall shape of expansion ring bands 36 a , 36 b may vary. As shown in FIG. 9 , ends 48 a , 48 b of expansion ring bands 36 a , 36 b may also include optional crimped portions 56 . Side walls 54 and/or crimped portions 56 may be provided at either end of bands 36 a , 36 b , i.e., side walls 54 and crimped portions 56 may cooperate with either drive mechanism 38 or ratchet mechanism 100 , or both.
[0045] In the illustrated embodiment, expansion ring bands 36 a , 36 b each span about half of the overall circumferential extent of expansion ring assembly 34 . However, it is within the scope of the present disclosure that expansion ring bands 36 a , 36 b may not be equal in length. In addition, more than two expansion ring bands may be used to form expansion ring assembly 34 , with drive mechanism 38 and/or ratchet mechanism 100 disposed at the junction between each respective ring band.
[0046] Turning now to FIGS. 3 and 4 , ratchet mechanism 100 includes pawl or tooth 102 formed in second ring band 36 b and a series or rack 104 of apertures or slots 106 formed in first ring band 36 a . In the illustrated embodiment, tooth 102 is integral with second ring band 36 b , and may be formed by punching tooth 102 out of the material of band 36 b . Tooth 102 is therefore an inwardly extending portion of second ring band 36 b , and is directed towards the center of expansion ring assembly 34 . Tooth 102 forms angle θ with a tangent plane contacting tooth 102 . Angle θ is sufficiently small to allow rack 104 to slide freely in an expanding direction, while being prevented from moving in a contracting direction, as discussed in detail below.
[0047] As best seen in FIG. 3 , rack 104 includes a plurality of apertures 106 sized to receive tooth 102 therein. Apertures 106 are successively arranged along one of ends 48 a of first ring band 36 a with spacing or pitch P between respective pairs of apertures 106 . Pitch P determines the resolution of adjustment of expansion ring assembly 34 using rack 100 . That is to say, as expansion ring assembly 34 is incrementally expanded by advancing tooth 102 from any of apertures 106 to the next neighboring aperture 106 in the direction of end 48 a of first ring band 36 a , the overall increase in the circumference of expansion ring assembly 34 will be equal to pitch P. Similarly, if the circumference of expansion ring assembly 34 is constrained from expanding by an amount equaling at least pitch P (such as by contact with wall 22 via gasket 26 , as discussed above), tooth 102 will not be able to advance to the next neighboring aperture 106 of rack 104 . As described in detail herein, drive mechanism may then be used for final non-incremental expansion of expansion ring assembly 34 . Thus, ratchet mechanism 100 provides a large-scale or macro adjustment in that expansion ring assembly 34 may only be adjusted using rack 104 by increments of pitch P. On the other hand, drive mechanism 38 ( FIGS. 1 , 9 and 10 ) may be used to continuously adjust the size of expansion ring assembly 34 by any amount, to allow precise control over the pressure exerted by expansion ring assembly 34 upon a gasket.
[0048] Referring now to FIGS. 3 and 4 , end 48 b of expansion ring band 36 b substantially overlaps end 48 a of expansion ring band 36 a at ratcheting mechanism 100 . This overlap is the result of expansion ring band 36 b extending past tooth 102 by a substantial amount, as seen in FIG. 4 . Moreover, expansion ring band 36 b extends past tooth 102 sufficiently far to ensure overlap between expansion ring bands 36 a , 36 b at ratcheting mechanism 100 even when tooth 102 is engaged with the aperture 106 closest to end 48 a of expansion ring band 36 a . Advantageously, this overlap produces a substantially continuous annular surface at the outside of expansion ring assembly 34 , which facilitates proper and continuous sealing pressure against an adjacent structure such as gasket 26 . This continuous pressure ensures a fluid-tight seal across the entire extent of ratcheting mechanism 100 , and throughout the entire range of motion of same, as described in detail below.
[0049] As best seen in FIGS. 9 and 10 , drive mechanism 38 generally includes a pair of first threaded members, such as a pair of block members 58 , and a second threaded member, such as bolt 60 , disposed between and threadingly connecting block members 58 . Block members 58 each include threaded bore 62 and a pair of shoulders 64 on opposite sides thereof. The bores 62 of a pair of block members 58 of each drive mechanism 38 are oppositely threaded, for reasons discussed below. Block members 58 are removably attached to respective ends 48 a , 48 b of expansion ring bands 36 a , 36 b by sliding shoulders 64 within crimped portions 56 of a pair of ends 48 a , 48 b of expansion ring bands 36 a , 36 b until front edges 66 thereof abut ledges 68 of block members 58 . The foregoing connection configuration between block members 58 and ends 48 a , 48 b of expansion ring bands 36 a , 36 b is exemplary, it being understood that many other types of configurations for removably connecting block members 58 to ends 48 a , 48 b may be devised. For example, it is within the scope of the present disclosure that block members 58 may have an external thread rather than an internal thread, and that bolt 60 may have internal threads adapted to cooperate with the external threads of block members 58 . Block members 58 may also be removably attachable to respective ends 48 a , 48 b of expansion ring bands 36 a , 36 b by any connection configuration in accordance with the connection configurations between block members and end portions of expansion ring bands described in U.S. Pat. No. 7,146,689, issued Dec. 12, 2006, entitled “Expansion Ring Assembly,” the entire disclosure of which is hereby expressly incorporated herein by reference.
[0050] Bolt 60 includes oppositely-threaded ends 70 a and 70 b ; for example, end 70 a has right-hand threads and end 70 b has left-hand threads, or vice-versa. Bolt 60 additionally includes a suitable tool-receiving structure between bolt ends 70 a and 70 b , such as hexagonal nut portion 72 integrally formed with bolt 60 . Although nut portion 72 is shown herein as having a hexagonal configuration, i.e., having six sides, other shapes for nut portion are possible, wherein nut portion may have four, five, six, or more sides, for example. Bolt ends 70 a and 70 b are threadingly engaged within the corresponding threaded bores 62 of block members 58 to connect block members 58 to bolt 60 .
[0051] Oversleeve 40 is formed of a segmented strip of material, such as stainless steel, other metals, or a plastic. Similar to expansion ring bands 36 a , 36 b , oversleeve 40 includes base wall 74 and a pair of side walls 76 extending therefrom to define a U-shaped cross-sectional profile complementary to that of expansion ring bands 36 a , 36 b , as described above. The distance between side walls 76 of oversleeve 40 is slightly wider than the corresponding distance between side walls 54 of expansion ring bands 36 a , 36 b , such that ends of 48 a , 48 b thereof may nest within oversleeve 40 between side walls 76 of oversleeve 40 , as shown in FIG. 10 .
[0052] 3. Operation of the Expansion Band
[0053] As a first step, expansion band assembly 34 is placed at the site of installation, such as adjacent gasket 26 at wall 22 , or adjacent gasket 35 at the junction between two pipes 32 a , 32 b , for example, as described above. Expansion band assembly 34 is in a contracted or partially contracted state upon being so placed, so that expansion band assembly 34 may be easily maneuvered into a proper position and orientation. Once in the proper position, ratcheting mechanism 100 may be actuated by simply pulling expansion rings bands 36 a , 36 b apart from one another by hand, thereby drawing tooth 102 over one or more apertures 106 of rack 104 . With the initial expansion complete, ratcheting mechanism may optionally be expanded further using ratchet tool 110 .
[0054] Turning now to FIG. 5 , ratchet tool 110 may be provided to actuate ratchet mechanism 100 . Ratchet tool 110 includes first engagement shaft 112 which is rigidly connected to handle 114 . Second engagement shaft 116 is pivotally connected to first engagement shaft 112 at pivot 118 . First engagement shaft 112 includes a generally cylindrical engagement end 120 sized to be received within a tool engagement structure such as tool aperture or hole 108 a formed in first ring band 36 a ( FIGS. 2 and 3 ). Alternatively, engagement end 120 of shaft 112 may be shaped to fit within one of apertures 106 , obviating the need for aperture 108 a or allowing aperture 108 a to be formed as one of apertures 106 in rack 104 . Second engagement shaft 116 includes second engagement end 122 sized to be received within another tool engagement structure such as any of a plurality of tool apertures 108 b formed in second ring band 36 b ( FIGS. 1 , 2 and 4 ). Referring to FIG. 3 , tool aperture 108 a is spaced from and separate from apertures 106 . Second engagement end 122 may include transverse pin 124 to control the depth of engagement of second engagement end 122 within tool apertures 108 b . Second engagement shaft 116 further includes bend 126 to orient second engagement end 122 to face tool apertures 108 b.
[0055] In use, ratchet tool 110 may be used to provide an expanding force to expansion ring assembly 34 at ratchet mechanism 100 . First engagement end 120 of first shaft 112 is engaged with tool aperture 108 a of first ring band 36 a . One of tool apertures 108 b is selected for engagement with second engagement end 122 of second shaft 116 , depending on the relative position of tooth 102 with respect to rack 104 . Once first and second engagement ends 120 , 122 are engaged with tool apertures 108 a , 108 b , force F is applied to handle 114 in the direction of second shaft 116 . Force F urges the expansion of expansion ring assembly 104 by forcing apertures 108 a , 108 b apart. Second shaft 116 pivots with respect to first shaft 112 about pivot 118 , allowing first and second engagement ends 120 , 122 to move apart from one another as expansion ring assembly 34 expands. Advantageously, ratchet tool 110 allows the use of ratchet mechanism 100 to incrementally expand expansion ring assembly 34 against gasket 26 , thereby aiding in the formation of a fluid tight seal and minimizing any further adjustment needed with drive mechanism 38 . Once ratchet mechanism 100 has been fully expanded using ratchet tool 110 , drive mechanism 38 may be used for final adjustment in the expansion or contraction of expansion ring assembly 34 to achieve a precise pressure upon a gasket, as described in detail below.
[0056] To actuate drive mechanism 38 , a suitable tool, such as an open-end wrench or a torque wrench, for example, is engaged with nut portion 72 of bolt 60 and used to rotate bolt 60 in a first direction as illustrated by arrow 78 (shown in FIG. 10 ). Upon rotation of bolt 60 , the threaded engagement between bolt ends 70 a and 70 b and threaded bores 62 of block members 58 drives block members 58 simultaneously away from one another along bolt 60 , thereby forcing a pair of ends 48 a , 48 b of expansion ring bands 36 a , 36 b apart from one another to non-incrementally expand the diameter of expansion ring assembly 34 . During such expansion, oversleeve 40 prevents relative lateral movement between ends 48 a , 48 b of expansion ring bands 36 a , 36 b at drive mechanism 38 , such that ends 48 a , 48 b are constrained to move apart from one another only along the direction indicated by arrow 80 .
[0057] Referring generally to FIGS. 1-3 and 10 , gasket 26 is shown disposed within opening 24 in wall 22 , and expansion ring assembly 34 is shown fitted within the interior of gasket 26 . At one side of expansion ring assembly 34 , ratchet mechanism 100 is provided to allow a rapid, large-scale adjustment of the circumference of expansion ring assembly by allowing apertures 106 of rack 104 to slide freely over tooth 102 as expansion rings bands 36 a , 36 b are moved relative to one another in an expanding motion. At another side of expansion ring assembly 34 , block members 58 of drive mechanism 38 are received within a pair of respective ends 48 a , 48 b of expansion ring bands 36 a , 36 b , and this pair of ends 48 a , 48 b are nested within oversleeve 40 , which overlaps ends 48 a , 48 b and spans the gap therebetween which is bridged by drive mechanism 38 . Drive mechanism 38 is oriented such that bolt 60 is disposed perpendicular to longitudinal axis L 1 -L 1 ( FIGS. 6 and 10 ) which axis is common to expansion ring assembly 34 , gasket 26 , and opening 24 .
[0058] The expansion of expansion ring assembly 34 compresses gasket 26 between expansion ring bands 36 a , 36 b and opening 24 in wall 22 to provide a fluid tight seal between gasket 26 and wall 22 . Bolt 60 may also be rotated in a second direction opposite the first direction along arrow 78 if needed, which simultaneously drives block members 58 toward one another along bolt 60 , thereby allowing expansion ring assembly 34 to contract. In this manner, expansion ring assembly 34 may be removed after installation if necessary, in order to reposition expansion ring assembly 34 or alternatively, to re-use expansion ring assembly 34 in another installation or application. For example, ring assembly 34 can be repositioned proximate another gasket and then ratcheting mechanism 100 and drive mechanism 38 can be actuated in the manner described above to expand ring assembly 34 such that ring assembly 34 cooperates with the other gasket to form a fluid tight seal.
[0059] Advantageously, the threaded engagement between the oppositely-threaded ends 70 a and 70 b of bolt 60 and block members 58 simultaneously drives block members 58 apart from one another along bolt 60 such that only a single tool need be used to actuate drive mechanism 38 . A single turn of a wrench, for example, drives both block members 58 apart from one another simultaneously, such that block members 58 need not be separately adjusted. Thus, the simultaneous use of multiple wrenches, as well as multiple manual adjustment steps, is avoided. Additionally, the threaded engagement between bolt ends 70 a and 70 b and block members 58 allows an infinitely variable degree of adjustment of drive mechanism 38 , such that expansion ring assembly 34 may be selectively expanded to any desired extent. In this manner, expansion ring assembly 34 can accommodate gaskets 26 of varying nominal sizes, and further, can also accommodate irregularities or size variations between gaskets 26 of the same nominal size.
[0060] Also advantageously, the combination of ratcheting mechanism 100 with drive mechanism 38 in a single expansion ring assembly 34 facilitates a rapid and precise installation by a single installer. Ratcheting mechanism may be used for large-scale adjustments, and may be placed within an opening to be sealed by a single person by manually expanding the band to roughly fit the required aperture size. With the installer's hands freed and the gasket (i.e., gasket 26 or 35 , for example) held in place, the installer can use ratchet tool 110 to further expand expansion ring assembly 34 , and finally, can use another tool to actuate drive mechanism 38 for fine adjustments, to quickly create a final and precise seal. In the exemplary embodiment shown in the figures, the final adjustment may be used to impart a specific, precise and known pressure upon a gasket by applying a specific, known torque to bolt 60 of drive mechanism 38 . Because the pressure exerted by expansion ring assembly directly correlates to the torque applied to bolt 60 , the pressure exerted upon the gasket may be inferred by the torque applied. In this way, drive mechanism 38 allows a highly precise adjustment in conjunction with the rapid expansion afforded by ratcheting mechanism 100 .
[0061] Yet another advantage of expansion ring assembly 34 is that, in the collapsed state, expansion ring assembly may be made small enough to fit easily within an installation space such as a manhole or pipe assembly. For example, the substantial overlap of expansion ring bands 36 a , 36 b allows expansion ring assembly 34 to be collapsed to a substantially smaller overall circumference as compared with the fully expanded circumference of expansion ring assembly 34 . Still further, this overlap cooperates with oversleeve 40 to ensure that, even when expansion ring assembly 34 is in a fully expanded condition, the outer or sealing surface of expansion ring assembly 34 defines a continuous annular surface that evenly distributes the sealing pressure against a gasket (such as, for example, gaskets 26 or 35 ). As best seen in FIG. 4 , step 101 presents only a minimal interruption in the continuity of the outer surface, with such disruption easily absorbed by a typical gasket.
[0062] While this invention has been described as having exemplary designs, the present disclosure can be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the disclosure using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains and which falls within the limits of the appended claims. | An expansion ring assembly seals a gasket with respect to an annular wall of a rigid structure. The expansion ring assembly includes two arcuate expansion ring bands that cooperate to define a generally circular profile. At one side of the expansion ring assembly, a first pair of ends of the expansion ring bands overlap and include a ratcheting mechanism which allows the ring to incrementally expand but not to contract. At another location of the expansion ring assembly, a second pair of ends are joined by a drive mechanism for engaging and driving apart the opposing ends of an expansion ring to thereby non-incrementally expand the ring. The ratchet mechanism may be used to initially set and hold the expansion ring against a gasket in a desired position and to provide an initial expansion pressure, i.e., for a coarse adjustment. The drive mechanism may then be used to provide a final expansion pressure of the gasket, i.e., for a fine adjustment. Advantageously, the coarse adjustment followed by the final adjustment allows a user to quickly and precisely achieve a desired gasket pressure by manipulating the torque applied to the drive mechanism. | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates generally to building systems, and more particularly, to an improved apparatus and method for forming a framed opening in a poured concrete wall made with insulated concrete forms, for example, that remain a permanent part of the wall.
2. Discussion of the Related Art
Conventional building construction utilizes concrete foundation walls which are normally produced by constructing form walls, pouring concrete into the space between the walls and, upon setting of the concrete, removing the form walls. Finishing materials are then added to the concrete foundation walls as required. Framing members, often made of wood, will then be constructed on top of the foundation walls. Insulation may then be inserted between the framing members and the wall finished inside and out as desired.
More recent building systems involve the use of insulated concrete forms (ICF's) which comprise a foam insulating material to construct permanent concrete form walls. The form walls are constructed by placing separate building components upon each other. The concrete is then poured and the form walls are left in place, even after the concrete hardens. The concrete wall so formed need not be confined to foundation walls but may comprise all of a building's walls. Generally, no further insulation is necessary, and known finishing materials of all types, including veneer finishes, stucco, gypsum boards, etc., may be applied to the interior and exterior of the wall as required. An example of a particularly advantageous type of ICF appears in U.S. Pat. No. 5,390,459 (Mensen) and U.S. Pat. No. 5,657,600 (Mensen), the disclosures of which are incorporated by reference herein in their entirety. As shown in FIG. 1, the ICF's of these patents are made from a building component 10 , which includes first and second high density foam sidepanels 12 and 14 . The sidepanels 12 and 14 are preferably made of expanded polystyrene and are arranged in spaced parallel relationship with their inner surfaces facing each other. Plastic bridging members 42 molded into the sidepanels hold them together against the forces applied by the poured concrete. Each bridging member includes end plates 44 , 46 , which line up when the components are stacked to form furring strips for attachment of finishing materials. As these building components 10 are stacked to become an ICF form wall, it becomes necessary to provide block-out systems known in the art as “bucks” to provide openings for installing components, such as windows or doors, within the ICF form wall.
In conventional, pre-ICF, concrete building systems discussed above, wood or metal bucks have been utilized to provide such a block-out opening in the wall. Many of these conventional bucks are removable once the concrete has hardened, similar to the wood forms used in these pre-ICF building systems, and are referred to within the construction art as “reusable bucks”. Examples of reusable buck systems are disclosed in U.S. Pat. No. 2,787,820 (Shields et al.) as well as in U.S. Pat. No. 5,169,544 (Stanfill et al.).
With the advent of the use of stay-in-place forms or permanent concrete formwork, such as ICF's, the current practice has been to build a wooden framed buck to provide an opening in the wall for installing a component, such as a window or a door. This frame is typically constructed from standard-sized lumber such as 2″×12″ or 1″×12″. If left in place after the poured concrete has cured, this wooden frame of the buck provides a fastening surface for the window or door and its finishing trim.
An example of such a known window buck in an ICF wall is denoted generally as 23 in FIG. 2, which shows the use of, for example, 2″×12″ lumber 25 to create the top and sides of the buck. The wooden buck retains the concrete and also provides solid attachment surfaces for interior and exterior finishes around the edge of the openings. The bottom 27 of the buck frame may be created with two 2″×4″'s in an arrangement which will provide a slot to allow proper placement and consolidation of concrete below the opening. In order to keep the wood frame properly aligned in the opening within the stacked wall forms, 1″×4″ wood strapping 29 may be fastened to the perimeter facings of the frame as shown in FIG. 2 . This will ensure alignment of the wall forms with the wood frame. The 1″×4″ strapping 29 may be removed and reused once the concrete has set.
When the wooden buck frame is to be left in the wall, it must be firmly secured to the concrete. The frame may be fastened to the concrete by using fasteners, such as nails or anchor bolts, secured to the frame and left hanging between the sidepanels of the ICF system. The subsequent pouring of wet concrete between the two sidepanels will cause the wet concrete to flow around the fastener and thus aid in holding the frame in place once the concrete has hardened.
The opening formed by a wood buck for a window and door opening typically require supplemental bracing inside the frame to prevent deflection of the wood members under pressure from the poured concrete. This can be accomplished, for example, by placing one or more pieces of lumber in the opening to brace from side to side and/or from top to bottom. Other bracing arrangements commonly used in the building construction arena utilize dimensional lumber (i.e. 2″×4″, 2″×6″, or 2″×8″, for example). Fiber tape has also been utilized to secure, or assist in securing, the attachment of the buck to the form while the concrete is setting.
The wooden construction of these conventional bucks results in a variety of problems because of the inherent qualities of wood. For example, wood may change dimensions over time as a result of variations in humidity and temperature. This results in a common problem known in the construction field as buck shrinkage, which can affect the thermal performance of the wall and the attached component. If the conventional buck frame members undergo buck shrinkage, they may cup, warp and/or twist. This frequently results in cracks in the wall providing opportunities for air infiltration thereby compromising the thermal performance of the walls. Moreover, the use of wooden framed bucks may lead to significant problems resulting from insect infestation. Also, the wood frame has low thermal insulative properties, which is becoming an increasingly significant issue in modem construction.
Current stay-in-place bucks, such as that shown in FIG. 2, use fasteners such as nails or screws to attach the window, door, or other component to be mounted within the opening to the buck. The fasteners connect the mounted component to the buck and are anchored either within the wooden buck frame itself or within the adjacent concrete of the building wall. While such an attachment method is feasible, it is often difficult to anchor fasteners within the hardened concrete of the building wall. Moreover, the inherent dimensional instability and other detrimental qualities of wood, including those discussed above, can result in undependable alignment of the mounted component within the form wall system, as well as cracking of interior wall finishing, such as dry wall. Moreover, the cost of constructing such wooden retainers in terms of material and labor is high, especially when constructing a large commercial building, or other structure with many wall openings.
As a result of the foregoing problems and disadvantages, there is a need in the building construction art for a more efficient, cost-effective and reliable apparatus and method for forming a framed opening in a poured concrete wall made with permanent concrete formwork, such as ICFs, which will provide dependable containment of wet concrete within the wall during curing, improve the structural stability of the overall building wall system, facilitate the attachment of components, such as windows and doors, within the wall opening, and overcome the problems inherent with currently used wood block-out wall opening systems.
SUMMARY OF THE INVENTION
The invention solves these problems and avoids the drawbacks and disadvantages of the prior art by providing a buck formed of insulating material compatible with the concrete form, such as plastic, that forms a friction fit with supporting portions of an insulated concrete form wall. As a result, the buck is more stable during construction and better able to dependably contain wet concrete within the wall during curing than prior art bucks. The buck of the invention may have a portion for receiving fasteners to secure a component mounted on the buck, thus facilitating the attachment of components to the buck within the wall opening, and reducing or completely eliminating the need for fasteners to penetrate hardened concrete. The buck may also include a separate portion, preferably integrated with the fastening portion, that provides for enhanced thermal insulation. The buck may also include anchoring fins around which the poured concrete may harden and securely and sealingly attach the buck to the form.
To achieve these and other advantages and in accordance with the purpose of the invention, as embodied and broadly described and according to a first aspect of the invention, a buck is provided for forming and framing the perimeter of an opening in an insulated concrete form wall and attaching a component mounted in the opening to the wall. This buck includes first and second portions configured to engage spaced portions of an insulated concrete form wall forming the perimeter of the opening; a fastening section for attaching a component to the buck; and an insulating section.
The fastening and insulating sections may be formed by a plurality of air chambers defined by walls of a multi-layer structure, which receive and retain fasteners, preferably entirely within the chambers to avoid having to penetrate the hardened concrete. An anchoring portion, such as a T-shaped fin, may be provided to hold the buck in the concrete and, with the frictional engagement of the buck and the ICF, sealingly attach the buck and the ICF together. Preferably, the buck is formed from plastic material and includes ribs and/or score lines for facilitating construction by increasing friction between the buck and component to be mounted and/or providing indicia locating placement of fasteners and/or cutting lines to remove a portion of the buck when certain types of finishing materials, like stucco, are to be applied. With the buck of the invention, the component may be center or flange (side) mounted within the opening, as with conventional wood bucks.
In a further aspect of the invention, a method of making framed openings in a poured concrete wall made with permanent concrete formwork, is provided. This method includes the steps of constructing permanent concrete formwork having an opening; providing plastic bucks having at least one insulating chamber; frictionally attaching the bucks to the perimeter of the concrete formwork forming the opening; and pouring concrete into the formwork. A window, door, or other wall component may be directly mounted to the buck by fasteners, preferably received entirely within the buck. The bucks may include insulating air chambers within which the fasteners are received. Also, a finishing material may be directly attached to the buck.
Additional features and advantages of the invention will be set forth or be apparent from the description that follows. The features and advantages of the invention will be realized and attained by the structures and methods particularly pointed out in the written description and claims hereof as well as the appended drawings.
It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory and are intended to provide explanation and context for the invention, the scope of which is limited solely by the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
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 detailed description serve to explain the principles of the invention. In the drawings:
FIG. 1 is a perspective view of a building component used in the construction of an insulated concrete form for building concrete walls.
FIG. 2 is a perspective view of a conventional wooden buck used to form an opening within an insulated concrete form building wall.
FIG. 3 is a schematic perspective view of a buck constructed according to the principles of a first embodiment of the invention.
FIG. 4 is a transverse, cross-sectional view of the buck of FIG. 3 .
FIG. 5 is a transverse, cross-sectional view of a buck made in accordance with a second embodiment of the invention.
FIG. 6 is a transverse, cross-sectional view of a buck made in accordance with a third embodiment of the invention.
FIG. 7 is a transverse, cross-sectional view schematically showing a buck of the invention mounted to an ICF building component.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Reference will now be made in detail to the preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings.
FIG. 3 is a schematic perspective view of a buck 60 constructed in accordance with the principles of the invention. FIG. 4 is a cross-sectional view of the buck 60 of FIG. 3 . Buck 60 is designed for forming a framed opening in a poured concrete wall made with insulated concrete forms having first and second parallel and spaced sidepanels of the type shown in FIG. 1 and described in more detail in U.S. Pat. Nos. 4,390,459 and 5,657,600, the disclosures of which have been incorporated by reference herein in their entirety. The opening may be a window opening such as illustrated in FIG. 2, a door opening, or any other opening into which wall components are to be mounted. As described in more detail below, in practice a plurality of bucks 60 are placed around the sides, top and bottom of the opening, similar to the wooden buck arrangement illustrated in FIG. 2 .
The buck 60 includes a top wall 62 having a surface for supporting a component to be mounted within the wall opening. At the sides of buck 60 , flanges 74 , 76 depend downwardly from top wall 62 to form first and a second sidepanel receiving sections 64 , 66 .
Flanges 74 , 76 are separated from each other by top wall 62 a sufficient distance such that the inner surfaces of flanges 74 , 76 engage the outer surfaces of sidepanels 12 , 14 with a friction fit, as illustrated best in FIG. 7, which shows the buck 60 in place mounted to and spanning across the space between the sidepanels. Although the flanges 74 , 76 are shown in FIG. 3 as forming right angles (90°) with top portion 62 , the flanges may be formed at angles slightly less than 90°, such that they tilt inwardly, to increase the frictional force between the flanges and sidepanels. A good friction fit is advantageous because it holds the entire wall and buck assembly in place during construction, thereby facilitating dimensional stability and installation. This friction fit also forms a seal to contain the concrete within the formwork at the wall openings during the period that the concrete has not yet completely cured and is still wet. At the middle of the buck a multi-chambered section 68 is provided, as described in more detail below, which also downwardly depends from top wall 62 . The outermost ends of multi-chambered section 68 are formed by walls 8 , 9 which extend generally parallel to flanges 74 , 76 , respectively. The ends of the sidepanels 12 , 14 may be trapped and engaged between wall 8 and flange 74 , and wall 9 and flange 76 , respectively, to increase the frictional fit and seal between the buck 60 and sidepanels 12 , 14 .
Multi-chambered section 68 thus is disposed between the first and section sidepanel receiving sections 64 and 66 underneath the top wall portion 62 . Section 68 has two main purposes, which are to act as a thermal insulator and to receive and anchor fasteners for securing the component to be mounted within the opening (typically a door or a window) to the buck 60 . Thus, section 68 includes a plurality of air chambers 13 , which act as insulators similar to the chambers provided in conventional vinyl windows. Chambers 13 are defined by a series of longitudinally extending inner walls 11 extending generally parallel to outer walls 8 , 9 and a bottom wall 82 extending between outer walls 8 , 9 . The ends of chambers 13 are open to permit air to be contained therein. A middle wall 70 may be disposed between and generally parallel to top wall 62 and bottom wall 82 to form additional chambers 15 . Middle wall 70 may even extend outwardly to flanges 74 , 76 to form further insulating air chambers 16 between flanges 74 , 76 , outer walls 8 , 9 and top wall 62 . Further intermediate walls 17 , 19 may be provided to divide chambers 16 further into smaller, separate chambers. An increased number of chambers results in increased thermal performance.
The inner chambers 13 , 15 also provide an alternative to securing fasteners for mounting the component within the buck frame to the concrete itself, as is done with conventional wood bucks. Especially if the concrete has already hardened, it can be difficult to secure the component to the buck using the conventional method. By disposing the chambers adjacent to each other in at least two rows, the fasteners are more securely attached because they pass through two mounting surfaces, the top wall 62 as well as the middle wall 70 .
Referring still to FIGS. 3 and 4, the buck 60 may also be provided with a pair of anchoring fins 72 depending downwardly from the bottom wall 82 of section 68 to hold the buck in place once the poured concrete around the anchoring fins 72 hardens. Although variously shaped anchoring fins could be used, a fin having a transverse member, such as the head of the T-shaped anchoring fins 72 , has been found to be advantageous to form a secure retainment anchor within the concrete as it hardens around the fin. The combination of the friction fit between the ends of the sidepanels and the buck, and the anchoring fins within the concrete, contribute to providing enhanced sealing between the buck and the ICF to increase the structural stability of the wall system, enhance the thermal performance of the wall system, and reduce the opportunity for air infiltration and air exfiltration between the buck and the cured concrete.
In order to avoid the problems discussed above in connection with regard to wooden framed bucks, the buck of the invention preferably is made of an insulating material, such as plastic. While a variety of such materials may be used, a currently preferred plastic is polyvinyl chloride (PVC) because of its high thermal insulating properties, strength, and relatively low costs. Either recycled or virgin PVC may be used as the insulating material. The PVC buck of the invention may be made in a variety of ways such as extrusion or injection molding, with extrusion being preferred currently for cost considerations. The buck may also be made of other insulative materials.
A plastic buck offers further advantages in that plastic is similar to the material used in the ICF form, and is also similar to a vinyl material, from which windows are typically formed in modem construction. As a result, the various pieces making up the final form wall with openings will advantageously expand and contract similarly.
As shown in FIGS. 3 and 4, outer flanges 74 , 76 each may include a score line 78 , 80 for indicating a cutting location. For example, when applying stucco finish or cladding to the foam panels of the EPS system, the outer flanges 74 and 76 of the installed buck 60 could interfere with the secure attachment of the stucco to the external sidepanels 12 and 14 of the building component. To facilitate removal of a portion of these outer flanges 74 and 76 , score lines 78 , 80 indicate where to cut the outer flanges 74 , 76 .
The component (door, window, etc.) to be mounted to the buck 60 may be either centermounted to the top wall 62 or flange-mounted to top wall 62 adjacent to the outer flange 74 or 76 . In a center mounted arrangement, the component to be mounted is fastened to the top wall 62 at a location over the insulating section 68 . A fastener, such as a screw, passes from the component to be mounted through the top wall 62 into the air chambers and, in the embodiment shown in FIGS. 3 and 4, through the middle wall 70 . The end of the fastener can then rest above wall 82 within the insulating section 68 . As a result, the wood securement problems of the prior art are avoided by providing a secure attachment location directly to the plastic buck. Moreover, there is no need to attempt to secure the fastener within the hardened concrete as the walls and chambers of the insulating section 68 also form a convenient fastener receiving section above the hardened concrete. However, if desired for any particular reason, it is possible to allow the fastener to pass through the bottom wall 82 for securing into the concrete itself.
The top wall 62 may be formed with linear, raised surfaces or ribs 21 , which serve several purposes. First, the two outer ribs 21 indicate the outer extent of the fastener receiving section, so an installer knows to locate the fasteners within the area defined by these ribs. The middle rib 21 indicates the longitudinal center of the buck. Ribs 21 also serve to increase the frictional forces between the outer surface of top wall 62 and the component (e.g., a window) to be mounted thereto.
In a flange mounted arrangement, the component to be mounted is placed on the top wall 62 , adjacent to one of outer flanges 74 and 76 . A bracket or the like attached to the component to be mounted will lie parallel and flush against an outer flange. A fastener, such as a nail or a screw, may then be passed though the outer flange and through the adjacent sidepanel 12 , 14 now mounted within the sidepanel receiving section 64 or 66 , as shown best in FIG. 7 . The fastener typically if long enough continues traversing through the particular sidepanel until it pierces outer wall 8 or 9 of the insulating section 68 . This is why outer walls 8 , 9 of the insulating section 68 preferably are formed with thicker dimensions as shown best in FIG. 6 . Thus, in this flange mounted arrangement, the fastener travels in a direction substantially parallel to the surface of the top wall 62 . In the center mounted arrangement described earlier, the fastener travels in a direction substantially perpendicular to the surface of the top wall 62 .
As shown in FIGS. 3 and 4, the outer flanges 74 , 76 may act as a furring strip for attaching interior and exterior finishing materials to the wall, as well as provide an indication of fastener locations. Specifically, in flange mounted arrangements, the installer knows to locate the fasteners above score lines 78 , 80 in order to contact wall 10 or 12 .
FIG. 5 is a cross-sectional view of a buck in accordance with a second embodiment of the invention. Like reference numerals have been used to designate similar parts, and only aspects of the design that differ from the previous embodiment are discussed in detail herein. The buck 160 of this embodiment differs from the first embodiment primarily in that it has only one anchoring fin 172 and only one row of chambers within section 168 .
FIG. 6 is a cross-sectional view of a buck in accordance with a third embodiment of the invention. Like reference numerals have been used to designate similar parts, and only aspects of the design that differ from the previous embodiment are discussed in detail herein. The buck 260 of this embodiment differs from the previous embodiments primarily in that its anchoring fin 272 is of a V-shaped as opposed to the T-shape of the previous embodiments. Also, section 268 has a pair of outer chambers with thickened receiving members 284 for offering a more secure anchoring of a fastener within the wall of section 268 at that location.
Although use of the various buck embodiments of the invention should be readily apparent to those skilled in the art from the above detailed description, a suitable method for using such a buck to form an opening within a poured concrete wall will now be described in conjunction with FIG. 7 and an insulated concrete form of the type described in FIG. 1 .
FIG. 7 shows the buck 60 of FIGS. 3 and 4 mounted on sidepanels 12 and 14 of FIG. 1, however, it is apparent that similar procedures could be used for the other embodiments illustrated herein. The buck 60 is mounted over the first and second sidepanels 12 and 14 of the ICF. Sidepanel 12 is received within and frictionally engaged by first sidepanel receiving section 64 . Sidepanel 14 is received within and frictionally engaged by the second sidepanel receiving section 66 . After concrete 300 is poured between the first and second sidepanels to cause the concrete to fill in between the first and second sidepanels 12 and 14 , it also flows around and eventually hardens about the anchoring fins 72 of the buck 60 , thus firmly securing the buck 60 into place on the now permanent ICF and concrete wall.
A framed opening within the ICF wall is formed by frictionally attaching four bucks 60 to form the top, bottom, and two sides of a buck frame around the perimeter of an opening within the formwork in a manner similar to that shown in FIG. 2 . This buck frame, being frictionally attached to the formwork, will retain the subsequently poured concrete within the wall and also provide solid attachment surfaces for the component to be mounted within the opening. This is because the friction fit will result in the buck staying in place during assembly. Despite the advantage of the friction fit of this invention, fiber tape may still be used, as it is with prior art bucks, to form an even more secure attachment of the buck to the form while the concrete is setting. Moreover, for large wall openings, it is recommended that bracing is placed within the opening to resist the force of the wet concrete. Bracing is preferably placed approximately every 30 inches within the opening in such a large wall opening for providing additional support.
Once the opening in the wall is so formed, a component, such as a window or a door, for example, may be mounted within the opening by securing the component to the top wall 62 of the buck 60 using at least one fastener, such as a screw, for example. The fastener is received and anchored within the walls and chambers of the multi-chambered section 68 and the component may be either side (flange) or center-mounted as described above. | The invention relates to a buck for forming and framing the perimeter of an opening in an insulated concrete form wall. The buck is formed of insulating material compatible with the concrete form, such as plastic, and forms a friction fit with supporting portions of the form wall to provide a seal therebetween. The buck may have a portion for receiving fasteners to secure a component mounted on the buck, thus facilitating the attachment of components to the buck within the wall opening, and reducing or completely eliminating the need for fasteners to penetrate hardened concrete. The buck may also include a separate portion, preferably integrated with the fastening portion, that provides for increased thermal insulation. The buck may also include anchoring fins around which the poured concrete may harden to securely attach the buck to the wall and enhance the seal therebetween. | 4 |
TECHNICAL FIELD
This invention relates to inkjet inks providing improved print quality on plain paper, particularly with respect to fiber show through.
BACKGROUND OF THE INVENTION
Color pigmented inks used in ink jet printing usually suffer from poor paper fiber show through properties when printed on plain paper. Paper fiber show through is a print quality defect arising because of incomplete wetting of the paper fibers when pigmented inks are laid down resulting in visible white spots on solid areas of the printed image.
To overcome the paper fiber show through problem the ink has to be formulated in such a way that the residence time of ink flow along the surface of the paper is higher, so that when the fluidity of pigment particles vanish due to the loss of the ink vehicle (mainly water and humectants) the pigment particles settle down on the top surface of the plain paper thus increasing the probability to stain the fibers on the surface of the paper and reducing paper fiber show through. The two main methods used to reduce fiber show through are 1). Increasing the viscosity of the ink by increasing the humectant loading to reduce penetration. 2) Reducing the surface tension thus in turn wetting all the fibers by enhancing the spreading rate. In the latter case the mobility of ink is reduced by the spreading rate. The ink spreading causes the ink film thickness to reduce drastically thus effecting reduced mobility and uniform staining of the paper fiber.
The drawbacks of adding higher amounts of high boiling humectants to increase viscosity are the slow drying rate of ink thus worsening the smear properties of ink on paper and poor jetting characteristics.
The drawbacks of reducing surface tension with pigmented ink are poor ink stability (shelf life) and poor jetting due to increased puddling of ink during jetting.
DISCLOSURE OF THE INVENTION
This invention incorporates less than about 5 percent by weight of the total weight of the inkjet ink of particulate metal oxide nanoparticles that exhibit negative charge in liquid suspension. The primary particle size of the nanoparticles is less than 200 nanometers (nm) and is preferably in the range of 10 to 30 nm.
The particulate metal oxide must be compatible with the pigment dispersion so that it does not precipitate the pigment. The pigment may be dispersed in a dispersant or may have surface characteristics, which disperse the pigment. In each case it is the dispersant or the equivalent characteristics which determine the electrical characteristic of the ink.
The following test results and examples that follow are with respect to anionic inks. Where the ink is cationic, metal oxides compatible with cationic inks would be used, for example zirconium oxide.
The preferred material for anionic inks is tin oxide. Tin oxide nanoparticles in aqueous dispersion has a pH of above 7, which is compatible with pigmented ink, which is anionic. Alternatively, zinc oxide in aqueous dispersion also has a pH above 7 and can be used with the pigmented ink of interest. Positively charged materials with pH below 7 would not be compatible with an anionic pigment suspension in water.
Drastic reduction of fiber show through of color pigmented inks on plain paper is achieved with the incorporation of the metal oxide.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
After a thorough investigation into the problem, it has been discovered that the paper-fiber-show-through problem is not as random as it was previously assumed.
Usually plain paper is made from two types of fibers namely, hardwood fibers and soft wood fibers. The softwood fibers are added during the paper manufacturing process to enhance the strength of paper. And hardwood fibers are added to enhance the printability of paper. The softwood fibers are longer and 5-10 times wider than the hardwood fiber. And softwood fibers are smoother than the hardwood fibers. Thus, when fine drops of pigmented inks are laid down on the plain paper surface containing a blend of these fibers, the ink pigment particles tend to come to rest on the rough and narrow fibers of hardwood than on the smoother, wider softwood fibers. The chemical compositions of the two types of fibers are the same.
Thus the problem seems to be solely dependent on the matrix formed by the fibers and the porosity of the paper. The paper made out of a higher percent of hardwood fiber forms a tighter matrix compared to the paper made out of a higher amount of softwood. And thus paper acts as a filter for the pigment particles thus facilitating ink flow along the surface of the paper rather than into the paper in hardwood rich papers enhancing pigment staining of the top surface fibers of the paper and reducing paper fiber show through.
The present invention may employ the SN15 or SN15ES aqueous nano dispersion of tin oxide particles from Nyacol Nano Technologies. The two do not differ chemically, but SN15ES has a lower viscosity.
The nano dispersions is added in the formulation to enhance the drag forces involved during flow thus increasing the residence time of ink flow along the paper and thus reducing the paper fiber show through. It is believed that the affinity of these nanoparticles to penetrate along with the ink vehicle into the paper matrix is quite low compared to the affinity of the pigment particles attached to the dispersant to penetrate along with the ink vehicle.
Thus the nanoparticles increase the drag forces significantly and prevent the pigment particles from penetrating into the paper. In other words they facilitate the separation of the pigment particles from the vehicle when the ink drop impacts the paper, thus helping the pigment particles to stay on top of the paper and in turn increase the probability of staining the paper fibers on the top surface of the paper resulting in reduced fiber show through.
Due to the extremely low particle size of the SN15 nanoparticles (10–30 nm), the surface area is enormously increased resulting in increased drag on a nanoscopic level. And the significantly higher surface area also means that very low amounts of this nano dispersion is sufficient to effect the desired drag to reduce the paper fiber show through problem drastically as discovered during fiber show through testing. Moreover, the SN 15 nanoparticle dispersion has similar pH and dispersion stability as the anionic pigmented inks making it an ideal choice for use in anionic pigmented ink formulations.
TESTING AND RESULTS
Different amounts (0.3%, 0.6% and 0.9% by weight) of the SN15 tin oxide nanoparticles (From Nyacol Nano Technologies) were added to the control cyan, magenta and yellow color pigmented inks in the respective ink formulations and tested for fiber show through properties on two types of plain paper. Lexmark International, Inc. Z65 tricolor printheads were used for print testing. The details of the SN15 tin oxide nanoparticle amounts (weight %) in inks, the cyan-magenta-yellow ink set combinations (with various levels of SN15 tin oxide nanoparticles) used in the Lexmark International Inc. Z65 tricolor printheads were used for print testing. The details of the SN 15 tin oxide nanoparticle amounts (weight %) in inks, the cyan-magenta-yellow ink set combinations (with various levels of SN15 tin oxide nanoparticles) used in the Lexmark International Inc. Z65 tricolor printhead and the results of paper fiber show through testing are tabulated in Table I.
The paper fiber show through was ranked based on the overall printed image with respect to paper fiber show through when printed on the plain papers (X9000 and Hammermill laser paper-HMLP). The grading was done qualitatively. The improvements were visibly significant.
TABLE I
Results of Fiber show through testing
Details of ink in the different printhead
Fiber show
Fiber show
chambers (Cyan chamber/Magenta
through-
through-
chamber/Yellow chamber)
X9000
HMLP
Cyan control/Magenta control/Yellow
BAD
BAD
control
Cyan (0.3% SN15)/Magenta
BAD
BAD
(0.3% SN15)/Yellow (0.3% SN15)
Cyan (0.6% SN15)/Magenta
GOOD
GOOD
(0.6% SN15)/Yellow (0.6% SN15)
Cyan (0.9% SN15)/Magenta
EXCELLENT
EXCELLENT
(0.9% SN15)/Yellow (0.9% SN15)
The significant improvements in color gamut volume are tabulated in Table II. The color gamut volume improvements were significant and noticeable in the printed images just as the paper fiber show through improvements.
TABLE II
Color gamut volume comparisons
Gamut
Gamut
Details of ink in the different printhead chambers
Volume-
volume-
(Cyan chamber/Magenta chamber/Yellow chamber)
X9000
HMLP
Cyan control/Magenta control/Yellow control
110773
145152
Cyan (0.3% SN15)/Magenta
114206
154900
(0.3% SN15)/Yellow (0.3% SN15)
Cyan (0.6% SN15)/Magenta
131527
164780
(0.6% SN15)/Yellow (0.6% SN15)
Cyan (0.9% SN15)/Magenta
151325
183812
(0.9% SN15)/Yellow (0.9% SN15)
Inks employed in the foregoing are consistent with the general technology disclosed in PCT Patent No. WO 03/014237 A1 of Akers et al. owned by the assignee of this invention. This invention can be implemented in a wide variety of inks. Color ink formulas of inks employing this invention may be based on the formulation given in the foregoing Akers application modified for firing through smaller, color nozzles and with the tin oxide addition. (The foregoing tests were conducted with somewhat different formulations). That formula in Askers is pigment, dispersant, thiodiethanol, polyethylene glycol 1000, 2-pyrrolidinone, hexanediol and water.
A representative formula of this invention is as follows:
Representative Formula
Percent by
Content
Weight
Pigment Blue 15:3 or Pigment Red 122 or Pigment Yellow 74
3
Aqueous Pigment Dispersant
1
Dipropylene Glycol
7.5
Glycerol
7.5
Tin oxide nanoparticles (SN15)
0.9
or
Tin oxide nanoparticles (SN15ES)
1.3
2,4,7,9-Tetramethyl-5-decyne-4,5-diol ethoxylate
0.5
(SURFYNOL 465)
Deionized water
Balance
The preferred dispersant for the dispersed color pigment is that described in the foregoing WO 03/014237. That dispersant is a graft polymer having hydrophilic segments as the backbone comprised of a methacrylic acid polymer, or a copolymer thereof with another monomer, such as styrene sulfonic acid. It has hydrophobic segments of a polymer or copolymer containing methacrylic acid derived monomers, particularly a methacrylate ester monomer or a methacrylate ester monomer with the alkyl group replaced with a siloxyl substituent. Preferred hydrophobic segments have a monomeric hydrophobic head and a polymeric body attached to the backbone, specifically, a poly (ethylene glycol) 2,4,6-tris(1-phenylethyl)phenyl ether methancrylate moiety. The preferred dispersant also has poly(propylene glycol) 4-nonyl ether acrylate moieties and is terminated with dodecanethiol. Low HLB (Hydrophile-Lipophile Balance) values and short polymer chains are preferred, consistent with the dispersant being water soluble and the ink being stable.
SUMMARY
The invention established the use of tin oxide nanoparticles in anionic color pigmented ink formulations to reduce paper fiber show through and increase gamut volume has been reported and the same is claimed. The effectiveness of tin oxide in reducing paper fiber show through and increasing the color gamut volume when added at low concentrations (less than about 5 weight percent, preferably less than about 2 weight percent) in anionic color pigmented inks. The good dispersion stability of this material makes it a very attractive solution for anionic color pigmented ink printing applications, in overcoming paper fiber show through and increasing the color gamut volume. | To reduce show through, particularly for color pigments, a particulate negative metal oxide. Specifically in an anionic ink, tin oxide of primary particle size in the range of about 10 to 30 nm, is incorporated in inkjet inks in amount of less than 2 percent by weight of the total weight of the ink. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a synthetic technical yarn formed from a number of endless bicomponent filaments of the sheath-core type of which both the sheath and the core are composed of a melt-spinnable polymer. The invention also comprises a process for the manufacture of such a yarn.
2. Description of the Prior Art
A yarn of the type indicated above is known from Netherlands Patent Application No. 6 512 920. In this known yarn, the core of the filaments preferably consists of polyethylene terephthalate and the sheath of nylon 6. The yarns described in said publication were to be used for the manufacture of a reinforcing fabric for elastomeric objects, more particularly pneumatic tires for vehicles. These known yarns are virtually colourless.
For various uses, such as nets, ropes and seat-belts for vehicles there are marketed at present black technical synthetic multifilament yarns that consist essentially of polyamide-6 or polyamide-66 or of polyester. In the melt spinning process used by fiber manufacturers, such black yarns may be obtained by injecting into the melt a black pigment, more particularly carbon black particles. Alternatively, the product may be obtained by feeding polymer granules blackened with a black pigment to an extruder.
Although reasonable results may be obtained with these known black polyamide or polyester yarns, they do display several disadvantages. One of these disadvantages is the fact that during the manufacture, treatment and processing of the yarn, such as drawing, winding, twisting and the like, the black pigment present on the surface of the yarn gives rise to great wear of various more or less costly machine parts, such as rollers, guiding elements, heating elements, including hot plates or hot pins, with which the yarn comes into contact. This drawback has in the last few years become of increased importance in view of the fact that manufacturers of synthetic yarns will replace the conventional process for manufacturing technical or industrial yarns with a more integrated spin-drawing process. In the conventional process referred to the yarn is spun and wound in a first process step and drawn and wound in a second, separate process step. In said spin-drawing process, however, the above-mentioned first and second process steps are combined into a single, continuous process in which the spun yarn is drawn and wound. In order to obtain a nylon or polyester technical yarn of sufficient strength, the practice is often to draw such a yarn at a draw ratio in the range of 5 to 6. Since after the change over from the conventional process to the integrated process the same output per spinning machine will be required, the drawing operation in the spin-drawing process wil take place at considerably higher speeds than in the conventional process. The higher yarn speeds and higher yarn tension will lead to a very significant increase in the wear of machine parts and said spin-drawing of black yarns will very readily cause deep incisions in the machine parts with which the yarns come into contact. The problem of these incisions is so serious that in actual practice it makes it impossible for spun-dyed, black yarns to be made by the spin-drawing process. The incision problems caused by black pigment likewise occur in the case of a reddish pigment made up of iron oxide particles and a whitish pigment made up of titanium dioxide particles of the rutil type. It should be added that titanium dioxide of the rutil type is described on page 246 of the book "Pigments, Herstellung, Eigenschaften, Anwendung", by H. Kittel, 1960, Wissenschaftliche Verlagsgesellschaft MBH, Stuttgart, BRD.
SUMMARY OF THE INVENTION
The invention has for its object the elimination of the above-mentioned drawbacks. The synthetic technical yarn consisting of a number of filaments which are each composed of one or more melt-spinnable polymeric materials is in the first place characterized according to the invention in that substantially only inwardly from their peripheral zone the filaments contain a black pigment composed of carbon black particles and/or a reddish pigment composed of iron oxide particles and/or a white pigment composed of titanium dioxide particles of the rutil type, which pigments are insoluble in the polymeric material, and the tenacity of the yarn is at least 50 cN/tex and not higher than 150 cN/tex. The synthetic technical yarn formed from a number of endless bicomponent filaments of the sheath-core type, of which both the sheath and the core are of a melt-spinnable polymer, are characterized according to the invention in that substantially only the core of the filaments contains a black pigment composed of carbon black particles and/or a reddish pigment composed of iron oxide particles and/or a white pigment composed of titanium dioxide particles of the rutil type, which pigments are insoluble in said core, and the tenacity of the yarn is at least 50 cN/tex and not higher than 150 cN/tex, but preferably 70 to 85 cN/tex. According to the invention the core of practically all of the filaments, for instance 50-150 filaments of the yarn, contains said pigments in an amount of 0.2 to 2 percent by weight and not more than 5% by weight, and preferably about 0.6% by weight, calculated on the weight of the core. The yarn according to the invention is advatageously characterized by an elongation at rupture in the range of 7 to 15%, preferably 11 to 15%. The yarn according to the invention preferably has a single filament titer in the range of from decitex 3 to 20. Since the pigments of black carbon black particles and/or reddish iron oxide particles and/or titanium dioxide particles of the rutil type are entirely or substantially present only in the core polymer of the bicomponent filaments of the yarn according to the invention, the sheath or said peripheral zone of the filaments and the surface of the yarn consequently being free of said pigments, the yarn according to the invention can be made by the spin-drawing process. Thus, an important economic advantage is obtained over the conventional yarns, wherein the pigment is distributed throughout the cross-section of the filaments and is also present on the surface thereof. The yarn according to the invention does not display any great abrasive or wearing action on various machine parts.
Despite the presence of said black and/or reddish and/or whitish pigment the yarn according to the invention is, as a result of its bicomponent structure, characterized in that for a yarn having 75 to 110 filaments and a linear density of about dtex 1000 the incision factor is smaller than 250 μm m 2 /hour and generally smaller than 150 μm m 2 /hour.
A favourable embodiment of the yarn of the present invention is characterized in that in the filaments the percent sheath by volume is 50 to 15%, preferably 25%, and the percent core by volume is 50 to 85%, preferably 75%. An effective embodiment of the yarn is characterized according to the invention, in that the sheath of the bicomponent filaments is transparent and composed of polyamide, more particularly nylon-6 or nylon-66, or of polyester, polypropylene, copolyester, copolyamide or copolyolefins.
Favourable results are obtained if for the core of the bicomponent filaments a polymer is chosen which is commonly applied for technical yarns, such as polyester, more particularly polyethylene terephthalate, polyamide, more particularly nylon-6 or nylon 66, or copolyester or copolyamide. The polyesters and polyamides mentioned here are to be understood as including both homopolymers and copolymers.
Also cords, cables, ropes, fishing nets or seat belts made from the yarns according to the invention display quite a few advantages, in addition to the fact that no significant wear or incision of machine parts is expected during manufacture and further processing. Furthermore, ropes obtained by braiding, laying or twisting yarns according to the invention possess improved strength efficiency.
Particularly when a fishing net has been made from bicomponent yarns having a nylon sheath and a polyester core, the net obtained will show the favourable knot strength of the nylon sheath while retaining the tenacity and the thermal properties of polyester.
The black bicomponent yarns according to the invention having a nylon-6 sheath and a polyethylene terephthalate core are also particularly suitable to be used for the manufacture of black fishing nets. Such nets made from the yarn according to the invention do not cause excessive wear during their manufacture or their use, often under a high load, on fishing boats. Further, when used in nets, the bicomponent yarns having a nylon sheath and a polyester core according to the invention have the advantage over the known black non-bicomponent and wholly nylon yarns that they have a smaller diameter and, hence, a smaller volume at approximately the same breaking strength and tenacity. For yarns having the same total linear density, the black or reddish or brownish bicomponent yarn according to the invention has a 7% smaller diameter and a 14% smaller volume than the wholly polyamide yarn. Owing to the smaller diameter and the smaller volume of the yarns according to the invention, the nets made of these yarns have a lower flow resistance in water, which leads to a considerable energy savings in fishery, especially when use is made of trawl nets. Moreover, the nets according to the invention have a higher speed of fall into the water and they take up less storage room than nets of wholly polyamide yarns. Another advantage is that the knots in the nets are smaller and, hence, permit using less yarn.
The invention is especially directed to a technical yarn, i.e. a yarn not intended for textile uses, but for technical or industrial uses, such as nets, ropes, seat belts and like products. The yarn according to the invention is essentially of the type having a total linear density of decitex 300 to 5000 and 30 to 600 filaments, a tenacity of 50 to 150 cN/tex and an elongation at rupture in the range of 7 to 25%. Of the yarn according to the invention having a sheath of nylon 6 and a core of polyethylene terephthalate, the knot strength, which is of importance for its use in nets, is in the range of 330 to 400 mN/tex. The knot strength of the bicomponent yarn according to the invention is consequently at the same level as that of known wholly polyamide yarns.
For certain uses, the yarn according to the invention has on its surface an oil content of 0.05 to 1% by weight.
The invention also comprises a process for the manufacture of a technical yarn in which molten synthetic polymer streams are so extruded through a large number of spinning orifices that bicomponent filaments of the sheath-core type are formed, which process is characterized in that substantially only to the core of the filaments there is added a black pigment made up of carbon black particles and/or a reddish pigment made up of iron oxide particles and/or a white pigment made up of titanium dioxide particles of the rutil type, which pigments are insoluble in the core of the filaments, and the yarn is drawn at such a draw ratio in the range of 3 to 8, more particularly 5 to 6, that the tenacity of the yarn is at least 50 cN/tex and at most 150 cN/tex, the core of the filaments containing 0.2 to 2%, preferably about 0.6% by weight of pigment, calculated on the weight of the core. According to a preferred embodiment of the method of the invention, the bicomponent yarn is spun and drawn in a continuous operation, i.e. spun-drawn and subsequently wound.
It should be added that in Japanese Patent Application No. 7150/66 (Publication No. 3001/68) there is described a bicomponent multifilament yarn of the sheath-core type of which both the sheath and the core are of different polyesters having intrinsic viscosities in the range of 0.56 to 0.7.
Example 1 of the Japanese publication describes a sheath-core yarn of which the core contains some unspecified percentage of carbon black particles. From the values of the intrinsic viscosities alone, it is apparent that said Japanese publication relates to a yarn intended for textile uses, in which case the problem of the abrasive and incisive action will not be so serious because of the lower forces and tensions, lower draw ratio and quite different practical uses.
It should also be added that for the purpose of rendering multifilament carpet yarn antistatic one or more antistatic filaments are incorporated into it. To that end, various types of bicomponent multifilaments may be used. Notably, U.S. patent specification No. 3,803,453 describes antistatic bicomponent filaments of the sheath-core type comprising a sheath of some synthetic polymer and a black core which is rendered electrically conductive by the presence of at least 15-20% by weight of carbon. Due to this large amount of carbon pigment, the physical properties, such as tenacity and elongation, of these antistatic filaments are so unfavourable and differ so much from those of normal filaments that they are only suitable for performing their antistatic function. Further, the sheath of the antistatic filaments contains titanium dioxide pigment in order to hide the black core colour as much as possible, which is undesirable in carpet yarns. In these known antistatic filaments the black core is less than 50% by volume. As mentioned before, the technical bicomponent yarn according to the invention has in its core only a small percentage of black and/or reddish and/or white pigment, as a result of which its physical properties are good and at a level which is usual for technical yarns. Moreover, the yarn according to the invention has a transparent sheath, so that the black core is properly visible and its black appearance is satisfactorily ensured even if use is made of a small amount of carbon pigment.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be illustrated with reference to the accompanying schematic drawing.
FIG. 1 shows the disposition of two spinnerets.
FIG. 2 is a cross-sectional view of one filament on a greatly enlarged scale.
FIG. 3 shows a number of filaments of a yarn according to the invention in cross-section.
FIG. 4 depicts a portion of a net made from cords according to the invention.
FIG. 5 is a schematic representation of a spin-drawing process.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIG. 1 the numerals 1 and 2 refer to parts of two spinnerets. The two plates are spaced from each other and arranged in parallel in a melt spinning assembly. Between the plates 1 and 2 and above the plate 2 are two chambers 3 and 4, respectively, which are connected to two feed lines for two spinning liquids (not shown). Through the spinneret 2 runs channels 5 which end in the chamber 3 at a point opposite channels 6 provided in the spinneret 1.
The channels 6 converge at their outlet ends at the lower side of the plate 1. Spinning liquid flowing through the channel 6 is cooled in the ambient air below the spinneret 1 to form filaments which are subsequently drawn off and wound in a known manner. Into the chamber 3 there is forced the sheath polymer, for instance a nylon-6 melt, and into the chamber 4 a melt of the core polymer, for instance of polyethylene terephthalate, containing 0.6% by weight of carbon particles.
In this process the polyethylene terephthalate is extruded through the channels 5 in the direction of the channels 6, to which also the nylon-6 melt is displaced. Through the channel 6 there will consequently be a downward flow of a skin or sheath of nylon 6 containing a core of polyethylene terephthalate. Thus, the filaments formed therefrom have a skin of nylon-6 and a black core of polyethylene terephthalate. At the outlet openings of the channels 5 in the spinneret plate 2 there are provided protrusions 7 and 8 and at the inlet openings of the channels 6 in the spinneret plate 1 there are protrusions 9 and 10. These protrusions may be in the form of circular rims or of cylinders concentrical with the channels. These protrusions 7 through 10 serve to influence the flow pattern in the constrictions formed by them.
FIG. 2 shows on an enlarged scale a cross-section through a filament spun from one of the spinning orifices 6, the flow of skin liquid to the channel 6 having taken place truly symmetrical and at a constant velocity. The resulting core 11 is round and truly concentrical with the skin 12.
FIG. 3 is a cross-sectional view of a great number of filaments of the technical yarn according to the invention.
FIG. 4 shows a detail of a fishing net 13 made from cords composed of the bicomponent yarns according to the invention.
FIG. 5 is a very schematic representation of a process for spindrawing the bicomponent yarn according to the invention. After having left the melt spinning assembly 14 containing spinnerets of the type shown in FIG. 1, a bundle 15 of bicomponent filaments is cooled by means of a blowbox 16, after which the bundle passes over a kiss roll 17 by which a lubricant is applied to it. Subsequently, the bundle is passed a few times around a driven feed roll 18 with idler roll 19, which have a constant peripheral velocity V 1 of the order of, for example, 400 m/min. Next, the yarn bundle 15 is passed over a pair of driven draw rolls 20 and 21, which have a constant peripheral speed V 2 and a temperature of, for example, 200° to 220° C. The velocity V 2 is considerably higher than the velocity V 1 and the ratio V2:V1 is the draw ratio of the yarn bundle. For the bicomponent filament yarns according to the invention having a core of polyethylene terephthalate or nylon 6, the draw ratio V 2 :V 1 will generally be in the range of 5 to 6. At a draw ratio of 6 the peripheral velocity V 2 may for instance be 2400 m/min. Subsequently, the yarn is passed over a pair of driven rolls 22, 23, which have a peripheral velocity V 3 , which is lower than V 2 and may be, for instance, 2375 m/min., the temperatures of the rolls 22, 23 being about 140°-160° C. Further, some coherency is imparted to the yarn in a tangling device 24 with the aid of air under pressure.
Finally, the tangled yarn is provided with a small amount of oil at a point 25 before being wound into a package 26.
For further elucidation of the invention and for testing the yarn and the cord properties, measurements were conducted on a number of yarns and cords. All 7 yarns were black and the various yarns are denoted hereinafter by the test numbers 1, 2, 3, 4, 5, 6 and 7. Table I gives the nature of the various yarns 1 through 7. Table II mentions the most important yarn properties and Table III gives the properties of the cords made from these yarns.
TABLE I__________________________________________________________________________ Titre AfterTest Yarn (dtex) oil Yarn compositionNo. type Process desired wt. % Core Sheath__________________________________________________________________________1 Bico conv. 940 0 75% PETP; 0.6 wt. % 25% PA.6 Ketjenprint 25 f76 η = 1.89 η = 2.752 Bico spindr. 940 0 75% PETP; 0.6 wt. % 25% PA. 0 Ketjenprint 25 f76 η = 1.89 η = 2.753 Bico spindr. 940 0.2 75% PETP; 0.6 wt. % 25% PA. Ketjenprint 25 f76 η = 1.89 η = 2.754 Mono conv. 1100 0 PETP; 0.6 wt. % -- f105 Ketjenprint 255 Mono conv. 1100 0.2 PETP; 0.6 wt. % -- f105 Ketjenprint 256 Bico spindr. 940 0 75% PETP; 0.6 wt. % 25% PETP Ketjenprint 25 f76 η = 1.89 η = 1.857 Bico spindr. 940 0.2 75% PETP; 0.6 wt. % 25% PETP Ketjenprint 25 f76 η = 1.89 η = 1.85__________________________________________________________________________
TABLE II__________________________________________________________________________ sample composition 2 3 6 7 PETP black/ 4 5 PETP black/property 1 PA white PETP black PEPT white__________________________________________________________________________titre dtex (actual) 948 947 948 1108 1108 952 953tenacity cN/tex 77.6 77.3 71.1 70.0 70.1 69.0 70.3elongation at 11.2 14.2 13.0 10.6 10.3 14.1 14.7rupture %loop breaking abt. 50 abt. 50 abt. 50 abt. 50 abt. 50 abt. 50 abt. 50strength cN/texhot-air shrinkage 6.4 ta 7.0 7.1 5.4 5.4 5.7 5.54 min - 160° C.incision factor 0 113 75 1350 900 none noneμm.sup.2 /hour__________________________________________________________________________
TABLE III__________________________________________________________________________ sample composition -- ETN25 -- ETN25 -- ETN25 1 2 3 4 5 6 7 PETP black/ PETP PETP black/property PA white black PEPT white__________________________________________________________________________titre dtex 3031 3009 3014 3604 3598 3012 3050tenacity cN/tex 69.0 65.8 66.2 60.5 61.2 62.6 62.8elong. at rupture % 15.8 18.7 18.8 16.6 16.7 17.6 19.2knot strength 33.0 31.2 39.0 30.9 32.0 31.7 38.9(dry) cN/texboiling shrinkagedry % 7.4 7.3 7.2 5.5 5.5 5.3 4.3wet % 7.4 7.3 7.2 5.3 5.4 5.2 4.3__________________________________________________________________________
The yarns 1, 2, 3, 6 and 7 are bicomponent multifilament yarns according to the invention. The filaments of the yarns 1, 2, 3, 6 and 7 have a core of polyethylene terephthalate (PETP), which forms 75% by volume of each filament.
Of the PETP used the relative viscosity was η rel =1.89 before spinning. Further, to the PETP in the core of all the yarns 1, 2, 3, 6 and 7 there had been added a black pigment in the form of carbon black particles in an amount of 0.6% by weight, calculated on the PETP of the core, which additive is marketed under the trade name Ketjen Print type 25 and conforms to the following specifications:
______________________________________Nigrometer value 88SurfaceDetermined by J.sub.2 method ASTM-D1510-79 mg/g 86N.sub.2 adsorption (ASTM-D3037-78) m.sup.2 /g 82Mean particles diameter ångstrom 310(electronic microscope)Tinting strength (ASTM-D3265-79) % 220DBP*.sup. 1 absorption powder (fluffy) ml/100 g 76(ASTM-D2414-79)Slurry pH (ASTM-D1512-75) 8.0Volatile constituents % 1.5Sieve residue (+325 mesh) (ASTM-D1514-79) max. % 0.03Moisture content (ASTM-D1509-79) max. % 1.5Ash content (ASTM-D1506-79) max. % 0.5Specific weight in compressed form g/l 250(powder-fluffy)______________________________________ *.sup.1 DBP = dibutylphthalate
Unlike the yarns 2, 3, 6 and 7, the yarn 1 was not made by the spindrawing process, but in a conventional manner, i.e. spinning and drawing were effected discontinuously in two separate processes. As far as the yarns 1, 2 and 3 are concerned, 25% by volume of each filament was formed by a skin of nylon-6 (PA-6), which had a relative viscosity of η rel =2.75 before spinning.
In the bicomponent yarns 6 and 7 the proportion by volume of the skin of each filament was 25%, the skin being spun from PETP of the 441 type which had a relative viscosity of η rel =1.85 before spinning. PETP of the 441 type differs from the PETP used in the core mainly in that it contains no black pigment. The above-mentioned relative viscosity values were determined at 25° C. in a 1% metracresol solution.
The yarns 4 and 5 are not yarns according to the invention, but monocomponent yarns. However, these yarns also are coloured black as a result of the addition of about 0.6% by weight of black pigment consisting of carbon black particles, which are uniformly distributed throughout the cross-section of each filament, so that the pigment is also present on the outer surface of the filaments.
In the monocomponent yarns 4 and 5 the filaments are entirely formed of PETP. The yarns 1 through 7 were made by applicant.
Table II gives the measuring results of a number of important properties of the yarns 1 to 7. They show that with the exception of incision these properties are at quite a good level for all yarns. For the monocomponent yarns 4 and 5 not made by the process of the invention, however, the incision factors are particularly unfavourable, viz. 1300 and 900 μm 2 /hour, respectively.
For the bicomponent yarns 1, 2, 3, 6 and 7 made according to the invention the measured incision factors are 0, 113, 75, 0 and 0, respectively. This incision factor was measured by passing the yarns 1 to 7 over a bar of hardened silver steel for a period of 2 hours at a speed of 100 m/min and under a tension of 1 cN/dtex. The magnitude of the incision was subsequently determined by measuring the surface (in μm2) of the incision made by the yarn into the bar.
Moreover, cords were formed from all of the yarns 1 to 7. To that end each of the yarns was given a Z-twist of 500 turns per meter and subsequently three of these Z-twisted yarns were twisted together while giving them an S-twist of 250 turns/meter, resulting in a 3-ply fishing net cord. Of the cords thus formed a number of important properties were measured which are summarized in Table III. They show that the cords made from the bicomponent yarns according to the invention compare very favourably with the conventional black monocomponent yarns. The yarns 3 and 7 have a better knot strength.
The tenacity of the yarns and cords was determined in accordance with ASTM-D885M, the main differences in the procedure being the use of a CRE-tester, a length between clamps of 500 mm, a constant rate of specimen extension of 500 mm/min and Instron-4D clamps.
The linear density of the yarns was mainly determined in accordance with ASTM-D885M, 11.3 and 11.3.1, the test specimens having a length of only 5.0 m instead of 9.0 m.
The elongation at rupture of the yarn and the cord was measured in accordance with ASTM-D885M, the main differences in the test procedure being the use of a CRE-tester, a length between the clamps of 500 mm, a constant rate of specimen extension of 500 mm/min and Instron-4D clamps.
The loop-breaking strength was determined in accordance with ASTM-D2256 alternative C, the main differences in test procedure being the use of a CRE-tester, a length between clamps of 500 mm and a constant rate of specimen extension of 500 mm/min.
The dry and wet boiling shrinkage were determined in accordance with DIN53866.
The knot strength of the cord was determined in accordance with DIN 53842, page 2, 8.3, FIG. 1, use being made of a CRE-tester, a distance between clamps of 500 mm and a constant rate of specimen extension of 500 mm/min.
The cores of the above-described bicomponent filament yarns 1, 2, 3, 6 and 7 according to the invention contain black pigment. Likewise, it is possible to make bicomponent filament yarns according to the invention in which a reddish iron oxide pigment and/or white titanium dioxide pigment of the rutil type is (are) only present in the core, in which case the incision factor also is reduced with respect to that of a monocomponent filament yarn wherein the iron oxide pigment or said titanium dioxide pigment is present throughout the cross-section of the filaments and on the surface thereof. A further alternative according to the invention consists in making bicomponent filament yarns whose filament cores contain a blend of black pigment made up of carbon black particles and reddish pigment made up of iron oxide particles, so that a brownish coloured yarn is formed.
Use also may be made of pigment blends containing said titanium dioxide pigment. Within the scope of the invention various modifications may be made. Although hereinbefore the yarn according to the invention is often referred to as a bicomponent yarn, it should be stressed that also yarns are meant by it whose filaments contain more than two, for instance three or four, polymer components or whose filaments contain only one polymer component. Of this latter type, the yarns 6 and 7 in Table I are examples in that both the core and the sheath of the filaments are of PETP. According to the invention it is essential that the pigments containing said carbon black particles or iron oxides or titanium oxide particles of the rutil type should primarily be present only in the core, i.e. within a sheath or a peripheral zone, of the filaments and said pigments should not be present, or should be present only to a neglible extent, in a zone which is to be more or less regarded as the skin or periphery of the filaments.
Also conceivable in principle is an embodiment in which the amount of pigment gradually decreases from the center of the cross-sectional area of the filament towards the outer circumferential surface thereof, a practically negligible amount of said pigment being present in a thin skin or peripheral zone. Another embodiment of the yarn according to the invention may in principle consist in that none or substantially none of the pigments are contained in the core zone provided in the center of each filament or in the peripheral or circumferential skin zone thereof, the pigment only being present in an annular zone located between the central core zone and the skin. It should be added that the yarn according to the invention can be made in an effective manner by the bicomponent spinning system according to FIG. 1, which is known in itself from NL 6 512 920, and from GB 1 207 062 and GB 1 165 853. Although the yarns according to the invention are preferably formed from filaments having a circular cross-section, it is possible in principle also to use filaments having a different cross-section, for instance a polygonal or lobed cross-section. Also, the core of the filaments need not be round. Alternatively, use might be made of a nonround, for instance triangular, polygonal or lobed core.
U.S. Pat. Nos. 4,207,376, as well as 3,803,453, describe antistatic, multicomponent thrads. These patents describe a few embodiments wherein the core of the filaments contain a high percentage of carbon black for the purpose of rendering the yarn sufficiently conductive. In said publication it is mentioned that the filaments may advantageously be applied in antistatic carpets or in dark-coloured uniforms and like textile products. U.S. Pat. No. 4,085,182 also describes a process of manufacturing electrically conductive bicomponent filaments of the sheath-core type, the core containing a high percentage of carbon black for promoting electric conductivity. | The invention relates to a synthetic technical multifilament bicomponent yarn, which is particularly meant for use in safety belts, ropes and nets.
The bicomponent yarn is preferably of the sheath-core type of which only the core contains a black pigment composed of carbon black particles and/or a reddish pigment composed of iron oxide particles and/or a whitish pigment composed of titanium dioxide particles of the rutil type, which pigments are insoluble in the polymeric material. The tenacity of the yarn may be about 70-85 cN/tex and the elongation at rupture of 7 to 15%. | 3 |
BACKGROUND OF THE INVENTION
(1) Field of Invention
Conventional evaporative cooler operates by using directly outside air. As the result in high temperature the useful air will not be cold enough and because of high temperature of the useful air and its content of moisture the occupant of an enclosure will not experience great degree of comfort. Also as the useful air should be discharged from the enclosure because of the high pressure of the air and this air discharging from the enclosure is colder as compared with outside air, so energy is wasted. But even now from the point of less energy cost in comparison with some other cooling devices and also because of possibility to produce it in big and small size and making the air fresh and clean, the evaporative cooler is the most useful device. For this reason removing deficiency of evaporative cooler is a very important matter.
(2) Description of the Prior Art
For the purpose of removing the deficiency of the evaporative cooler a variety of designs have been proposed wherein the heat absorptive action of evaporative is employed to reduce the temperature of a heat exchanger apparatus and the fresh air is then passed through the heat exchanger apparatus for purpose to be cold. The air which is used to effect evaporation (working air) is conducted to the atmosphere and the useful air is directed into the room. In this way effort is made to remove the deficiency of the evaporative cooler. In these designs wasting of energy is high and useful air is not fresh and with water vapor and enough coldness. At 5/11/72 the design No. 10584 was proposed and patented by the inventor of the present invention wherein a portion of the useful air was employed to reduce the temperature of a heat exchanger apparatus and the inlet fresh air by passing through the said heat exchanger was precold before to be employed as working air for evaporation and as the result the cooler produced useful air colder and with less water vapor in comparison with ordinary evaporative cooler. Although this invention was useful, because of low efficiency of the heat exchanger and using a portion of the useful air, the waste of energy was high to some extent. Then other designs have been proposed wherein the indoor air which was precold by passing through a heat exchanger was employed as working air for evaporation. So the working air (the indoor air) was precold before being employed for evaporation and this precold indoor air after again being cooled inside the device by evaporation was used to reduce the temperature of the heat exchanger in which the outdoor air passed for being cooled and entering the room. The heat exchanger which is used in these design is made by laminating of corrugated plates between flat plate to have two air flows crossing orthogonally. These heat exchanger has nothing in their canals to help the exchange of the heat and corrugate plates which cause the air passing through the canals only in one side has enough contact with the adjacent wall. This heat exchanger which is used inside the air condition has limit heat exchanging surface and makes the entire system big and as the air employing for evaporation exhaust near the ports in which the inlet fresh air is sucked, it needs dehumidifying system and as the result the air of the enclosure would not be pleasant. These designs not being simple as evaporative cooler nevertheless change the nature of evaporative cooler because in these designs outdoor fresh air is not employed as working air to produce useful air fresh, cold clean with water vapor as is true with evaporative cooler. So none of these designs could replace evaporative cooler completly, the reason being that although above mentioned designs have some privileges they do not hold special privileges of the evaporative cooler like simplicity and less cost of energy and inexpensive and also making the air cold clean with water vapor which is desirable in the dry climate. In these designs the working air which leaves the device to atmosphere is colder than the outside temperature so a lot of energy is wasted. The evaporative cooler is a useful device; its problem is that when the weather is too hot the water vapor of the useful air is high and the useful air is not cold enough. Another important deficiency of the evaporative cooler is that when as the result of the high air pressure the useful air leaves the room it takes coldness generated by the evaporative cooler to outside, so the energy is wasted.
The present invention satisfies the foregoing deficiency of the evaporative cooler without having much energy cost and even in some instances without further energy cost.
SUMMARY OF INVENTION
The invention which is here disclosed shows an evaporative cooler with a reverse canal and a heat exchanger. The precooled air of the enclosure is conducted on the top of the heat exchanger by the reverse canal and the said air after passing through the heat exchanger and making it cool leaves the heat exchanger to atmosphere and the fresh inlet air by passing through the heat exchanger (separately independent with the indoor air which exhaust through the heat exchanger) is heat removed (precold) to be still colder by evaporation inside the evaporative cooler.
A heat exchanger here is disclosed with canals wide enough to let the air pass through them very easily meanwhile with highly heat exchange efficiency which could be manufactured very easily by very thin aluminum sheet also it could be manufactured easily with numerous canals with enough surface for good heat exchanging process. Aluminum folded sheet lace is provided in the said canals which by its wires which are parallel to the walls of the canals will conduct the air toward the walls of the canals and also with its wires which extend between the walls of the canals exchanges the heat between the canals and with its wires attached to the canals wall make a rough surface on them thus providing desirable heat transfer gradient and as the result heat exchanging process is performed very efficiently. The heat exchanger consist of numerous canals. The walls of the adjacent canals are the same and the canals are separated from each other so the air passing through the canals are separated and as the result heat exchanging process between the inlet fresh air and the air discharging from enclosure passing through adjacent canals is performed without addition of water vapor to the inlet fresh air, consequently just before entering the cooler the inlet air loses some of its temperature to become still colder by evaporation inside the evaporative cooler. Thus the device helps the cooler exit the useful air colder and with less water vapor than conventional evaporative cooler and prevents wasting of energy.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows the evaporative cooler with reverse canal which is inserted the room through the opening of a partition.
FIG. 2 shows the heat exchanger from the rear side.
FIG. 3 shows the heat exchanger from the front side (the front side is fixed on the back of the evaporative cooler).
FIG. 4 shows the air flow in an exhaust canal.
FIG. 5 shows the air flow in a suction canal.
FIG. 6 shows the complete arrangement.
FIG. 7 shows aluminum sheet which is folded to make the canals in beginning stage.
FIG. 8 shows the aluminum sheet lace which will be inserted in the canal.
FIG. 9 shows FIG. 7 when the bottom of the exhaust canals and the top of the suction canals are closed (the aluminum sheet lace inserted in the canals are not illustrated for the purpose of keeping the drawings simple).
FIG. 10 shows FIG. 9 from the rear side when a part of rear side of the canals is closed to provide exhaust valves.
FIG. 11 shows FIG. 9 from the front side when a part of the side of the canals is closed to provide suction valves.
FIG. 12 shows the case of the heat exchanger from the rear side in which the canals which are shown in FIG. 10 will be inserted in it.
FIG. 13 shows the heat exchanger from the front side in which the the canals from the front side which are shown in FIG. 11 will be inserted in it.
FIG. 14 shows a view of the connecting duct within the evaporative cooler.
DESCRIPTION OF THE PREFERRED EMBODIMENT
As it was described before the system comprises of a conventional evaporative cooler and a reverse canal and a heat exchanger.
Referring to FIG. 1 of the drawings there is illustrated a conventional evaporative cooler 10 with reverse canal 11 and the opening of a partition 12 (the partition separates the indoor side from the outdoor side) through which the front part of the evaporative cooler 13 and the front part of the reverse canal 14 inserted into the room. The cooler includes a plurality of exhaust ports disposed on the surface of the front side of the evaporative cooler 15 in the indoor side and a plurality of suction ports disposed on surface of the rear side of the evaporative cooler 16 in the outdoor side. The construction of the evaporative cooler is well known and it is not necessary to be described. The fresh outdoor air is sucked into the evaporative cooler through the plurality of the suction ports 16 (as is shown by the left hand arrow). When the fresh outdoor air which is sucked inside the evaporative cooler has heat removed inside the cooler due to the heat of evaporative required for the water to be vaporized, thereby to provide the useful air having a lower temperature than the outdoor air. Then the useful air through exhaust ports 15 (as is shown by the left hand arrow) is delivered to the room. But the useful air introduced to the room after making the room cool by the pressure of the air accumulation should escape to outdoor. So by the assumption that there is no other hole in the room except reverse canal 11 the indoor air escapes from the room through the reverse canal 11 (as is shown by the right hand arrow). If there is another hole in the room an air blower should be provided inside the reverse canal 11 to push the indoor air inside the reverse canal. The vertical front side of the reverse canal 14 is open and the vertical end of the reverse canal 17 is closed and the horizontal beneath end of the reverse canal 18 is open so the air escaping the room through the reverse canal from the horizontal beneath open part of the reverse canal 18 will flow down (as is shown by the downward arrow).
Reffering to FIGS. 2 and 3 there are illustrated the heat exchanger from rear side and front side. FIG. 2 shows the heat exchanger from the rear side and FIG. 3 shows the heat exchanger from the front side. The heat exchanger comprises of the exhaust canals 19 and the suction canals 20 and a case 21 in which the canals 19 and 20 are fixed (it will be described more particularly later). The walls of the case 22 are longer than the canals 19 and 20 except in the front side 23. In the front side of the heat exchanger (on the case) there is provided a frame 24 which will be fixed on the back of the cooler 25 in FIG. 1 to cover the suction ports 16 in FIG. 1. The horizontal open beneath end of the reverse canal 18 in FIG. 1 is fixed on the top of the heat exchanger 26 so the indoor air flowing down through the horizontal open beneath end of the reverse canal 18 in FIG. 1 passes through the heat exchanger.
The heat exchanger consists of multitude of exhaust canals 19 and suction canals 20. The heat exchanger are so designed as there is a exhaust canal 19 next to a suction canal 20 in such a way that the air flow in the exhaust canals 19 are kept effectively independent from the air flow in the suction canals 20 (it will be described more particularly in the detailed construction). There are provided aluminum lace in the canals which helps exchanging of the heat between the canals (aluminum lace provided in the canals are not illustrated for the purpose of keeping the drawings simple). The exhaust canals 19 are open on the top 19 but closed on the bottom 27 and are connected to the exhaust outlet opening 28. The suction canals 20 are closed on the top 29 and are open on the bottom 20 and are connected to the suction inlet opening 30.
Reffering to FIG. 4 the air flow in one exhaust canal is shown. As it could be seen in the direction of arrow the air enters the exhaust canal from its top 19 which is open and after passing through the exhaust canal 19 leaves the canal through exhaust outlet opening 28.
Referring to FIG. 5 the air flow in one suction canal is shown. As it could be seen in the direction of arrow the air is sucked from the bottom of the suction canal 20 which is open and after passing through the suction canal leaves the suction canal through its suction inlet opening 30.
Reffering to FIG. 6 the complete arrangement is illustrated, which comprises a conventional evaporative cooler 10 a reverse canal 11 a partition 12 through which the front part of the evaporative cooler 13 and the front part of the reverse canal 14 are inserted inside the room and a heat exchanger 31. The frame on the front side of heat exchanger 24 is fixed to the back of evaporative cooler 25 to cover the suction ports. If the evaporative cooler also sucks the air from the sides the heat exchanger should also be fixed on the sides (the heat exchanger fixed on the sides and the suction ports which is covered by the frame 24 are not illustrated for the purpose of keeping the drawings simple). Top of the heat exchanger 26 is fixed to the horizontal open beneath of the reverse canal 18. If the evaporative cooler sucks the air from the sides and as the result the heat exchanger is also fixed on the sides the reverse canal should also be fixed on the heat exchanger which are fixed on the sides (the reverse canal fixed on the heat exchanger which are fixed on the sides of the evaporative cooler are not illustrated for the purpose of keeping the drawing simple). In operation the indoor air enters the reverse canal 11 through its open front side 14 and by passing the reverse canal 11 (as is shown by right hand arrow) through its horizontal beneath open end 18 enters the exhaust canal 19 and after passing the exhaust canals leaves the exhaust canals through the exhaust outlet opening 28 and as the result makes the heat exchanger cool. The direction of the air flow through the last exhaust canal from the left side 19 and through its exhaust outlet opening 28 is shown by arrow (direction of the air flow in the other exhaust canals and exhaust valves are not illustrated for the purpose of keeping the drawing simple). The fresh out door air through the bottom of suction canals 20 which are open is sucked inside the suction canals 20 and after passing through suction canals 20 and is heat removed (because heat exchanger is cooled) enters the evaporative cooler through the suction melt opening 30 to become still colder by evaporation inside the evaporative cooler. The air flow through the last suction canal from the right side 20 and its suction inlet opening 30 is shown by arrow (direction of air flow in the other suction canals 20 and other suction valves 30 are not illustrated for the purpose to keep the drawing simple).
Referring to FIGS. 7-13 detail construction of the heat exchanger is shown. Initially the aluminum sheet is folded to make the canals in beginning stage as is shown in FIG. 7. Then aluminum sheet lace with good heat conductivity is bent to make the shape as is shown in FIG. 8 and is inserted into all canals (the aluminum lace inserted into the canals are not illustrated for the purpose to keep the drawing simple) thereby firstly preserving distance of the walls of the canals from each other and secondly as its wires which are parallel to the walls of the canals 33 will conduct the air toward the walls of the canals and as its wires 34 which extend between the walls of the canals and as some of its wires which attach the walls of the canals 35 makes a rough surface on the walls of the canals, helps heat exchange between the canals. The aluminum sheet and aluminum lace should be strong enough so that their shape do not change as the air is passing through the canals. Then the bottom of the exhaust canals 27 and the top of the suction canals 29 should be closed as is shown in FIG. 9 (aluminum lace inserted in the canals is not illustrated for the purpose of keeping the drawing simple. FIG. 9 shows the rear side of the canals. Now we leave free the lower part of the rear side equal to the length of the exhaust valves 28 and we seal the remainder of the rear side surface by a cardboard or aluminum sheet to shape out the set as is shown in FIG. 10 in which the exhaust valve 28 could be seen. We carry out the same process in the front side of the set, the only difference being that in this case we leave free the upper part of the front side equal to the length of the suction inlet opening 30 and we seal the remainder of the front side surface by a cardboard or aluminum sheet to shape out the set as is shown in FIG. 11 in which the suction inlet opening could be seen 30. There after the mentioned set is inserted in a case as is shown in FIGS. 12 and 13. The set is fitted in the case in such a way to have the exhaust outlet opening 28 aligned along the corresponding exhaust slot 36 in the case and suction inlet opening 30 aligned along the corresponding suction slot 37 in the case and the top of the canals 19 and 29 aligned along the corresponding top of the case 38. The material of the case should not be good heat conductivity. The canals should be fitted in the case air tight at the places of contact. | Fresh inlet air is precold by the cool air discharging from the enclosure by the means of a heat exchanger to become still colder as the result of evaporation inside the evaporative cooler so producing useful air colder and with less water than conventional evaporative cooler. A heat exchanger is disclosed which comprises of numerous exhaust and suction canals adjacent to each other in which is provided aluminium lace for the purpose of exchanging the heat. The cool discharged air passes through the exhaust canals and leaves the heat exchanger cool to outside space and inlet fresh air passes through the suction canals separately relationship with discharged air and after becoming cool leaves the heat exchanger inside the evaporative cooler to effect evaporation. | 5 |
TECHNICAL FIELD
The present invention generally relates to semiconductor processing, and in particular to a nozzle for applying an edge bead removal material to the edge of a photoresist material layer disposed on a semiconductor wafer.
BACKGROUND OF THE INVENTION
In the semiconductor industry, there is a continuing trend toward higher device densities. To achieve these high densities there has been and continues to be efforts toward scaling down device dimensions (e.g., at submicron levels) on semiconductor wafers. In order to accomplish such high device packing density, smaller and smaller features sizes are required. This may include the width and spacing of interconnecting lines, spacing and diameter of contact holes, and the surface geometry such as corners and edges of various features.
The requirement of small features with close spacing between adjacent features requires high resolution photolithographic processes. In general, lithography refers to processes for pattern transfer between various media. It is a technique used for integrated circuit fabrication in which a silicon structure is coated uniformly with a radiation-sensitive film, the resist, and an exposing source (such as optical light, x-rays, or an electron beam) illuminates selected areas of the surface through an intervening master template, the mask, for.a particular pattern. The lithographic coating is generally a radiation-sensitive coating suitable for receiving a projected image of the subject pattern. Once the image is projected, it is indelibly formed in the coating. The projected image may be either a negative or a positive image of the subject pattern. Exposure of the coating through a photomask causes the image area to become either more or less soluble (depending on the coating) in a particular solvent developer. The more soluble areas are removed in the developing process to leave the pattern image in the coating as less soluble polymer.
Due to the extremely fine patterns which are exposed on the photoresist material, thickness uniformity of the photoresist material is a significant factor in achieving desired critical dimensions. The photoresist material should be applied such that a uniform thickness is maintained in order to ensure uniformity and quality of the photoresist material layer. The photoresist material layer thickness typically is in the range of 0.1 to 3.0 microns. Good resist thickness control is highly desired, and typically variances in thickness should be less than ±10-20 Å across the wafer. Very slight variations in the photoresist material thickness may greatly affect the end result after the photoresist material is exposed by radiation and the exposed portions removed.
Application of the resist onto the wafer is typically accomplished by using a spin coater. The spin coater is essentially a vacuum chuck rotated by a motor. The wafer is vacuum held onto the spin chuck. Typically, a nozzle supplies a predetermined amount of resist to a center area of the wafer. The wafer is then accelerated to and rotated at a certain speed, and centrifugal forces exerted on the resist cause the resist to disperse over the whole surface of the wafer. The resist thickness obtained from a spin coating process is dependent on the viscosity of the resist material, spin speed, the temperature of the resist and temperature of the wafer.
After the photoresist is spin coated onto the wafer, a rim or bead of photoresist remains on the edge of the wafer. This rim or bead is removed by applying an edge bead removal solvent by using an edge bead removal (EBR) nozzle, so that loose particles from the rim or bead do not become a source of contamination that can cause wafer defects. Typically, the solvent is either applied at the bottom edge of the wafer, while the wafer is spun causing the solvent to wick around the edge and wash off the photoresist bead or the solvent is applied on the top outside edge of the wafer. However, applying the solvent to the top edge of the wafer has its own inherent problems. One of the problems is that when the solvent spray or jet is shut off, a drop of solvent can remain in a nozzle tip of the nozzle, and may free fall onto the wafer undesirably dissolving useful portions of the photoresist material layer, thus destroying the uniformity of the wafer ultimately causing wafer defects.
In view of the above, an edge bead removal nozzle is needed that ensures that droplets formed at a nozzle tip of the nozzle do not fall onto a photoresist material layer that is being worked upon.
SUMMARY OF THE INVENTION
The present invention relates to an edge bead removal system and method that employs a nozzle for applying edge bead removal solvent to an edge bead of a photoresist material layer disposed on a wafer. The edge bead removal solvent can be a developer, a rinse or a cleanser. The nozzle includes a liquid chamber that can be connected to a supply of edge bead removal solvent that the nozzle applies through a nozzle tip. The nozzle also includes an air supply chamber that can be connected to a supply of air. The supply of air is isolated from the liquid supply chamber during application of the edge bead removal solvent to the edge bead formed on the wafer. The supply of air communicates via the air supply chamber to the liquid supply chamber thus removing any droplets of edge bead removal solvent remaining in the nozzle tip after application of the edge bead removal solvent is completed. The supply of air can be either positive or negative or both depending on the specific configuration of the nozzle.
One particular aspect of the invention relates to an edge bead removal system that includes an edge bead removal nozzle and an absorbent material that moves from a rest position, during application of the edge bead removal solvent to the edge bead formed on the wafer, to an absorbing position that removes or catches any droplets of edge bead removal solvent remaining on the nozzle tip after application of the edge bead removal solvent is completed. In another aspect of the invention the nozzle includes a liquid supply chamber with an inner cylindrical surface that is rendered hydrophobic for repelling the solvent from the liquid supply chamber or hydrophilic for holding the solvent in the chamber after application of the solvent is completed. The surface can be rendered hydrophobic or-hydrophilic by either being made of a hydrophobic or hydrophilic material or having a surface that is coated with a hydrophobic or hydrophilic material. For example, a hydrophobic material can be coated on the inner cylindrical surface of the liquid supply chamber near the nozzle tip, while a hydrophilic material can be coated on the remainder of the inner cylindrical surface of the liquid supply chamber, or a hydrophilic material can be coated on the inner cylindrical surface of the liquid supply chamber near the nozzle tip, while a hydrophobic material can be coated on the remainder of the inner cylindrical surface of the liquid supply chamber.
Another aspect of the present invention relates to an edge bead removal system for applying an edge bead removal solvent on an edge bead formed on a wafer by a photoresist material application system. The edge bead removal system is adapted to remove a droplet of edge bead removal solvent from a nozzle tip of an edge bead removal nozzle after the edge bead removal nozzle has completed application of the edge bead removal solvent. The system includes a supply of edge bead removal solvent, a supply of air, and an edge bead removal nozzle with a nozzle tip. The nozzle includes a liquid supply chamber adapted to be in fluid communication with the supply of edge bead removal solvent and an air supply chamber adapted to be in fluid communications with the supply of air. The edge bead removal nozzle has a first state for applying the edge bead removal solvent and a second state for removing the edge bead removal solvent from the nozzle tip. The air supply chamber is in fluid communication with the liquid supply chamber in the second state.
Another aspect of the present invention relates to an edge bead removal system for applying an edge bead removal solvent on an edge bead formed on a wafer by a photoresist material application system. The edge bead removal system is adapted to receive a droplet of edge bead removal solvent from a nozzle tip of an edge bead removal nozzle after the edge bead removal nozzle has completed application of the edge bead removal solvent. The system includes a supply of edge bead removal solvent, an edge bead removal nozzle with a nozzle tip. The nozzle is in fluid communication with the supply of edge bead removal solvent and adapted to apply edge bead removal solvent onto an edge bead formed on a wafer. The system also includes an absorbent material adapted to receive a droplet of edge bead removal solvent from the nozzle tip after the application of the edge bead removal solvent is completed.
Yet another aspect of the present invention relates to an edge bead removal system for applying an edge bead removal solvent on an edge bead formed on a wafer by a photoresist material application system. The system includes means for supplying an edge bead removal solvent, means for supplying air, and means for applying the edge bead removal solvent to an edge bead formed on a wafer. The means for applying the edge bead removal solvent includes a liquid supply path for moving the edge bead removal solvent from the means for supplying an edge bead removal solvent to the edge bead formed on the wafer and an air supply path for supplying a supply of air to the liquid chamber for removing an edge bead droplet formed on an end of the liquid supply path.
In yet another aspect of the invention an edge bead removal nozzle with a nozzle tip for applying an edge bead removal solvent on an edge bead formed on a wafer by a photoresist material application system is provided. The edge bead removal nozzle includes a liquid supply chamber adapted to be in fluid communication with a supply of edge bead removal solvent. The liquid supply chamber includes a first inner cylindrical surface made of a material that repels the solvent and a material that attracts the solvent.
Another aspect of the invention relates to a method for applying an edge bead removal solvent on an edge bead formed on a wafer by a photoresist material application system, and removing a droplet of edge bead removal solvent from a nozzle tip of an edge bead removal nozzle after applying the edge bead removal solvent. The method includes the step of providing an edge bead removal nozzle with a nozzle tip where the nozzle includes a liquid supply chamber adapted to be in fluid communication with a supply of edge bead removal solvent and an air supply chamber adapted to be in fluid communications with a supply of air. The edge bead removal nozzle has a first state for applying the edge bead removal solvent and a second state for removing the edge bead removal solvent from the nozzle tip. The air supply chamber is in fluid communication with the liquid supply chamber in the second state. The method further includes the steps of applying a supply of edge bead removal solvent to the edge bead formed on the wafer and providing a supply of air to the air supply chamber causing the removal of any remaining edge bead removal solvent from the nozzle tip of the nozzle.
To the accomplishment of the foregoing and related ends, the invention, then, comprises the features hereinafter fully described and particularly pointed out in the claims. The following description and the annexed drawings set forth in detail certain illustrative embodiments of the invention. These embodiments are indicative, however, of but a few of the various ways in which the principles of the invention may be employed. Other objects, advantages and novel features of the invention will become apparent from the following detailed description of the invention when considered in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a front cross sectional view of an edge bead removal nozzle in an edge bead removal system in accordance with the present invention;
FIG. 2 illustrates a cross-sectional view of the edge bead removal nozzle of FIG.1 with a flap in an open position in accordance with the present invention;
FIG. 3 illustrates a cross-sectional view of the edge bead removal nozzle of FIG. 1 along the lines A—A in accordance with the present invention;
FIG. 4 illustrates a cross-sectional view of the edge bead removal nozzle of FIG. 1 along the lines B—B in accordance with the present invention;
FIG. 5 illustrates a cross-sectional view of the nozzle of FIG. 1 with a second flap in accordance with the present invention;
FIG. 6 illustrates a cross-sectional view of the nozzle of FIG. 1 with a movable flap in a liquid supply chamber in accordance with the present invention;
FIG. 7 illustrates a front view of an alternate nozzle in a rest state in accordance with the present invention;
FIG. 8 illustrates a front view of the alternate nozzle of FIG. 7 in an operating state in accordance with the present invention;
FIG. 9 illustrates a bottom view of an alternate nozzle tip in an open position in accordance with the present invention;
FIG. 10 illustrates a bottom view of the alternate nozzle tip of FIG. 9 in a closed position in accordance with the present invention;
FIG. 11 illustrates a cross-sectional view of yet another embodiment of a nozzle in accordance with the present invention; and
FIG. 12 illustrates a cross-sectional view of a variation of the nozzle in FIG. 9 in accordance with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The present invention is now described with reference to the drawings, wherein like reference numerals are used to refer to like elements throughout. The present invention is described with reference to an edge bead removal nozzle that employs various techniques for ensuring that droplets left in the nozzle, after application of an edge bead removal solvent on a wafer, do not fall onto the wafer. It should be understood that the description of these embodiments are merely illustrative and that they should not be taken in a limiting sense.
Referring initially to FIG. 1, an edge bead removal nozzle 10 is provided that includes a liquid chamber 14 surrounded by a housing 12 . A liquid supply port 16 is connected at a first end of the liquid chamber 14 . The liquid supply port 16 is connected to a supply of an edge bead removal solvent 15 . The liquid chamber 14 extends through the housing from the first end to a second end that is provided with a liquid discharge aperture 22 for dispensing the edge bead removal solvent. An air chamber 18 is also provided and is in a communicative relationship with the liquid chamber 14 . The air chamber 18 is disposed at a location near the liquid discharge aperture 22 , and has a longitudinal axis that is generally perpendicular to the longitudinal axis of the liquid supply chamber 14 . The air chamber 18 is connected on one end to an air supply port 20 that is connected to a supply of air 17 . The supply of air 17 can be either a positive or negative (e.g. vacuum) supply depending on specific configuration of the nozzle 10 . A flap 24 is disposed at the other end of the air chamber 18 . The flap 24 controls the communication of air chamber 18 with the liquid chamber 14 . The flap 24 is biased toward the liquid chamber 14 , but is limited in its direction of travel by the air chamber 18 . The flap 24 has a closed position during the dispensing of liquid, and an open position for removing excess liquid from a dispensing nozzle tip 21 .
FIG. 2 illustrates the flap 24 in its open position. After the nozzle 10 finishes dispensing the edge bead removal solvent, a supply of air of the negative or vacuum type is activated that is coupled to the air supply port 20 causing the flap 24 to open, which provides communication of the air supply port 18 with the liquid chamber 14 . FIG. 3 illustrates a cross-sectional view of the liquid chamber of FIG. 1 along the lines A—A. In FIG. 3, the flap 24 is shown partially opened, revealing the air supply chamber 18 and the air supply port 20 . The vacuum supply eventually causes the flap 24 to completely open, so that any remaining edge bead removal solvent in the liquid chamber 14 and the nozzle tip 21 is removed. FIG. 4 illustrates a cross-sectional view of the air supply chamber 18 of FIG. 1 along the lines B—B. The flap 24 is shown in its closed position and is limited in its length of travel by a peripheral flange 26 at the other end of the air chamber 18 . This ensures that the flap 24 can only open into the air supply chamber 18 and not into the liquid supply chamber 14 , so that the flap 24 does not interfere with the dispensing of edge bead removal solvent. In another embodiment, the opening and closing of the flap 24 is controlled electronically as opposed to by the supply of air.
An alternate embodiment of the nozzle of FIGS. 1-4 is illustrated in FIG. 5, where a second flap 28 is disposed in the liquid supply chamber 14 above the flap 24 . The second flap 28 is biased to a closed position and moves toward its open position by pressure applied to it by the edge bead removal solvent. After the nozzle 10 finishes dispensing edge bead removal solvent, the second flap 30 returns to its closed position. The vacuum supply can then be activated causing the flap 24 to open, so that excess edge bead removal solvent can be removed. It is to be noted that the flap 24 and the second flap 28 can be biased in such a way that the second flap 28 does not open during the vacuum operation. In yet another embodiment, the air supply port 20 is connected to a supply of air for providing positive air flow through the air chamber 18 . In this embodiment, the flap 24 can either be opened into the liquid supply chamber 14 or moved farther into the air chamber 18 . The positive supply of air causes the excess edge bead removal solvent to flow out of the liquid discharge aperture 22 . The positive supply of air can be turned on at or near the time the flow of the edge bead removal solvent is shut off, so that the edge bead removal solvent flow is continuous, until the nozzle tip 21 is emptied. The positive air flow also ensures that the second flap 28 remains closed during the removal or cleansing operation.
Another alternate embodiment of the edge bead removal nozzle is illustrated in FIG. 6 . In the embodiment of FIG. 6, the nozzle includes a movable flap 30 disposed inside the liquid chamber 14 . The movable flap moves between a first position closing off the liquid chamber 14 from the liquid discharge aperture 22 , and a second position closing the air chamber 18 from the liquid chamber 14 . In this embodiment, the air supply port 20 can be connected to a positive supply of air, so that the edge bead removal solvent can move the movable flap 30 to the second position during discharge of the solvent, and move the movable flap 30 to the first position during removal or cleansing of the residual solvent in the nozzle tip 21 . It is to be appreciated that the air supply port 20 can be switch between both a positive supply of air and a negative supply of air. The positive supply of air can force the movable plate to its first position blocking any residual solvent remaining in the liquid chamber 14 , while simultaneously forcing the residual solvent out of the nozzle tip 21 . The negative supply of air can force the movable plate to its second position, so that the edge bead removal solvent can be dispensed with out interference of the movable flap 30 , while simultaneously closing off the air chamber 18 . It is to be appreciated that the flap 24 and/or the second flap 28 or the movable flap 30 can be located at a variety of different locations within the liquid supply chamber 14 and/or the air supply chamber 14 , so that the present invention can be carried out with either a positive or negative air supply or both a positive and negative air supply.
Referring now to an alternate embodiment of the invention for removing excess edge bead removal solvent from the tip of a nozzle, FIGS. 7-8 illustrate a nozzle 60 that utilizes a material external to the nozzle 60 for absorbing droplets of edge bead removal solvent. The nozzle 60 includes a liquid chamber 66 surrounded by a housing 64 . A liquid supply port 62 is connected at a first end of the liquid chamber 66 . The liquid supply port 62 is adapted to be connected to a supply of edge bead removal solvent. The liquid chamber 66 extends through the housing from the first end to a second end that is provided with a discharge aperture 62 for dispensing the edge bead removal solvent. A moving mechanism 65 is provided that includes a holder 72 having a path 70 for moving a spherical ball bearing 68 . A handle 74 connects the ball bearing 68 to a plate 76 . An absorbing material 78 is disposed on top of the plate 76 . The absorbing material 78 can be any sponge or cloth like material adapted to absorb droplets of edge bead removal solvent from a nozzle tip 81 . The moving mechanism 65 moves the material 78 from a rest position 80 , illustrated in FIG. 7, to an absorbing position 85 , illustrated in FIG. 8 . The absorbing material 78 is moved to the rest position 80 , while edge bead removal solvent is being dispensed through a liquid discharge aperture 82 in the nozzle tip 81 , and is moved to the absorbing position 85 immediately after the nozzle tip 81 terminates dispensing of the edge bead removal solvent. It is to be appreciated that a variety of moving mechanisms can be employed to move the absorbing material 78 from a rest position to an absorbing position, in addition to the example discussed above.
FIGS. 9-10 illustrate an alternate nozzle tip 85 that can be employed in the nozzle 60 . The alternate nozzle tip 85 is formed of a plurality of shutters 86 forming an iris 87 that moves from a open position as illustrated in FIG. 9 to a closed position as illustrated in FIG. 10 . The shutters 86 are formed from or covered with an absorbent material, such that droplets are absorbed by the absorbent material after application of the solvent onto the wafer. This eliminates the need for using the moving mechanism 65 and the plate 76 illustrated in FIGS. 7 and 8.
FIGS. 11-12 illustrate yet another alternate embodiment of the invention for removing excess edge bead removal solvent from the tip of an edge bead removal nozzle. A nozzle 90 is provided that includes a liquid chamber 96 surrounded by a housing 94 . A liquid supply port 92 is connected at a first end of the liquid chamber 96 . The liquid supply port 92 is adapted to be connected to a supply of edge bead removal solvent. The liquid chamber 96 extends through the housing 94 from the first end to a second end that is provided with a discharge aperture 102 for dispensing the edge bead removal solvent. Referring initially to FIG. 9, the liquid supply chamber 96 includes a first inner cylindrical surface 98 and a second inner cylindrical surface 100 . The second inner cylindrical surface 100 is disposed at a location near the discharge aperture 102 , and covers a much smaller area than the first inner cylindrical surface 98 . If the solvent is aqueous, the first inner cylindrical surface 98 is made of or covered with a hydrophillic material and the second surface is made of or covered with a hydrophobic material. If the solvent is organic, the first inner cylindrical surface 98 is made of or covered with a lypophilic material and the second surface is made of a lypophobic material. The edge bead removal solvent is dispensed through the liquid supply chamber 14 by pressure. After the edge bead removal solvent supply is turned off, the residual edge bead removal solvent will be held on the first inner cylindrical surface 98 , and repelled by the second inner cylindrical surface 100 , so that no drops of edge bead removal solvent will be formed on a nozzle tip 101 .
Alternatively, the first inner cylindrical surface 98 can be made of or coated with a hydrophobic material for aqueous solvents and lypophobic for organic solvents, while the second inner cylindrical surface 100 is made of or coated with a hydrophilic material for aqueous solvents and lypophilic for organic solvents. The residual edge bead removal solvent will then be repelled by the first inner cylindrical surface 98 and attracted or held by the second inner cylindrical surface 100 . In this way, any residual edge bead removal solvent remains on the second inner cylindrical surface 100 and not form a droplet on the nozzle tip 101 that may fall onto the wafer being worked upon. An alternate embodiment is illustrated in FIG. 10, where the nozzle 90 includes the liquid supply chamber 96 which has a single inner cylindrical surface 104 made of or coated with either a hydrophobic or a hydrophilic material for aqueous solvents and either a lypophobic or lypophilic material for organic solvents. The single cylindrical surface 104 either repels or attracts any residual edge bead removal solvent, thus preventing any droplets of edge bead removal solvent from forming on the nozzle tip 101 . Additionally the outside surface 105 of the nozzle tip 101 can be made of or covered with a hydrophobic material for aqueous solvents and lypophobic material for organic materials, while the single inner cylindrical surface is made of or covered with a hydrophilic material for aqueous solvents and a lypophilic material for organic solvents. This causes the droplets to be sucked back into the nozzle 90 .
What has been described above are preferred embodiments of the present invention. It is, of course, not possible to describe every conceivable combination of components or methodologies for purposes of describing the present invention, but one of ordinary skill in the art will recognize that many further combinations and permutations of the present invention are possible. Accordingly, the present invention is intended to embrace all such alterations, modifications and variations that fall within the spirit and scope of the appended claims. | An edge bead removal system and method is provided that employs a nozzle for applying edge bead removal solvent to an edge bead of a photoresist material layer disposed on a wafer. The nozzle includes a liquid chamber that can be connected to a supply of edge bead removal and an air supply chamber that can be connected to a supply of air. The supply of air is isolated from the liquid supply chamber during application of the edge bead removal solvent and communicates via the air supply chamber to the liquid supply chamber after application of the edge bead removal solvent thus removing any droplets of edge bead removal solvent remaining in the nozzle tip. A system is also provided that includes an absorbent material that moves from a rest position, during application of the edge bead removal solvent, to an absorbing position that removes or catches any droplets of edge bead removal solvent remaining on the nozzle tip after application of the edge bead removal solvent is completed. A nozzle is also provided that includes a liquid supply chamber with an inner cylindrical surface that is made of or coated with either a hydrophobic material and/or a hydrophilic material. | 8 |
CROSS-REFERENCE TO RELATED PATENT APPLICATIONS
Japan Priority Application 10-347549, filed Dec. 7, 1998 including the specification, drawings, claims and abstract, is incorporated herein by reference in its entirety. This application is a Continuation of U.S. application Ser. No. 11/790,181, filed Apr. 24, 2007, incorporated herein by reference in its entirety, which is a Divisional of U.S. application Ser. No. 11/357,985, filed Feb. 22, 2006, now U.S. Pat. No. 7,215,948, incorporated herein by reference in its entirety, which is a Continuation of U.S. application Ser. No. 10/397,524, filed Mar. 27, 2003, incorporated herein by reference in its entirety, which is a Continuation of U.S. application Ser. No. 09/456,377, filed Dec. 7, 1999, now U.S. Pat. No. 6,542,755, incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a multicast communication method to be performed in a CDMA (Code Division Multiple Access) mobile communication system.
2. Description of the Related Art
As a conventional multicast communication method in the CDMA mobile communication system, Japanese Patent Laid-Open Hei 10 (1998)-107770 discloses a multicast communication method in which service negotiations for the multicast communication is performed in a calling procedure between a mobile subscriber (abbreviated as MS, hereinafter) and a base station system (abbreviated as BSS, hereinafter) for the MS obtaining a spread code to be used for each multicast communication method.
Alternatively, in a plurality of BSSs, each multicast service data has been transmitted by using a broadcast channel of each BSS without any linkage to one another.
However, the following problems were inherent in the foregoing conventional multicast communication method in the CDMA mobile communication system.
(1) Regarding a system where a spread code is allocated for each multicast communication method by service negotiations in a calling procedure between the MS and the BSS, since a registration operation for the spread code is executed for each multicast service in MS that receives information, processing becomes complex. Thus, the system is not suitable for the multicast communication method of advertising use where information is simultaneously transmitted to a large number of MS. In addition, since the spread code must be fixed for each multicast communication method to be notified, dynamic use of limited number of spread codes is not allowed. Thus, this system lacks efficiency.
(2) Regarding a system where each multicast communication data is transmitted by each BSS by using respective broadcast channels, since the position of MS cannot be specified when a multicast operation is performed, transmission power in each BSS must be set to a maximum in order to enable possible MS located in the vicinity of a boundary to receive a signal sent from BSS. But if signal for data is transmitted by an output more than necessary, noises are generated in other MS. Consequently, a capacity of the entire system is reduced.
The present invention was made in order to solve the foregoing problems inherent in the prior art, and it is an object of the invention to provide a multicast communication method in a CDMA mobile communication system, which is capable of reducing transmission power in BSS and performing an efficient multicast operation for a large number of MS.
SUMMARY OF THE INVENTION
In order to achieve the foregoing object, in accordance with an aspect of the present invention, a multicast communication method in a CDMA mobile communication system, which comprises a plurality of mobile subscribers, a plurality of base station systems connected to the mobile subscribers by radio channels, a plurality of mobile switching centers connected to the base station systems and a multicast communication server connected to the mobile switching centers for providing information to be distributed to the mobile subscribers, the method is characterized in that each of the base station systems transmit information which is necessary for enabling the mobile subscriber to receive the multicasting information through respective broadcast channels to each of the mobile subscribers before multicasting information is transmitted.
The method comprises:
(1) sending a multicast request to at least one anchor base station system together with area information for multicasting;
(2) instructing a multicast request from the anchor base station system to at least one branch base station system necessary for covering multicasting area indicated by the area information;
(3) transmitting multicast starting information and spread code to be used for multicasting information to mobile subscribers through respective broadcast channels of the anchor base station system and the branch base station system; and
(4) transmitting multicasting information from the anchor base station system and the branch base station system after proper time interval, during which the mobile subscribers have been ready for receiving multicasting information, has been elapsed.
The multicast communication method set forth above, wherein the anchor base station system uses a diversity hand-over trunk for establishing links to the branch base station systems.
The multicast communication method set forth above, wherein the method further comprises receiving multicasting information, at the mobile subscriber, transmitted from a plurality of base station systems, and performing a RAKE combine process for respective received signals.
In another aspect, the method comprises:
(1) sending a multicast request to at least one anchor base station system together with area information for multicasting;
(2) instructing a multicast request and link establishment request from the anchor base station system to at least one branch base station system necessary for covering multicasting area indicated by the area information;
(3) sending back information of link establishment completion and information of decided spread code for multicasting information at each base station system to the anchor base station system from the branch base station system,
(4) transmitting multicast starting information together with a list indicating base station systems transmitting identical multicasting information and spread code to be used for multicasting information to mobile subscribers through respective broadcast channels of the anchor base station system and the branch base station system; and
(5) transmitting multicasting information from the anchor base station system and the branch base station system after proper time interval, during which the mobile subscribers have been ready for receiving multicasting information, has been elapsed.
The multicast communication method in a CDMA mobile communication system set forth above, wherein the method further comprises:
(6) detecting, at the mobile subscriber, receivable base station systems listed in the list transmitted through the broadcast channel, and preparing reception of multicasting information by setting spread codes indicated in said list; and
(7) receiving multicasting information, at the mobile subscriber, transmitted from a plurality of base station systems, and performing a RAKE combine process for respective received signals.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a view showing an embodiment of a multi-cast communication method in a CDMA mobile communication system according to the present invention.
FIG. 2 is a view showing a specific example of a configuration including MS, BSS and MSC shown in FIG. 1 .
FIG. 3 is a view illustrating a flowchart of a multicast communication method operation in the CDMA mobile communication system shown in FIGS. 1 and 2 .
FIG. 4 is a view illustrating another flowchart of a multicast communication method operation in the CDMA mobile communication system shown in FIGS. 1 and 2 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A preferred embodiment of the present invention will be described with reference to the accompanying drawings.
FIG. 1 shows an embodiment of the CDMA mobile communication system in which the multicast communication method of the present invention is performed.
As shown in FIG. 1 , the embodiment comprises a plurality of mobile subscribers (MSs 1 and 2 ), base station systems (BSSs 3 to 6 ) connected to the MSs 1 and 2 by radio channels for playing main roles of information multicasting to the MSs 1 and 2 , mobile switching centers (MSCs 7 and 8 ) connected to the BSS 3 and also connected to the BSSs 4 to 6 for processing calls originated from the MSs 1 and 2 or calls incoming thereto, updating location information of the MSs 1 and 2 , a gateway mobile switching center (G-MSC 9 ) connected to the MSCs 7 and 8 for performing connections to other networks, a multicast communication server 10 connected to the G-MSC 9 , and also another multicast communication server 11 connected to the MSCs 7 and 8 . Radio connections between the MS 1 and the BSS 3 , and between the MSs to the BSSs 4 to 6 are respectively established by a mobile communication procedure using the CDMA system.
The multicast communication servers 10 and 11 store contents information of multicast services, area information of each multicast service as a destination for multicasting information, and time for multicasting information. Timers are installed inside of server. These timers are set for each stored information, and by the timers, time for starting multicasting the stored information can be detected. Further, a service identifier is set for each multicast service so as to enable distributed information to be identified in the MSs 1 and 2 .
FIG. 2 shows a specific example of the embodiment composed of the MS 2 , the BSSs 4 to 6 and the MSC 8 shown in FIG. 1 .
As shown in FIG. 2 , BSSs are classified into an anchor BSS 5 for playing main roles of information multi-casting, and branch BSSs 4 and 6 for subordinately contributing to information multicasting by means of link connection between each branch BSS and the anchor BSS 5 . The anchor BSS 5 and branch BSSs 4 and 6 are connected to each other by links 18 and 19 .
Functional sharing between the anchor BSS and the branch BSSs may be different for each multicast information. Also, even for identical information, functional sharing may be different for each multicasting information, for example between day and night.
The BSSs 4 to 6 respectively include diversity hand-over trunk (DHT) 12 to 14 provided to perform a soft hand-over operation in the CDMA system, and radio sections 15 to 17 provided to perform radio signal transmission and reception processing, and signal modulation and demodulation. The soft hand-over operation is one of unique features of the CDMA system. As the CDMA system uses the same frequency for radio communication, a MS can establish a plurality of radio channels to a plurality of BSSs as long as radio signal condition is good for each BSS. Therefore, as for the reverse channel signal, the BSS 5 can receive signal from the MS 2 not only via the radio section 15 of own BSS but also via the radio section 16 of the BSS 4 and the radio section 17 of the BSS 6 , and the strongest signal is selected as the received signal at the DHT 12 in the BSS 5 .
The area information to be transmitted, which has been stored in the multicast communication servers 10 and 11 , contains bits of information regarding which BSS should be set as an anchor BSS and which BSS should be set as a branch BSS. The area information may be different for each multicasting information. For G-MSc 9 and MSCs 7 and 8 , a different BSS configuration may be specified each time a multicast transmission request is transmitted. For example, even for identical multicast information, area information different between day and night may be specified.
In order to perform communications between BSSs 3 to 6 and MSs 1 and 2 , the mobile communication system includes a broadcast channel provided to simultaneously inform system information or the like to a plurality of MSs, and a traffic channel provided to transmit specific data mainly to respective MS. MSs 1 and 2 include means provided to enable individual broadcast channel reception to be performed.
Next, a multicast communication method in the mobile communication system configured in the foregoing manner will be described.
FIG. 3 illustrates a flowchart of an embodiment of a multicast communication method in the CDMA mobile communication system shown in FIGS. 1 and 2 .
First, in the multicast communication server 10 or 11 , when a time comes to transmit accumulated data, information to be transmitted is notified together with area information to be transmitted to G-MSC 9 or MSCs 7 and 8 , and a request is made to perform a multicast operation (step S 1 ). Here, if G-MSC 9 receives a request transmitted from the multicast communication server 10 or 11 , the request is transferred to MSCs 7 and 8 corresponding to the requested area information. In G-MSC 9 , this request is copied when necessary, and transferred to a plurality of MSCs.
On the other hand, if MSCs 7 and 8 receive a request transmitted from the multicast communication server 10 or 11 , the request is transferred to the anchor BSSs 3 and 5 corresponding to the requested area information. In the MSCs 7 and 8 , this request is copied when necessary, and transferred to a plurality of anchor BSSs.
Upon having received the request transferred from the MSC 8 , the anchor BSS 5 hunts the DHT 12 for a multicast operation, and informs the starting of information transmission to surrounding branch BSSs 4 and 6 corresponding to the area for information transmission. Then, links 18 and 19 are established for transmission of the notified information between branch BSSs 4 and 6 (step S 2 ).
Then, in the branch BSSs 4 and 6 , information necessary for transmitting information regarding a spread code or the like at the time of information transmission is selected and decided (step S 3 ). A spread code may be different not only for performing a multicast operation for different information, but also for transmitting identical information at a different time. Then, in each of BSSs 4 to 6 , the starting of information transmission by the multicast operation is notified through the broadcast channel to subordinate MS 2 (step S 4 ). At this time, identification information indicating the selected spread code, information for deriving the spread code or the spread code itself is simultaneously notified. Also, information other than the spread code, which is necessary for data reception by the MS 2 , is notified.
After the starting of the multicast operation has been notified to the MS 2 , with an appropriate time interval, data is transmitted from the anchor BSS 5 through the DHT 12 to the branch BSSs 4 and 6 . Subsequently, in a branch BSS that has received the data transmitted from the BSS 5 , a multicast operation is performed by using the pre-selected and decided spread code (step S 5 ).
In the MSS 1 and 2 , the broadcast channel has been received for receiving the paging of an incoming call during waiting or system information. Upon having received the starting of the multicast operation through the broadcast channel, in the MSs 1 and 2 , the identification information indicating the spread code, the information for deriving the spread code or the spread code itself used for information transmission is received through the broadcast channel of the same BSS.
If the identification information indicating the spread code or the information for deriving the spread code is received, based on the information, the spread code is introduced, and setting is made for data reception based on the spread code. Also, information other than the spread code, which is necessary for data reception, is received.
In the MSs 1 and 2 , after the starting of the multi-cast operation has been recognized based on the information received through the broadcast channel, in order to detect whether the same information is transmitted from surrounding BSSs, a receiving operation is also performed for the notified information transmitted from another BSS. If the transmission of the same information from another BSS is recognized, then setting is made for data reception by the same procedure.
If MS can receive data from a plurality of BSSs, setting is made for performing the RAKE combine.
Other Embodiments
FIG. 4 illustrates a flowchart of another embodiment of a multicast communication method in the CDMA mobile communication system shown in FIGS. 1 and 2 .
First, in the multicast communication server 10 or 11 , when a time comes to transmit accumulated data, information to be transmitted is notified together with area information to be transmitted to the G-MSC 9 or the MSCs 7 and 8 , and a request is made to perform a multicast operation (step S 11 ). Here, if the G-MSC 9 receives a request transmitted from the multicast communication server 10 or 11 , the request is transferred to the MSCs 7 and 8 corresponding to the requested area information. In the G-MSC 9 , this request is copied when necessary, and transferred to a plurality of MSCs.
On the other hand, if the MSCs 7 and 8 receive a request transmitted from the multicast communication server 10 or 11 , the request is transferred to the anchor BSSs 3 and 5 corresponding to the requested area information. In the MSCs 7 and 8 , this request is copied when necessary, and transferred to a plurality of anchor BSSs.
Upon having received the request transferred from the MSC 8 , the anchor BSS 5 hunts the DHT 12 for a multicast operation, and informs the starting of information transmission to surrounding branch BSSs 4 and 6 corresponding to the area for information transmission. Then, links 18 and 19 are established for transmission of the notified information between branch BSSs 4 and 6 (step S 12 ).
Subsequently, in the branch BSSs 4 and 6 , information necessary for transmitting information regarding a spread code or the like at the time of information transmission is selected and decided, and transmitted to the anchor BSS 5 (step S 13 ). A spread code may be different not only for performing a multicast operation for different information, but also for transmitting identical information at a different time. Then, in the anchor BSS 5 , the information transmitted from the branch BSSs 4 and 6 is combined with the information for data transmission, such as the spread code selected and set in the anchor BSS 5 . Then, a list of BSS to which identical information is transmitted, and a list of information regarding the spread code or the like used by each BSS, are made, and notified to the branch BSSs 4 and 6 (step S 14 ).
In the branch BSSs 4 and 6 , when the starting of the multicast operation is notified, the list of BSS to which identical data is transmitted and the list of information regarding the spread code or the like used by BSS are also notified simultaneously, these lists having been received from the anchor BSS 5 . Also, in the anchor BSS 5 , when the starting of the multicast operation is notified, the list of BSS to which identical data is transmitted and the list of information regarding the spread code or the like used by BSS are simultaneously notified (step S 15 ).
After the information transmitted from the BSSs 4 to 6 have been received, in the MS 2 , detection is made as to existence of receivable BSS in the list of BSS to which received identical data is transmitted. If receivable BSS exists, then the information regarding the spread code or the like used by BSS, which has been received beforehand, is used, and setting is made to receive data from a plurality of BSSs.
With a proper time interval from processing in step S 15 , in the anchor BSS 5 , data is transmitted through the DHT 12 to the branch BSS 5 4 and 6 . Then, in the BSS that has received the above data, a multicast operation is performed for the data by using the setting of pre-selected and decided spread code or the like (step S 16 )
Because of the foregoing configuration, the present invention is effective in the following respects.
(1) Signals transmitted from a plurality of base station systems can be combined by performing the RAKE combine in a mobile subscriber locating in the vicinity of the boundary of the cell. Accordingly, even if transmission power is set low in one base station system, a signal strength after RAKE combined in the mobile subscriber can be kept high. Thus, transmission power can be reduced in the base station system that performs a multicast operation.
(2) A multicast operation can be performed without any complex procedures such as a calling operation. A multicast operation can be efficiently performed for a large number of mobile subscribers. | A multicast communication method in a CDMA mobile communication system is disclosed, which is capable of reducing a transmission power in a base station system and performing an efficient multicast operation for a large number of mobile subscribers is provided. Starting of information distribution by a multicast operation and identification of information indicating content are notified through a broadcast channel to a mobile subscriber. Through the broadcast channel, information necessary for actual reception of communication data is notified. In the mobile subscriber, a surround environment of the mobile subscriber is checked to determine the possibility of simultaneous receiving from a plurality of other base station systems. If possible, similar notified information is also received from other base station systems. Thus, all kinds of information regarding the spread code or the like to be used for receiving distributed information are obtained. | 8 |
This is a divisional application of U.S. application Ser. No. 07/478,704 filed Feb. 8, 1990, now pending, which is a file wrapper continuation-in-part of U.S. application 07/111,197, filed Oct. 22, 1987, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention:
The present invention relates to tendons for posttensioned prestressed concrete structures, which can be completely protected from corrosion without requiring grouting, can integrally be incorporated into prestressed concrete structures after being tensioned, and can easily be used for prestressing concrete structures, and also relates to a method of using such tendons.
2. Description of the Prior Art:
In the conventional posttensioning process for forming a prestressed concrete structure, sheaths are arranged prior to the placement of concrete, prestressing steel members such as steel bars, wires or strands are inserted in the sheaths after or before the concrete has set, and then the prestressing steel members are tensioned when the concrete has the desired strength. Then, a cement slurry or the like is injected under pressure into the sheaths for corrosion prevention and for integrally bonding the prestressing steel members to the concrete structure. The insertion of the prestressing steel members into the sheaths and the injection of the cement slurry or the like require very complicated work requiring a long time and much labor and increasing the cost of prestressed concrete structures. Furthermore, since, in most cases, the prestressing tendon is arranged in curvature, it is difficult to fill up the sheaths perfectly with the cement slurry or the like, and hence it is possible that the prestressing steel members in unfilled portions of the sheaths are corroded.
A method of eliminating such disadvantages of the conventional posttensioning process is proposed, for example, in Japanese Pat. Publication No. 53-47609 corresponding to U.S. Pat. No. 3,646,748, in which a prestressing member is formed by coating a steel material with a grease and encasing the steel material coated with the grease in a plastic case. This method completely prevents corrosion of the prestressing steel by grease or the like and makes injection of a cement slurry or the like unnecessary. However, the prestressing steel remains not bonded to the concrete structure after the same has been tensioned. Accordingly, when the prestressing tendon is overloaded temporarily, a load is concentrated on the fixed portions of the prestressing tendon to break the prestressing steel at the fixed portions. Since the prestressing steel is not bonded to the concrete structure, breakage of the prestressing steel, even at a single point thereon, affects the strength of the prestressed concrete structure entirely. Furthermore, the ultimate bending strength of a prestressed concrete structure having an unbonded prestressing tendon is lower than that of an equivalent prestressed concrete structure having a bonded prestressing tendon.
Austrian Pat. No. 201,280 and EP 219,284 propose structure of this general type but which do not teach or disclose a sheath. EP 129,976 shows corrugated sheaths in the drawings, but they are not seamless, and thus lack anticorrosion characteristics. U.S. Pat. No. 4,726,163 to Jacob shows an insulating material 9 in its drawings but this lacks a detailed explanation in the specification. U.S. Pat. No. 3,646,748 to Lano teaches a method of manufacturing a seamless sheath with a long span but does not teach a method of manufacturing a corrugated sheath. Therefore, the prior art is still characterized by difficulty in manufacturing a tendon with a corrugated sheath that is seamless and which has a long span.
SUMMARY OF THE INVENTION
The present invention has been made to eliminate the drawbacks of the conventional prestressing tendon.
Accordingly, it is an object of the present invention to provide tendons for prestressed concrete structures, comprising a core member, capable of perfectly preventing the corrosion of the core member, capable of firmly adhering to concrete and not having a weakness at the fixed portions thereof.
It is another object of the present invention to provide a method of using such tendons.
According to a first aspect of the present invention, the tendon comprises a core member for prestressing a concrete structure, such as a steel wire, a steel strand or a steel bar, and the core member for prestressing a concrete structure is coated with a substantially uniform film of 20 μ or above in thickness of an unset bonding material having a setting time adjusted so that the unset bonding material does not set before the core member is tensioned and sets at an ordinary temperature after the core member has been tensioned and the tendon has been fixed to the concrete structure.
According to a second aspect of the present invention, the tendon comprises a core member for prestressing a concrete structure, such as a steel wire, a steel strand or a steel bar, the core member for prestressing a concrete structure is coated with a film of 20 μ or above in thickness of an unset bonding material having a setting time adjusted so that the unset bonding material does not set before the core structure is tensioned and sets at an ordinary temperature after the core structure has been tensioned and the tendon has been fixed to the concrete structure, and the core member coated with such an unset bonding material is encased in a sheath to facilitate handling.
According to a third aspect of the present invention, the tendon comprises a core member for prestressing a concrete structure, such as a steel wire, a steel strand or a steel bar, the core structure is coated with an unset bonding material, and the adhesion of the core structure is increased after the bonding material has set.
According to a fourth aspect of the present invention, the tendons each comprise a core member for prestressing a concrete structure, such as a steel wire, a steel strand or a steel bar, coated with a film of 20 μ or above in thickness of an unset bonding material having a setting time adjusted so that the unset bonding material does not set before the core member is tensioned and sets at an ordinary temperature after the core member has been tensioned and the tendon has been fixed to the concrete structure are arranged in a predetermined arrangement, concrete is placed, and then the core members are tensioned before the bonding material sets, after the strength of the deposited concrete has increased to a predetermined degree.
According to a fifth aspect of the present invention, the tendons each comprise a core member for prestressing a concrete structure, such as a steel wire, a steel strand or a steel rod, coated with a film of 20 μ or above in thickness of an unset bonding material having a setting time adjusted so that the bonding material does not set before the core structure is tensioned and sets at an ordinary temperature after the core structure has been tensioned and the tendon has been fixed to the concrete structure, and encased in a sheath are arranged in a predetermined arrangement in a mold, concrete is placed, and then the core member is tensioned before the bonding material sets, after the strength of the concrete has increased to a predetermined degree.
Thus, according to the present invention, the setting time of the unset bonding material coating the core member is adjusted so that the bonding material will not set before the tendon is tensioned and will set at an ordinary temperature after the tendon has been tensioned and fixed to the concrete structure, because the uniform propagation of a tensile force applied to the tendon through the entire length of the tendon is obstructed by adhesion of the tendon to the concrete structure if the bonding material sets before the application of a tensile force to the tendon.
Generally, it takes approximately 170 hours after placement for the strength of concrete containing General-Use Cement to increase to a degree to permit tensioning tendons, and approximately 70 hours after placement for the strength of concrete containing High-Early-Strength Cement to increase to such a degree. Accordingly, a bonding material having a setting time adjustable to 70 hours or longer is used preferably for coating the core member and, more preferably, a bonding material having a setting time adjustable to 170 hours or longer is used for coating the core member. This is referred to as a latent normal temperature settable adhesive, meaning a latent settable and normal temperature settable adhesive as described above. A latent adhesive preferably has a setting time adjustable to 70 hours or more, and more preferably, 170 or longer. A normal temperature settable adhesive means that it sets at a normal temperature without being heating before setting. Since it is desirable that the bonding material coating the core member sets quickly after the core structure has been tensioned, it is preferable that the setting time is one year or less.
When the thickness of the film of the unset bonding material coating the core member is less than 20 μ, it is possible that pin holes are developed in the film to deteriorate the corrosion preventing effect of the film, and the film is unable to separate the core member satisfactorily from the concrete structure, so that the frictional resistance of the concrete member to movement of the core member during tensioning operation is increased. When the core member is a steel strand for prestressed concrete structure, the core surface of the core member cannot be coated by the bonding material so as to have a uniform thickness. In such case, the core structure is coated with the bonding material so that the thickness of the thinnest portion of the film is 20 μ or above.
There is no particular restriction on the method of application of the bonding material provided that the core structure is coated with the bonding material in an appropriate thickness; the bonding material may be applied through any suitable coating process, for example, a brush coating process or a dip coating process.
Thus, an unset bonding material prepared so that it will not set before the core member is tensioned is applied to the core members of the tendons, the tendons are arranged in a desired arrangement, concrete is placed, and then the core members are tensioned after the strength of the concrete has reached a degree to permit tensioning the core members. Accordingly, the bonding material does not set before the core members are tensioned and hence the core members are not bonded to the concrete structure before the core members are tensioned, so that the core members can be tensioned uniformly over the entire length. After the core members have been tensioned, the bonding material sets gradually to bond the core members firmly to the concrete structure.
Thus, the present invention provides the following excellent effects.
(A) The core structures ar coated with the bonding material at the place of manufacture, and hence the work necessary for arranging sheaths, inserting the core members into the sheaths and injecting a cement slurry into the sheaths, which has been performed in the conventional posttensioning process, is not necessary, so that labor necessary for forming a prestressed concrete structure and the cost of the prestressed concrete structure are reduced remarkably.
(B) The bonding material coating the core members sets gradually by chemical reaction without requiring any artificial process such as heating, so that neither labor nor an apparatus is necessary for setting the bonding material and no dangerous work is required for forming a prestressed concrete structure.
(C) The core members are coated perfectly with the bonding material and the bonding material sets after the core members have been tensioned, so that the core members are completely prevented from corrosion.
(D) The bonding material sets to bond the core members firmly to the concrete structure, which improves the drawbacks of the unbonded core members incorporated into the concrete structure.
(E) The core members coated with the bonding material can be encased in sheaths, respectively, at the place of manufacture, so that the tendons can be manufactured under sufficient quality control and the corrosion of the core members attributable to the use of an inappropriate grout is positively prevented.
There has not previously existed a tendon with a sheath that has corrugated outer and inner surfaces which is seamless and has a long span due to the fact that it was technically impossible to manufacture a tendon of this type. In the prior art, a tendon with a corrugated sheath would necessarily be of shorter length, that is, less than 20-30 m, and would be fabricated by inserting the core member into the prefabricated ready-made corrugated sheath or winding the tape spirally on the core member.
As recognized in accordance with the present invention, if it becomes possible to manufacture a relatively long span tendon, this would be advantageous in the posttensioning concrete industry. This is because it is desirable to supply a tendon with a length exceeding 20-30 m due to an increase in larger-scale buildings, bridges, highways, etc. and also due to a strong demand for these products.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objects, features and advantages of the present invention will become apparent from the following description taken in conjunction with the accompanying drawings, in which:
FIG. 1 is a fragmentary longitudinal sectional view of a tendon, in a preferred embodiment, according to the present invention;
FIG. 2 is a fragmentary longitudinal sectional view of a tendon, in another embodiment, according to the present invention;
FIG. 3 is a graph showing the variation of setting time with the content of a hardener;
FIG. 4 is a graph showing the variation of the adhesive strength of the core members with the lapse of time after the tendons have been buried in concrete
FIG. 5 is a graph showing the relation between pull-out load and the amount of slip of tendons relative to a concrete cylinder;
FIG. 6 is a graph showing the load-displacement curves of the concrete beams with both ends sustained;
FIG. 7 illustrates the method of manufacturing the tendon with a corrugated sheath;
FIGS. 8a-c and 9 illustrate details of the forming dies and vacuum chamber using the method of FIG. 7 wherein FIG. 8c is a view taken along line A--A in FIG. 8b;
a
FIGS. 10 and 11 show the effect of the forming die on the sheath in the method of FIG. 7;
FIG. 12 shows different types of sheaths used in the method of FIG. 7; and
FIG. 13 shows an alternate embodiment of the conveyors used in the method of FIG. 7.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Embodiment 1
Referring to FIG. 1, a tendon 100, in a first embodiment, according to the present invention comprises a core member 1 and a bonding material 2 coating the core member 1 in a film of a thickness in the range of 0.5 to 1 mm. The core member 1 is a steel strand of 12.7 mm in diameter for prestressed concrete. The bonding material 2 is a mixture of an epoxy resin and 0.3 percent by weight of an amine hardener containing a setting accelerator, having a setting time of approximately six months. Although there is not any particular restriction on the type of the bonding material, preferably, the bonding material 2 is a bonding material containing, as a principal ingredient, an epoxy resin, a polyurethane resin or a polyester resin in the light of sufficient strength of adhesion to the steel core member 1 and the necessity of avoiding the corrosive action of the bonding material 2 on the steel core structure 1.
A plurality of the tendons 100 are arranged in a predetermined arrangement, and then concrete 3 is placed so as to bury the tendons.
Referring to FIG. 3 showing the variation of the setting time of the bonding material 2 with the contents of the hardener, the setting time of the bonding material 2 can be adjusted to an optional time by selectively determining the content of the hardener.
The tendons 100 were arranged in a predetermined arrangement or pattern one month after the manufacture thereof and the concrete 3 was deposited. The tendons 100 thus placed in the concrete 3 were subjected to tensioning tests two months after the manufacture thereof, in which the rate of reduction of tensile force applied to one end of each tendon 100 during propagation to the other end of the tendon 100 was measured.
The results of the tensioning tests are shown in FIG. 4, in which an area 8 represents the variation of the rate of loss of tensile force as compared with the lapse of time with the tendons 100 of the present invention, and an area 7 represents the variation of the rate of loss of tensile force as compared with the lapse of time with conventional unbonded tendons each comprising a steel strand for prestressed concrete subjected to the tensioning tests as controls. As is obvious from FIG. 4, the rate of loss of tensile force applied to one end of the tendon 100 of the present invention remains at a low level, substantially the same as that of the conventional unbonded tendon within six months after the manufacture. The rate of loss with the tendons 100 starts increasing from a period of time six months after manufacture, which infers that the core members 1 of the tendons 100 are bonded firmly to the concrete 3 six months after manufacture. Thus, the tendon 100 of the present invention can be tensioned satisfactorily within six months after the manufacture.
Although the setting time of the bonding material 2 of the second embodiment is adjusted to six months, the setting time of the bonding material 2 can be adjusted to an optional time by properly determining the contents of the ingredients thereof taking into consideration the time in which the strength of the concrete 3 increases to a value to permit tensioning the tendon.
The tendons 100 were subjected further to pullout tests, in which a pulling force was applied to the tendons 100 after the bonding material 2 had set and the slip of the tendons 100 relative to the concrete 3 was measured. Measured results are shown in FIG. 5, in which a curve 10 represents the relation between the pulling force applied to steel strands for prestressed concrete buried directly in concrete and the average slip of the steel strands relative to the concrete, and a curve 11 represents the relation between the pulling force applied to the tendons 100 coated with an unset bonding adhesive without covering by a sheath, curve 12 represent the relation between pulling force and the average slip for steel strands covered by a sheath of polyethylene with both inner and outer surfaces corrugated in accordance with the present invention, while curve 16 shows a similar relation where the steel strands are covered by a sheath of polyethylene with both inner and outer surfaces made flat and curve 17 shows the relation where the steel strands are covered by the sheath of polyethylene with the outer surface corrugated.
As is obvious from FIG. 5, the average maximum adhesive strength of 95.4 kg/cm 2 , namely, a pulling force to which the adhesive strength of the tendon yielded, of the tendon 100 of the present invention is far greater than the average maximum adhesive strength of 46.6 kg/cm 2 of the control. It is also clear from FIG. 5 that the product manufactured by the present invention (i.e., line 12) is superior to other products. To gain the test result of line 12 of FIG. 5, it is very important that the depth of the indented portions of the plastic sheath exceeds the thickness of the plastic forming the sheath, as shown in FIG. 12a and to avoid having a depth which is too thin as shown in FIG. 12b.
Embodiment 2
Referring to FIG. 2, showing a tendon 200, in a second embodiment, according to the present invention, the tendon 200 comprises a core member 1, which is similar to that of the first embodiment, a bonding material 2 coating the core member 1, and a corrugated sheath 4 encasing the core steel 1 coated with the bonding material 2 therein. A plurality of the tendons 200 are arranged in a predetermined arrangement, and then the concrete 3 is placed.
The bonding material 2 of the second embodiment is the same as that of the first embodiment. The setting time of the bonding material 2 is approximately six months.
The core member 1 is a steel strand of 12.7 mm in diameter for prestressed concrete. The core member 1 was dipped in the bonding material 2 to coat the core member 1 with the bonding material 2 to a thickness in the range of 0.5 to 1 mm.
Although the sheath 4 is formed of a polyethylene resin in this embodiment, the sheath 4 may be formed of any suitable resin or an ordinary metal such as a steel. The sheath 4 is corrugated to restrain the sheath 4 from axial movement relative to the concrete 3.
The tendons 200 were subjected to pull-out tests. The test procedures were the same as those taken for testing the adhesive strength of the tendons 100 of the first embodiment. The results of the pull-out tests are represented by a curve 12 in FIG. 5. The average maximum adhesive strength of the tendons 200 is 96.0 kg/cm 2 , which is far greater than that of the conventional tendons.
The prestressed concrete test beams A incorporating the tendons 200, prestressed concrete test beams incorporating steel strands of 12.7 mm in diameter for prestressed concrete and fabricated through the ordinary pottensioning process and the cement grouting process, and the prestressed concrete test beams C incorporating unbonded steel strands for prestressed concrete were subjected to bending tests specified in JIS (Japanese Industrial Standards) A 1106. Test results are shown in FIG. 6, in which curves 13, 14 and 15 are load-displacement curves respectively for the prestressed concrete test beams A, B and C. As is obvious from FIG. 6, the prestressed concrete test beams A and B are substantially the same in bending strength and load-displacement characteristics, and the bending characteristics of the prestressed concrete test beam A are superior to those of the prestressed concrete test beams C.
To meet the requirement of supplying, for example, 202 tendons having a length of 70 m for constructing an office building, P. C. strands having a length of 1,510 m were manufactured by the method of this invention, and were wound on reels for storage. Then the P. C. strands were cut to a length of 70 m each after feeding them out from the reels, and anchorages were attached to the end of each strand. It took only 8 hours to finish this operation. Though this was completed at a factory, it was also possible to do it at the construction site.
By comparison, using the method of the prior art, it would take about 160 hours to finish this operation. This is because in the prior art the P. C. strands are cut to the predetermined length, the corrugated sheaths are prepared with a predetermined length, the P. C. strand is inserted into the sheath, the interstices are filled between the P. C. strand and the sheath is filled with an unset bonding adhesive and the anchorage is attached to the end of each P. C. strand. As mentioned below, insertion of P. C. strand into the sheath is very difficult when the length of P. C. strand exceeds 20-30 m.
The method of manufacturing the tendon with a corrugated sheath will now be described.
FIG. 7 illustrates the manufacturing process of the tendon in accordance with this invention. A wire strand core member 1 is passed into the pressure chamber 20 filled with an unset resin 2 and excess unset resin is removed by a circular die 21 at the outlet of the chamber 20.
Then, the core member 1 coated uniformly with the resin 2 passes through the throat 22 of the tubing die 23. A molten thermoplastic polymer 24 is extruded as a tube around the coated core member 1.
After completion of this process, the plastic polymer 24 shrinks and forms a seamless plastic sheath around said core member 1. While the extruded plastic polymer 24 is still hot, the tendon is passed between the forming dies 25 attached to a caterpillar or a pair of endless conveyors, and is pressed and deformed to some extent as shown in FIG. 10 which illustrates the inlet of the caterpillar and die 25. In this stage, because unset resin 2 exists in the inner side of the sheath 4, the inner surface of the plastic sheath is not deformed enough but protrudes slightly due to the pressure of pressed resin 2. Therefore, it is necessary to apply suction to the outer surface of the sheath 4 by the vacuum pump to form corrugated surfaces on both the inside and outside surface of the sheath 4. The extent of vacuum applied may be adjusted according to the strength and thickness of the sheath.
The forming die 25 has holes 26 connected to the vacuum chamber 32 as shown in FIGS. 8 and 9. The vacuum chamber 32 is kept under a vacuum by the operation of the vacuum pump 33. When the tendon passes this portion of the caterpillar, the outer surface of the plastic sheath undergoes suction by operating the vacuum pump 33 and is shaped as shown in FIG. 11 along the contacted surface of the forming die. After this, the tendon is passed into a cooling bath 28 and the plastic sheath is cooled and hardened quickly. As a result a corrugated sheath can be provided.
It is also possible to make the corrugated surfaces by passing the tendon between vertically indented rollers 40 and then rollers 42 set horizontally as shown in FIG. 13.
The moving speed of the tendon, the extruding speed of thermoplastic polymer and the distance from the extruding die to the caterpillar are adjusted so as to keep the temperature of the thermoplastic polymer adequate for forming and maintaining the outward shape.
Although the invention has been described in its preferred form with a certain degree of particularity, many changes and variations are possible without departing from the spirit and scope thereof. It is therefore to be understood that the invention is not limited to the specific embodiments thereof except as defined in the appended claims. | A tendon for prestressed concrete structure comprises a core member such as a steel wire for prestressed concrete structures, a steel strand for prestressed concrete structures or a steel bar for prestressed concrete structures, and an unset bonding material coating the core structure in a predetermined thickness, having a specific setting time determined by selectively determining the respective contents of the ingredient of the bonding material and capable of setting at an ordinary temperature. The tendon is arranged in a desired arrangement for forming a prestressed concrete structure, concrete is placed so as to bury the tendons therein, and then the tendons are tensioned and fixed after the strength of the deposited concrete has increased to a degree to permit tensioning the tendons and before the unset bonding material sets. Thus, the unset bonding material sets after the tendons have been tensioned and fixed to bond the tendons firmly to the prestressed concrete structure. | 4 |
CROSS-REFERENCE TO RELATED APPLICATION
The present application claims priority from and is a divisional of U.S. patent application Ser. No. 10/394,076, filed Mar. 21, 2003 now U.S. Pat. No. 7,327,957, which claims priority under 35 U.S.C. 119 from Republic of Korea patent application number 2002-24493, filed May 3, 2002.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a light source providing a wavelength-selective output. In more detail, it relates to a wavelength-tunable light source whose output wavelength can be externally controlled and a wavelength-division multiplexed (WDM) transmission system using the source.
2. Description of the Related Art
The light source providing output at a specific wavelength is one of the key-elements of a wavelength-division multiplexed transmission system, in which each channel is discriminated by its wavelength.
In order to minimize the interference between adjacent channels, the light source of wavelength-division multiplexed transmission system should have a stable wavelength and a sufficient side mode suppression ratio (SMSR). It is also desirable to have a high output power and a narrow line width.
A distributed feed-back laser diode (DFBLD) is a representative light source in the prior art that meets the requirements described above.
However, the DFBLD is very expensive and requires a complicated control process to fix its output wavelength at a specified point. A spectrum-sliced system, which uses a broad-band light source instead of wavelength-specified light source, has been demonstrated to reduce the cost and the complexity of system.
Incoherent broad-band light sources (ILSs) such as a light emitting diode (LED), a super-luminescent diode (SLD), and optical amplifiers emitting amplified spontaneous emissions (ASEs) are representative light sources being used for spectrum-sliced system. Spectrum-sliced systems using these light sources are very attractive since they are able to simply the wavelength control process compared with the distributed feed-back laser diode.
U.S. Pat. No. 5,440,417 (System for spectrum-sliced fiber amplifier light for multi-channel wavelength-division-multiplexed applications) discloses a method of spectrum-slicing by using optical amplifier light source. And U.S. Pat. No. 5,694,234 (Wavelength division multiplexing passive optical network including broadcast overlay) discloses a spectrum-sliced system by using a directly-modulated LED.
However, they also have several disadvantages. For example, LED or an SLD hardly provides sufficient output power and an optical amplifier light source requires an expensive external modulator even though its output power is comparatively large.
That is to say, the system presented in U.S. Pat. No. 5,440,417 requires an additional external modulator and the system presented in U.S. Pat. No. 5,694,234 hardly provides sufficient output power.
On the other hand, a wavelength-tunable light source improves the functionality of a wavelength-division multiplexed transmission system.
One can tune the output wavelength of a distributed feed-back laser diode (DFBLD) by temperature control, however, the tunable wavelength range is only about a few nanometers in 1270˜1600 nm band, the low-loss wavelength regime of a general silica-based single mode fiber.
Therefore, wavelength-tunable light sources employing an external cavity have been mainly studied in the prior art, however, they are costly and require complex devices to tune the output wavelength.
SUMMARY OF THE INVENTION
The present invention is proposed to solve the problems of the prior art mentioned above. The present invention presents a wavelength-tunable light source using a Fabry-Perot laser diode and a wavelength-division multiplexed transmission system employing the light source.
A Fabry-Perot laser diode can provide higher output power than both LED and SLD and is relative simple to manufacture compared with a distributed feed-back laser diode (DFBLD). However, it had not been used for a wavelength-division multiplexed transmission system since it is a multi-mode light source.
However, KR Patent 1003256870000 (A light source for wavelength-division multiplexed telecommunication system using a Fabry-Perot laser diode wavelength-locked by an injected incoherent light, registered at Feb. 8, 2002) presents a method to obtain a wavelength-selective output by using a Fabry-Perot laser diode. By externally injecting a narrow-band light into a Fabry-Perot laser diode, the side mode suppression ratio increased and a high output power at a specific wavelength is obtainable.
As described above, a wavelength-tunable light source in accordance with the present invention is constituted to be able to tune the output wavelength by controlling the wavelength of the externally injected light.
With this characteristic, the characteristics of the wavelength-tunable light source such as side mode suppression ratio, noise property, output power and output spectrum also can be controlled by controlling the bias current supplied to the Fabry-Perot laser diode.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram of an embodiment of a wavelength-tunable light source in accordance with the present invention.
FIG. 2 is a schematic diagram of an experimental setup for measuring the characteristics of an embodiment of a wavelength-tunable light source in accordance with the present invention.
FIG. 3 a .˜ FIG. 3 c are optical spectra measured by the experimental setup described in FIG. 2 .
FIG. 4 a .˜ FIG. 4 b are optical spectra measured by the experimental setup described in FIG. 2 with a different optical filter.
FIG. 5 a is an experimental setup for measuring an eye diagram in a prior spectrum-sliced system and FIG. 5 b is an experimental setup for measuring an eye diagram of a light source in accordance with the present invention.
FIG. 6 a and FIG. 6 b are eye diagrams measured by the experimental setup described in FIG. 5 a and FIG. 5 b respectively.
FIG. 7 is the first embodiment of a wavelength-division multiplexed transmission system in accordance with the present invention.
FIG. 8 is the second embodiment of a wavelength-division multiplexed transmission system in accordance with the present invention.
FIG. 9 is the third embodiment of a wavelength-division multiplexed transmission system in accordance with the present invention.
FIG. 10 is the fourth embodiment of a wavelength-division multiplexed transmission system in accordance with the present invention.
FIG. 11 is the fifth embodiment of a wavelength-division multiplexed transmission system using a light source in accordance with the present invention.
DESCRIPTION OF THE NUMERALS (SYMBOLS) ON THE MAIN PARTS OF THE DRAWINGS
100 : an optical transmission system
BLS: a broad-band light source
EDFA: a two-stage Erbium-doped fiber amplifier
(D)MUX 1 : a 2N×1 (de)multiplexer
(D)MUX 2 : an N×1 (de)multiplexer
DR: a laser diode driving circuit
EM: an external modulator
EMDR: an external modulator driving circuit
FPLD: a Fabry-Perot laser diode
IL: an wavelength interleaver
OC: an optical circulator
OSA: an optical spectrum analyzer
OSC: an oscilloscope
RX: an optical receiver
TBPF: a tunable band-pass filter
TEC: a temperature controller
WDM: a wavelength-division multiplexer
DETAILED DESCRIPTION OF THE EMBODIMENTS
Hereinafter, referring to appended drawings, the structures and operation principles of embodiments of the present invention are described in detail.
As described in FIG. 1 , a wavelength-tunable light source in accordance with the present invention comprises a broad-band light source (BLS), a tunable band-pass filter (TBPF), an optical circulator and a Fabry-Perot laser diode.
Here, a broad-band light source is either one of a incoherent light sources such as a fiber optical amplifier emitting amplified spontaneous emissions, a semiconductor optical amplifier, a light emitting diode and a super-luminescent or a coherent light source super continuum source.
It is desirable that a Fabry-Perot laser diode (FPLD) should not contain an optical isolator for a efficient light injection.
A tunable band-pass filter (TBPF) selectively passes the light to be injected.
A Fabry-Perot laser diode (FPLD) is a multi-mode light source without an external light being injected thereto, however, if a light is injected thereto from outside, among the oscillation modes of the Fabry-Perot laser diode, a mode or modes within the range of the injected light will output relatively high power while the modes out of the range will be suppressed.
Consequently, a wavelength-selective output is outputted through an optical circulator (OC) connected to a Fabry-Perot laser diode (FPLD).
Here, since the output wavelength of the light source is determined by the light injected into a Fabry-Perot laser diode (FPLD), it can be tuned by controlling the band-pass of a tunable band-pass filter (TBPF).
The wavelengths of cavity modes of a Fabry-Perot laser diode (FPLD) vary according to the temperature of the Fabry-Perot laser diode.
With this characteristic, the characteristics of a wavelength-tunable light source such as side mode suppression ratio, noise property, output power, and output spectrum can be controlled by controlling the bias current supplied to the Fabry-Perot laser diode (FPLD).
In addition, the characteristics of a wavelength-tunable light source such as side mode suppression ratio, noise property, output power, and output spectrum also can be controlled by controlling the current of a Fabry-Perot laser diode (FPLD).
The output power of the wavelength-tunable light source varies as the bias current applied to a Fabry-Perot laser diode (FPLD).
Thus, a wavelength-tunable light source can be modulated not only by using an external modulator but also directly.
If an appropriate current is being applied to a Fabry-Perot laser diode (FPLD), the output of a wavelength-tunable light source is polarized, however, the reflected injection light can be unpolarized.
With this characteristic, the extinction ratio of a modulated optical signal can be improved by additionally installing a polarization controller and a polarizer at the output port of an optical circulator (OC).
That is to say, by controlling a polarization controller for the output power of a wavelength-tunable light source to be maximized, the extinction ratio of the output of a wavelength-tunable light source can be maximized.
In a light source in accordance with the present invention, an optical circulator (OC) is used to reduce optical insertion losses.
However, even though an optical circulator (OC) is substituted with a low-cost optical power combiner, a light source having the similar characteristics can be achieved.
FIG. 2 shows an experimental setup for measuring the characteristics of an embodiment of a wavelength-tunable light source in accordance with the present invention.
A two-stage Erbium-doped fiber amplifier (EDFA) is used for an broad-band light source (BLS) in FIG. 1 , and a Fabry-Perot etalon filter is used for a tunable band-pass filter (TBPF).
The two-stage Erbium-doped fiber amplifier (EDFA) outputs amplified spontaneous emission (ASE), which is a incoherent light having a band-width larger than 30 nm.
A Fabry-Perot etalon filter (FPEF) with a 3-dB band-width of about 2.5 GHz selectively passes erbium-doped fiber amplifier (EDFA) output and the pass-band can be controlled by applying the voltage.
The power of the incoherent light injected into a Fabry-Perot laser diode (FPLD) through an optical circulator (OC) is −2 dBm, the threshold current of the Fabry-Perot laser diode (FPLD) is 10 mA, and a bias current of 17 mA is applied thereto.
The cavity length of the Fabry-Perot laser diode (FPLD) is about 400 um and the mode spacing is about 100 GHz, which corresponds to 40 times of the 3-dB band-width of the Fabry-Perot etalon filter (FPEF).
In the figure, OSA represents an optical spectrum analyzer.
FIG. 3 a shows output spectra of a Fabry-Perot laser diode (FPLD) measured without an ASE injection, FIG. 3 b shows the spectra of lights injected into a Fabry-Perot laser diode, and FIG. 3 c shows the output spectra of a wavelength-tunable light source after the lights in FIG. 3 b being injected thereto respectively.
The peak wavelengths of the lights injected into a Fabry-Perot laser diode (FPLD) are 1530 nm, 1545 nm and 1560 nm, respectively, and the temperature of the Fabry-Perot laser diode (FPLD) was set for the side mode suppression ratio measured in FIG. 3 c to be maximized in each case.
After a light injection, a Fabry-Perot laser diode provides a wavelength-selected output with a specific wavelength according to the wavelength of the injected light. The side mode suppression ratios measured are more than 30 dB and the output powers were about 0 dBm.
Therefore, it can be noticed that a light source in accordance with the present invention provides a narrow-band output with about more than 30 nm of wavelength-tunable range.
FIG. 4 a is an optical spectrum measured by the experimental setup described in FIG. 2 with a different optical filter, whose 3-dB bandwidth is about 100 GHz.
The center wavelength of the filter is about 1558.8 nm.
Here, the 3-dB bandwidth of the filter is comparable to the mode spacing of a of the Fabry-Perot laser diode (FPLD). In general, the light source in accordance with the present invention is can be realized while a light with a 3-dB bandwidth of several times of the mode spacing of Fabry-Perot laser diode is injected into the Fabry-Perot laser diode.
FIG. 4 b is an optical spectrum measured by the same experimental setup, however, the temperature of the Fabry-Perot laser diode is tuned in order that the center wavelength of the injected light corresponds to the a mid-point of two cavity modes.
In this case, the light source provides a wavelength-selective output.
A Fabry-Perot laser diode (FPLD) used for a wavelength-tunable light source in accordance with the present invention can suppress the intensity noise of an injected incoherent light.
That is to say, as presented in the paper by Jae-Seung Lee (“Signal-to-noise ratio measurement of a 2.5-Gb/s spectrum-sliced incoherent light channel”, IEEE Photon. Technol. Lett ., vol. 1, no. 1, pp. 94-96, 1997), a spectrum-sliced incoherent light has a large intensity noise.
This kind of intensity noise degrades the performance of a spectrum-sliced system.
In a wavelength-tunable light source in accordance with the present invention, a Fabry-Perot laser diode suppresses intensity noise of the injected incoherent light.
An experimental setup can be constituted for confirming this characteristic as described in FIG. 5 .
The experimental setup described in FIG. 5 a is for a prior spectrum-sliced system, which uses an external modulator (EM) followed by a tunable band-pass filter (TBPF) modulates narrow-band incoherent filter and thereafter measures its eye diagram using an oscilloscope (OSC).
The experimental setup described in FIG. 5 b is for a wavelength-tunable light source in accordance with the present invention, which injects an incoherent into a Fabry-Perot laser diode (FPLD), directly modulates the Fabry-Perot laser diode, and thereafter measures its eye diagram using an oscilloscope (OSC).
A Fabry-Perot etalon filter (FPEF) with a 3-dB bandwidth of about 2.5 GHz was used as a tunable band-pass filter (TBPF).
In both cases, the modulation bit rate were 622 Mb/s and the length of pseudo-random block signal (PRBS) applied to the external modulator or the Fabry-Perot laser diode (FPLD) was 2 31 −1.
FIG. 6 a and FIG. 6 b are showing the eye diagrams measured in both cases respectively. Referring to the figures, it can be noticed that a wavelength-tunable light source in accordance with the present invention is suppressing the intensity noise of the incoherent light.
As mentioned thereinbefore, a wavelength-tunable light source in accordance with the present invention can be used for various applications in a wavelength-division multiplexed transmission system.
FIG. 7 shows the first embodiment of a wavelength-division multiplexed transmission system using a light source in accordance with the present invention, which outputs N first-group wavelength-division-multiplexed optical signals (λ 1 , λ 3 , . . . , λ 2N−1 ) through an optical fiber and receives N second-group wavelength-division-multiplexed optical signals (λ 2 , λ 4 , . . . , λ 2N ) inputted through the fiber.
As described in FIG. 7 , a wavelength-division multiplexed transmission system in accordance with the present invention comprises N Fabry-Perot laser diodes (FPLD 1 , FPLD 2 , . . . , FPLDn), N laser diode driving circuits (DR 1 , DR 2 , . . . , DRn), N laser diode temperature controllers (TEC 1 , TEC 2 , . . . , TECn), N optical receivers (RX 1 , RX 2 , . . . , RXn), a 2N×1 (de)multiplexer ((D)MUX 1 ), a (de)multiplexer temperature controller (TEC), two wavelength interleavers (IL 1 , IL 2 ), an optical circulator (OC) and an broad-band light source (BLS).
A (de)multiplexer ((D)MUX 1 ) demultiplexes wavelength-division multiplexed optical signals inputted through a common and outputs them through 2N input/output ports respectively. Or, it multiplexes the optical signals having different wavelengths, which are inputted through 2N input/output ports respectively, and outputs them through the common port.
The wavelengths of the first-group optical signals (λ 1 , λ 3 , . . . , λ 2N−1 ) and the second-group optical signals (λ 2 , λ 4 , . . . , λ 2N ) are arranged to be interlaid. The first-group optical signals (λ 1 , λ 3 , . . . , λ 2N−1 ) can be transferred between a common port and odd-numbered ports (1, 3, . . . , 2N−1) of a (de)multiplexer ((D)MUX 1 ) and the second-group optical signals (λ 2 , λ 4 , . . . , λ 2N ) can be transferred between a common port and even-numbered ports (2, 4, . . . , 2N) of a (de)multiplexer.
An broad-band light source (BLS) emits a wide-band light.
The optical circulator (OC) outputs the optical signals inputted through the first port through the second port and the optical signals inputted through the second port through the third port.
The wavelength interleavers (IL 1 , IL 2 ) transfer the first-group optical signals (λ 1 , λ 3 , . . . , λ 2N−1 ) and block the second-group optical signals (λ 2 , λ 4 , . . . , λ 2N ) between the first port and the second port, and on the other hand, they transfer the second-group optical signals (λ 2 , λ 4 , . . . , λ 2N ) and block the first-group optical signals (λ 1 , λ 3 , . . . , λ 2N−1 ) between the first port and the third port.
The connection of a transmission system ( 100 ) described above can be performed as follows:
N Fabry-Perot laser diodes (FPLD 1 , FPLD 2 , . . . , FPLDn) are connected to the odd-numbered ports of a (de)multiplexer ((D)MUX 1 ), and N optical receivers (RX 1 , RX 2 , . . . , RXn) are connected to the even-numbered ports of the (de)multiplexer ((D)MUX 1 ) respectively.
The common port of a (de)multiplexer ((D)MUX 1 ) is connected to the first port of a first wavelength interleaver (IL 1 ), the second port of the first wavelength interleaver (IL 1 ) is connected to the second port of an optical circulator (OC), the first port of the optical circulator (OC) is connected to an broad-band light source (BLS) and the third port of the optical circulator (OC) is connected to the second port of a second wavelength interleaver (IL 2 ).
The third port of the first wavelength interleaver (IL 1 ) and the third port of the second wavelength interleaver (IL 2 ) are connected to each other, and the first port of the second wavelength interleaver (IL 2 ) becomes an output port of a transmission system ( 100 ).
Looking into the operation principle of a transmission system ( 100 ), an broad-band light source (BLS) emits a wide-band light, the emitted light is then inputted through the first port of an optical circulator (OC), passing through the second port, and then inputted into the second port of a first wavelength interleaver (IL 1 ).
Then, the first wavelength interleaver (IL 1 ) outputs some portion of the inputted wide-band light through the first port.
The output from the first wavelength interleaver (IL 1 ) is inputted into the common port of a (de)multiplexer ((D)MUX 1 ), and outputted through corresponding odd-numbered ports of the (de)multiplexer ((D)MUX 1 ) respectively.
The outputs from the (de)multiplexer ((D)MUX 1 ) are inputted into N Fabry-Perot laser diodes (FPLD 1 , FPLD 2 , . . . , FPLDn) respectively, and then N Fabry-Perot laser diodes (FPLD 1 , FPLD 2 , . . . , FPLDn) output first-group optical signals (λ 1 , λ 3 , . . . , λ 2N−1 ) whose wavelengths are within the pass-bands of the odd-numbered ports of the (de)multiplexer ((D)MUX 1 ) respectively.
The first-group optical signals (λ 1 , λ 3 , . . . , λ 2N−1 ) are multiplexed by the (de)multiplexer ((D)MUX 1 ), and then inputted into the first port of the first wavelength interleaver (IL 1 ).
The first-group optical signals (λ 1 , λ 3 , . . . , λ 2N−1 ) inputted into the first wavelength interleaver (IL 1 ) are outputted through the second port, passing through the second port and the third port of the optical circulator (OC), and then inputted into the second port of a second wavelength interleaver (IL 2 ) to be outputted through the first port of the second wavelength interleaver (IL 2 ).
The second-group optical signals (λ 2 , λ 4 , . . . , λ 2N ) inputted into the first port of the second wavelength interleaver (IL 2 ) are outputted through the third port, and then inputted into the third port of the first wavelength interleaver (IL 1 ) to be outputted through the first port, and thereafter inputted into the common port of the (de)multiplexer ((D)MUX 1 ).
The second-group optical signals (λ 2 , λ 4 , . . . , λ 2N ) inputted through the common port are outputted through the corresponding even-numbered ports of the (de)multiplexer ((D)MUX 1 ), and then received by optical receivers (RX 1 , RX 2 , . . . , RXn) respectively.
Here, the transmission system ( 100 ) may further comprise N laser diode driving circuits (DR 1 , DR 2 , . . . , DRn) to modulate N Fabry-Perot laser diodes N Fabry-Perot laser diodes (FPLD 1 , FPLD 2 , . . . , FPLDn), N laser diode temperature controllers (TEC 1 , TEC 2 , . . . , TECn) for controlling the temperatures of N Fabry-Perot laser diodes (FPLD 1 , FPLD 2 , . . . , FPLDn) and a temperature controller (TEC) for controlling the temperature of the (de)multiplexer ((D)MUX 1 ).
FIG. 8 shows the second embodiment of, a wavelength-division multiplexed transmission system using a light source in accordance with the present invention, which outputs N third-group wavelength-division-multiplexed optical signals (λ 1 , λ 2 , . . . , λ 2N ) through an optical fiber and receives N fourth-group wavelength-division-multiplexed optical signals (λ N+1 , λ N+2 , . . . , λ 2N ) inputted through the fiber.
As described in FIG. 8 , a wavelength-division multiplexed transmission system in accordance with the present invention comprises N Fabry-Perot laser diodes (FPLD 1 , FPLD 2 , . . . , FPLDn), N laser diode driving circuits (DR 1 , DR 2 , . . . , DRn), N laser diode temperature controllers (TEC 1 , TEC 2 , . . . , TECn), N optical receivers (RX 1 , RX 2 , . . . , RXn), a 2N×1 (de)multiplexer ((D)MUX 1 ), a (de)multiplexer temperature controller (TEC), two wavelength-division multiplexers (WDM 1 , WDM 2 ), an optical circulator (OC) and an broad-band light source (BLS).
A (de)multiplexer ((D)MUX 1 ) demultiplexes wavelength-division multiplexed optical signals inputted through a common port and outputs them through 2N input/output ports respectively. Or, it multiplexes the optical signals having different wavelengths, which are inputted through 2N input/output ports respectively, and outputs them through the common port.
The wavelengths of the third-group optical signals (λ 1 , λ 2 , . . . , λ N ) and the fourth-group optical signals (λ N+1 , λ N+2 . . . , λ 2N ) are arranged in different wavelength-bands respectively. The third-group optical signals (λ 1 , λ 2 , . . . , λ N ) can be transferred between a common port and the (first˜N-th) ports of a (de)multiplexer ((D)MUX 1 ) and the fourth-group optical signals (λ N+1 , λ N+2 , . . . , λ 2N ) can be transferred between a common port and the (N+1-th˜2N-th) ports of a (de)multiplexer.
An broad-band light source (BLS) emits a wide-band light.
The optical circulator (OC) outputs the optical signals inputted through the first port through the second port and the optical signals inputted through the second port through the third port.
The wavelength-division multiplexers (WDM 1 , WDM 2 ) transfer the third-group optical signals (λ 1 , λ 2 , . . . , λ N ) and block the fourth-group optical signals (λ N+1 , λ N+2 , . . . , λ 2N ) between the first port and the second port, and on the other hand, they transfer the fourth-group optical signals (λ N+1 , λ N+2 , . . . , λ 2N ) and block the third-group optical signals (λ 1 , λ 2 , . . . , λ N ) between the first port and the third port.
The connection of a transmission system ( 100 ) described above can be performed as follows:
N Fabry-Perot laser diodes (FPLD 1 , FPLD 2 , . . . , FPLDn) are, connected to the (first˜N-th) ports of a (de)multiplexer ((D)MUX 1 ), and N optical receivers (RX 1 , RX 2 , . . . , RXn) are connected to the (N+1-th˜2N-th) ports of the (de)multiplexer ((D)MUX 1 ) respectively.
The common port of a (de)multiplexer ((D)MUX 1 ) is connected to the first port of a first wavelength-division multiplexer (WDM 1 ), the second port of the first wavelength-division multiplexer (WDM 1 ) is connected to the second port of an optical circulator (OC), the first port of the optical circulator (OC) is connected to an broad-band light source (BLS) and the third port of the optical circulator (OC) is connected to the second port of a second wavelength-division multiplexer (WDM 2 ).
The third port of the first wavelength-division multiplexer (WDM 1 ) and the third port of the second wavelength-division multiplexer (WDM 2 ) are connected to each other, and the first port of the second wavelength-division multiplexer (WDM 2 ) becomes an output port of a transmission system ( 100 ).
Looking into the operation principle of a transmission system ( 106 ), the output of an broad-band light source (BLS) is inputted through: the first port of an optical circulator (OC), passing through the second port, and then inputted into the second port of a first wavelength-division multiplexer (WDM 1 ).
Then, the first wavelength-division multiplexer (WDM 1 ) outputs some portion of the inputted wide-band light through the first port.
The output from the first wavelength-division multiplexer (WDM 1 ) is inputted into the common port of a (de)multiplexer ((D)MUX 1 ), and outputted through the corresponding (first˜N-th) ports of the (de)multiplexer ((D)MUX 1 ) respectively.
The outputs from the (de)multiplexer ((D)MUX 1 ) are inputted into N Fabry-Perot laser diodes (FPLD 1 , FPLD 2 , . . . , FPLDn) respectively, and then N Fabry-Perot laser diodes (FPLD 1 , FPLD 2 , . . . , FPLDn) output third-group optical signals (λ 1 , λ 2 , . . . , λ N ) whose wavelengths are within the pass-bands of the (first˜N-th) ports of the (de)multiplexer ((D)MUX 1 ) respectively.
The third-group optical signals (λ 1 , λ 2 , . . . , λ N ) are multiplexed by the (de)multiplexer ((D)MUX 1 ), and then inputted into the first port of the first wavelength-division multiplexer (WDM 1 ).
The third-group optical signals (λ 1 , λ 2 . . . , λ N ) inputted into the first wavelength-division multiplexer (WDM 1 ) are outputted through the second port, passing through the second port and the third port of the optical circulator (OC), and then inputted into the second port of a second wavelength-division multiplexer (WDM 2 ) to be outputted through the first port of the second wavelength-division multiplexer (WDM 2 ).
The fourth-group optical signals (λ N+1 , λ N+2 , . . . , λ 2N ) inputted into the first port of the second wavelength-division multiplexer (WDM 2 ) are outputted through the third port, and then inputted into the third port of, the first wavelength-division multiplexer (WDM 1 ) to be outputted through the first port, and thereafter inputted into the common port of the (de)multiplexer ((D)MUX 1 ).
Then, the signals inputted through the common port are outputted through the corresponding (N+1-th˜2N-th) ports of the (de)multiplexer ((D)MUX 1 ) and received by optical receivers (RX 1 , RX 2 , RXn) connected to the ports respectively.
Here, the transmission system ( 100 ) may further comprise N laser diode driving circuits (DR 1 , DR 2 , . . . , DRn) to modulate N Fabry-Perot laser diodes (FPLD 1 , FPLD 2 , . . . , FPLDn), N laser diode temperature controllers (TEC 1 , TEC 2 , . . . , TECn) for controlling the temperatures of N Fabry-Perot laser diodes (FPLD 1 , FPLD 2 , . . . , FPLDn) and a temperature controller (TEC) for controlling the temperature of the (de)multiplexer ((D)MUX 1 ).
FIG. 9 shows a third embodiment of a wavelength-division multiplexed transmission system using a light source in accordance with the present invention, which outputs N fifth-group wavelength-division-multiplexed optical signals (λ 1 , λ 2 , . . . , λ N ) through an optical fiber and receives N sixth-group wavelength-division-multiplexed optical signals (λ N+1 , λ N+2 , . . . , λ 2N ) inputted through the fiber.
As described in FIG. 9 , a wavelength-division multiplexed transmission system in accordance with the present invention comprises N Fabry-Perot laser diodes (FPLD 1 , FPLD 2 , . . . , FPLDn), N laser diode driving circuits (DR 1 , DR 2 , . . . , DRn), N laser diode temperature controllers (TEC 1 , TEC 2 , . . . , TECn), N optical receivers (RX 1 , RX 2 , . . . , RXn), an N×1 (de)multiplexer ((D)MUX 2 ), a (de)multiplexer temperature controller (TEC), (N+2) wavelength-division multiplexers (WDM 1 , . . . , WDMn +1 , WDMn +2 ), an optical circulator (OC) and an broad-band light source (BLS).
A (de)multiplexer ((D)MUX 2 ) demultiplexes wavelength-division multiplexed optical signals inputted through a common port and outputs them through N input/output ports respectively. Or, it multiplexes the optical signals having different wavelengths, which are inputted through N input/output ports respectively, and outputs them through the common port. Here, the signal transfer characteristics between the common port and each input/output port are repeated with a wavelength interval of I(an arbitrary integer) times the free spectral range of the (de)multiplexer ((D)MUX 2 ).
The wavelengths of the fifth-group optical signals (λ 1 , λ 2 , . . . , λ N ) and the sixth-group optical signals (λ N+1 , λ N+2 , . . . , λ 2N ) are arranged in different wavelength-bands respectively. Both the fifth-group-optical signals (λ 1 , λ 2 , . . . , λ N ) and the sixth-group optical signals (λ N+1 , λ N+2 , . . . , λ 2N ) can be transferred between a common port and N input/output ports of a (de)multiplexer ((D)MUX 2 ), however, the wavelengths of the fifth-group optical signals (λ 1 , λ 2 , λ N ) and the sixth-group optical signals (λ N+1 , λ N+2 , . . . , λ 2N ) are arranged to be apart from each other with the interval of I(an arbitrary integer) times the free spectral range of the (de)multiplexer ((D)MUX 2 ) respectively.
An broad-band light source (BLS) emits a wide-band light.
The optical circulator (OC) outputs the optical signals inputted through the first port through the second port and the optical signals inputted through the second port through the third port.
The wavelength-division multiplexers (WDM 1 , . . . , WDMn + 1, WDMn + 2) transfer the fifth-group optical signals (λ 1 , λ 2 , . . . , λ N ) and block the sixth-group optical signals (λ N+1 , λ N+2 , . . . , λ 2N ) between the first port and the second port, and on the other hand, they transfer the sixth-group optical signals (λ N+1 , λ N+2 , . . . , λ 2N ) and block the fifth-group optical signals (λ 1 , λ 2 , . . . , λ N ) between the first port and the third port.
The connection of a transmission system ( 100 ) described above can be performed as follows:
N input/output ports of a (de)multiplexer ((D)MUX 2 ) are connected to the first ports of N wavelength-division multiplexers (WDM 3 , . . . , WDMn + 1, WDMn + 2), N Fabry-Perot laser diodes (FPLD 1 , FPLD 2 , . . . , FPLDn) are connected to the second ports of N wavelength-division multiplexers (WDM 3 , . . . , WDMn + 1, WDMn + 2), and N optical receivers (RX 1 , RX 2 , . . . , RXn) are connected to the third ports of N wavelength-division multiplexers (WDM 3 , . . . , WDMn + 1, WDMn + 2) respectively.
The common port of a (de)multiplexer ((D)MUX 2 ) is connected to the first port of a first wavelength-division multiplexer (WDM 1 ), the second port of the first wavelength-division multiplexer (WDM 1 ) is connected to the second port of the optical circulator (OC), the first port of an optical circulator (OC) is connected to an broad-band light source (BLS) and the third port of the optical circulator (OC) is connected to the second port of a second wavelength-division multiplexer (WDM 2 ).
The third port of the first wavelength-division multiplexer (WDM 1 ) and the third port of the second wavelength-division multiplexer (WDM 2 ) are connected to each other, and the first port of the second wavelength-division multiplexer (WDM 2 ) becomes an output port of a transmission system ( 100 ).
Looking into the operation principle of a transmission system ( 100 ), the output of an broad-band light source (BLS) is inputted through the first port of an optical circulator (OC), passing through the second port, and then inputted into the second port of a first wavelength-division multiplexer (WDM 1 ).
Then, the first wavelength-division multiplexer (WDM 1 ) outputs some portion of the inputted light through the first port.
The output from the first wavelength-division multiplexer (WDM 1 ) is inputted into the common port of a (de)multiplexer ((D)MUX 2 ), and then outputted through the corresponding input/output ports of the (de)multiplexer ((D)MUX 2 ) respectively.
The outputs from the (de)multiplexer ((D)MUX 2 ) are inputted into the first ports of N wavelength-division multiplexers (WDM 3 , . . . , WDMn +1 , WDMn + 2), and then outputted through the second ports to be inputted into N Fabry-Perot laser diodes (FPLD 1 , FPLD 2 , . . . , FPLDn) respectively.
N Fabry-Perot laser diodes (FPLD 1 , FPLD 2 , . . . , FPLDn) output fifth-group optical signals (λ 1 , λ 2 , . . . , λ N ) whose wavelengths are within the pass-bands of the N input/output ports of the (de)multiplexer ((D)MUX 2 ) respectively.
The fifth-group optical signals (λ 1 , . . . λ 2 , λ N ) are transferred through N wavelength-division multiplexers (WDM 3 , . . . , WDMn +1 , WDMn +2 ) to be inputted into the (de)multiplexer ((D)MUX 2 ) and multiplexed therein. Then the multiplexed signals are inputted into the first port of the first wavelength-division multiplexer (WDM 1 ).
The fifth-group optical signals (λ 1 , λ 2 , . . . , λ N ) inputted into the first wavelength-division multiplexer (WDM 1 ) are outputted through the second port, passing through the second port and the third port of the optical circulator (OC), and then inputted into the second port of the second wavelength-division multiplexer (WDM 2 ) to be outputted through the first port of the second wavelength-division multiplexer (WDM 2 ).
The sixth-group optical signals (λ N+1 , λ N+2 , . . . , λ 2N ) inputted into the first port of the second wavelength-division multiplexer (WDM 2 ) are outputted through the third port, and then inputted into the third port of the first wavelength-division multiplexer (WDM 1 ) to be outputted through the first port, and thereafter inputted into the common port of the (de)multiplexer ((D)MUX 2 ).
The sixth-group optical signals (λ N+1 , λ N+2 , . . . , λ 2N ) inputted through the common port are outputted through the corresponding input/output ports of the (de)multiplexer ((D)MUX 2 ) to be inputted into the first ports of N wavelength-division multiplexers (WDM 3 , . . . , WDMn +1 , WDMn +2 ) respectively.
The sixth-group optical signals (λN +1 , λ N+2 , . . . , λ 2N ) inputted into N wavelength-division multiplexers (WDM 3 , . . . , WDMn +1 , WDMn +2 ) are then outputted through the third ports of the wavelength-division multiplexers to be received by optical receivers (RX 1 , RX 2 , . . . , RXn).
Here, the transmission system ( 100 ) may further comprise N laser diode driving circuits (DR 1 , DR 2 , . . . , DRn) to modulate N Fabry-Perot laser diodes (FPLD 1 , FPLD 2 , . . . , FPLDn), N laser diode temperature controllers (TEC 1 , TEC 2 , . . . , TECn) for controlling the temperatures of N Fabry-Perot laser diodes (FPLD 1 , FPLD 2 , . . . , FPLDn) and a temperature controller (TEC) for controlling the temperature of the (de)multiplexer ((D)MUX 2 ).
FIG. 10 is the fourth embodiment of a wavelength-division multiplexed transmission system using a light source in accordance with the present invention.
As described in FIG. 10 , a wavelength-division multiplexed transmission system in accordance with the present invention comprises N Fabry-Perot laser diodes (FPLD 1 , FPLD 2 , . . . , FPLDn), N laser diode temperature controllers (TEC 1 , TEC 2 , . . . , TECn), an N×1 (de)multiplexer ((D)MUX 2 ), a (de)multiplexer temperature controller (TEC), an optical circulator (OC), an broad-band light source (BLS), an external modulator (EM), and an external modulator driving circuit (EMDR).
A (de)multiplexer ((D)MUX 2 ) demultiplexes wavelength-division multiplexed optical signals inputted through a common port and outputs them through N input/output ports respectively. Or, it multiplexes the optical signals having different wavelengths, which are inputted through N input/output ports respectively, and outputs them through the common port.
An broad-band light source (BLS) emits a wide-band light.
The optical circulator (OC) outputs the optical signals inputted through the first port through the second port and the optical signals inputted through the second port through the third port.
The connection of a transmission system ( 100 ) described above can be performed as follows:
N Fabry-Perot laser diodes (FPLD 1 , FPLD 2 , . . . , FPLDn) are connected to N ports of a (de)multiplexer ((D)MUX 2 ) respectively, and the common port of the (de)multiplexer ((D)MUX 2 ) is connected to the second port of an optical circulator (OC).
The first port of the optical circulator (OC) is connected to an broad-band light source (BLS) and the third port of the optical circulator (OC) is connected to an external modulator (EM).
An external modulator driving circuit (EMDR) is connected to the external modulator (EM), and thus electric signals are inputted into the external modulator driving circuit (EMDR) and modulated optical signals are outputted through the external modulator (EM).
Looking into the operation principle of a transmission system ( 100 ), the output of an broad-band light source (BLS) is inputted through the first port of an optical circulator (OC), passing through the second port to be inputted into the common port of a (de)multiplexer ((D)MUX 2 ), and then outputted through the corresponding N ports of (de)multiplexer ((D)MUX 2 ) respectively.
The outputs from the (de)multiplexer ((D)MUX 2 ) are inputted into N Fabry-Perot laser diodes (FPLD 1 , FPLD 2 , . . . , FPLDn) respectively, and each of the Fabry-Perot laser diodes (FPLD 1 , FPLD 2 , . . . , FPLDn) outputs optical signals whose wavelengths are within the within the pass-bands of the N ports of a (de)multiplexer ((D)MUX 2 ) respectively.
The outputs from N Fabry-Perot laser diodes (FPLD 1 , FPLD 2 , FPLDn) are multiplexed by the (de)multiplexer ((D)MUX 2 ), passing through the optical circulator (OC), and then inputted into the external modulator (EM). Then, the external modulator (EM) modulates the inputted optical signals, with using the received electric signals, and outputs the modulated signals.
In a transmission system ( 100 ) described above, by controlling the currents applied to the Fabry-Perot laser diodes (FPLD 1 , FPLD 2 , . . . , and FPLDn), it is possible to control that optical signals with a (or more than 2) specific wavelength(s) are outputted through the external modulator (EM).
A transmission system ( 100 ) of the present invention further comprises N polarization controllers (PC 1 , PC 2 , . . . , PCn) connected between the input/output ports of a (de)multiplexer ((D)MUX 2 ) and N Fabry-Perot laser diodes (FPLD 1 , FPLD 2 , . . . , FPLDn) or a polarization controller (PC) connected between an external modulator (EM) and an optical circulator (OC).
The transmission system ( 100 ) further comprises N laser diode temperature controllers (TEC 1 , TEC 2 , . . . , TECn) for controlling the temperatures of N Fabry-Perot laser diodes (FPLD 1 , FPLD 2 , . . . , FPLDn) and a temperature controller (TEC) for controlling the temperature of a (de)multiplexer ((D)MUX 2 ).
FIG. 12 shows the fifth embodiment of a wavelength-division multiplexed transmission system using a light source in accordance with the present invention, which further comprises an optical receiver (RX) with the structure of a transmission system described in FIG. 10 .
An optical receiver (RX) converts the input optical signals into electric signals.
With comprising an additional optical receiver (RX), when optical signals with a specific wavelength is externally inputted, the system can converts the signal into electric signal, and then converts it back to the optical signal(s) with a (or more than 2) wavelength(s).
Here, the wavelengths of optical signals outputted through an external modulator (EM) can be varied by controlling the currents applied to the Fabry-Perot laser diodes (FPLD 1 , FPLD 2 , . . . , FPLDn).
As mentioned thereinbefore, a transmission system using a light source in accordance with the present invention reduces the cost per channel. Moreover, it can increase the output power, and thus it makes it easy to constitute a transmission system and expand the network coverage.
In addition, a wavelength-division multiplexed transmission system in accordance with the present invention is constituted for wavelength-division multiplexed optical signals to be inputted and/or outputted through the same optical fiber, and thus it can reduce the number of fibers required for optical communication to be half of that of the prior art.
Since those having ordinary knowledge and skill in the art of the present invention will recognize additional modifications and applications within the scope thereof, the present invention is not limited to the embodiments and drawings described above. | The present invention relates to a wavelength-tunable light source whose output wavelength can be externally controlled and a wavelength-division multiplexed transmission system using the source.
A wavelength-tunable light source in accordance with the present invention is constituted to be able to vary the output wavelength of a Fabry-Perot laser diode, that is wavelength-locked to an injected light, by controlling the wavelength of the injected light.
A wavelength-tunable light source in accordance with the present invention provides comparatively large output power and excellent economic features.
The present invention also presents a wavelength-division multiplexed transmission system using, the wavelength-tunable light source. | 7 |
RELATED APPLICATIONS
[0001] This application claims the benefit of provisional application Ser. No. 60/419,674 filed on Oct. 18, 2002 which is incorporated by reference herein in its entirety.
BACKGROUND OF THE INVENTION
[0002] The proliferation of the wireless local area networks (WLANs) has led to the search for ways in which its utilization can be increased. By WLAN, we include all instantiations of such technologies as 802.11 a, 802.11 b, 802.11 g, Bluetooth and any similar WLAN versions. For example, the specification for the IEEE 802.11 version of WLAN includes an access scheme called the distributed control function, which permits the network to support both data and voice applications. Today voice over wireless local area network (VoWLAN) is a reality. The voice may be encoded and transmitted using voice over internet protocol (VoIP) format and protocols such as G.711, G.726, G.729, SIP, MEGACO, H.323, or other similar protocols that are being developed.
[0003] One of the issues in WLAN is that there is a limited range of operation due to power requirements. For example, a typical IEEE 802.11 WLAN has a range of at most 300 yards from the access point that connects the mobile devices to the wired LAN. Thus, when an IEEE 802.11-based mobile device roams beyond this range, any call in progress is forcibly terminated.
SUMMARY OF THE INVENTION
[0004] The present invention concerns a scheme that enables seamless roaming between the WLAN and the cellular carrier network. The method enables a user that originates a call in the WLAN and happens to go outside the range of the WLAN to automatically switch over to the cellular carrier network without losing connection with the other party. This solution assumes that the mobile device has the capability to operate in at least two modes that include the WLAN mode and one of the cellular carrier modes, such as the GSM, IS-95 CDMA, IS-136 TDMA, and iDEN.
[0005] The above and other features of the invention including various novel details of construction and combinations of parts, and other advantages, will now be more particularly described with reference to the accompanying drawings and pointed out in the claims. It will be understood that the particular method and device embodying the invention are shown by way of illustration and not as a limitation of the invention. The principles and features of this invention may be employed in various and numerous embodiments without departing from the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] In the accompanying drawings, reference characters refer to the same parts throughout the different views. The drawings are not necessarily to scale; emphasis has instead been placed upon illustrating the principles of the invention. Of the drawings:
[0007] FIG. 1 is a block diagram showing the architecture of a typical WLAN that supports Voice communications;
[0008] FIG. 2 is a timing diagram showing the initial mobile device registration process;
[0009] FIG. 3 is a timing diagram showing the handoff procedure for a mobile device with a PSTN-based call in progress;
[0010] FIG. 4 is a timing diagram showing the handoff procedure for a mobile device with cellular network-based call in progress; and
[0011] FIG. 5 is a timing diagram showing the procedure for cellular network-to-WLAN handoff.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0012] A typical WLAN is comprised of access points (APs) that are connected to the enterprise LAN via an access controller (AC) or a wireless LAN switch. The access controller/wireless LAN switch AC is the center of intelligence of the WLAN and is responsible for admission control, authentication and mobile device roaming coordination. One AC/wireless LAN switch can control several APs and multiple ACs/wireless LAN switches can be in the same network. Another device called the Cellular Proxy (CP) is a gateway that connects the enterprise LAN to the cellular network. If the enterprise PBX is not VoIP-capable, the cellular proxy also provides the VoIP interface between the enterprise LAN and the PBX. The Cellular Proxy is located in the part of the enterprise building that has a very good cellular coverage.
[0013] The Cellular Proxy is not necessarily tightly coupled to any cellular network. To any cellular network, it is a bank of radios. It hides the details of the movement of the mobile devices within the enterprise premises from the cellular network thereby preventing the cellular network from making frequent updates to its database. Also, it can connect to multiple cellular networks simultaneously because it contains radios for different types of cellular network technologies, such as CDMA, AMPS TDMA, GSM TDMA, iDEN, WCDMA, CDMA2000, GPRS, 1XRTT, 1xEVDO, and 1xEVDV. Thus, the Cellular Proxy can proxy for mobile devices in CDMA-based and TDMA-based cellular networks simultaneously.
[0014] Mobile devices, such as laptops that are equipped with wireless network interface cards and personal digital assistants access the network via the APs. A typical network is shown in FIG. 1 . In the figure, the access controller and/or wireless LAN switch are not shown; they are assumed to be part of the enterprise LAN infrastructure.
[0015] Each dual-mode mobile device MD has two telephone numbers: one number is assigned by the enterprise as an extension of the enterprise's PBX, and the other number is assigned by the cellular carrier. The default network for each mobile device is the enterprise (or hotspot) WLAN, which means that when a mobile device is turned on, it first searches for the enterprise's WLAN and registers with the network, if it is found. If the enterprise WLAN is not found the mobile device MD then registers with the cellular carrier network. The rationale for this operational requirement is to save the enterprise money by ensuring that mobile device users do not accrue air charges when they are within the corporate WLAN. All calls generated by the mobile device while it is on the enterprise network are routed via the corporate PBX to the public switched telephone network (PSTN).
[0016] Since each mobile device has two telephone numbers, it can be reached in two ways: via the PBX when calls come from the PSTN, and via the Cellular Proxy CP when calls come from the Cellular Proxy. Regardless of how the calls arrive, they are converted into voice over IP (VoIP) packets by the appropriate device and presented to the mobile device via the WLAN. These calls are based on the Session Initiation Protocol (SIP), which has the advantage over the ITU-T H.323 protocol in that it is a lightweight protocol that leverages the Internet protocols.
[0017] Each mobile device MD goes through an initialization process when it is turned on in the WLAN. As discussed earlier, the default network is the enterprise WLAN. Therefore, when a mobile device is turned on it sends a Registration Request message to the appropriate authentication server in the enterprise LAN. After the authority server has authenticated the mobile device, it returns a Registration Complete message to the device. The authentication server, which has information on each mobile device's cellular service provider's network, then sends a Registration Request message to the Cellular Proxy instructing the latter to register the mobile device in the device's cellular carrier network. The Cellular Proxy CP first sets up a TCP connection to the mobile device MD via the appropriate access controller (or wireless LAN switch) and access point before commencing the registration of the device in the cellular network. After the Cellular Proxy has successfully registered the mobile device in the cellular network, it returns a Registration Complete message to the authentication server. The Cellular Proxy then starts listening on the appropriate paging channel for calls destined for the mobile device from the cellular carrier network and will deliver such calls to the mobile device via the appropriate access controller (or the wireless LAN switch) and access point. The message flow for the registration process is illustrated in FIG. 2 .
[0018] Consider a dual-mode mobile device that originates a call within a WLAN. As the user moves closer to the edge of the network the signal quality begins to degrade. The degradation will reach a point where the signal strength is almost imperceptible, which causes the call to be terminated.
[0019] Here, the mobile device MD has the capability to monitor the signal quality by measuring the signal-to-noise ratio (SNR). Assume also that from practical experience acquired through measurements it is known that when SNR reaches some threshold value d, the voice quality becomes unacceptable. The goal is to prevent the call quality from degrading to this critical point. Thus, when the SNR drops to a cutoff value r>d, the system initiates a handoff with the objective of completing the handoff procedure before the SNR drops down to the threshold value d. Thus the scheme operates in the following manner:
[0020] When a mobile device experiences SNR measurement value of r, it sends a Handoff Request message to the Cellular Proxy via the TCP connection that exists between the two devices.
[0021] When Cellular Proxy receives the message it takes one of two actions that depend on where the other party in the call is located.
[0022] If the other party is located in the PSTN, which means that the call passes through the PBX, then it takes the following actions: 1) the Cellular Proxy uses one of its own carrier-assigned telephone numbers to call the mobile device's carrier-assigned telephone number; 2) since the mobile device is not physically connected to the cellular network, the Cellular Proxy will also receive the call on behalf of the device; 3) after receiving the parameters of the call from the cellular network, such as the channel or code to use, power level, etc., the Cellular Proxy will forward these parameters to the mobile device over the TCP connection that it established between the two and commands the mobile device to switch its radio to the cellular network using those parameters; 4) the Cellular Proxy will then close the TCP connection, stop proxying for that device in the cellular network to avoid cloning problems, and will thereafter forward the call to the mobile device over the new connection established via the cellular network; and 5) on receiving the call parameters, the mobile device will immediately switch its radio to the cellular network without having to register again since it has already been registered and authenticated in the cellular controller by the Cellular Proxy. As it moves from base station to base station outside the enterprise network, the mobile device will be subject to the handoff mechanism that applies within the cellular network.
[0023] This sequence of activities is illustrated in FIG. 3 .
[0024] If the other party is located in the cellular carrier network, which means that the call passes through the Cellular Proxy without reaching the PBX, it takes the following set of actions: 1) since the Cellular Proxy has all the parameters of the call, it returns these parameters to the mobile device via the TCP connection between the two and commands the mobile device to switch its radio to the cellular network using those parameters; 2) the Cellular Proxy will then close the TCP connection and stop proxying for the mobile device to avoid creating cloning problems in the cellular network; 3) Upon receiving the information, the mobile device will tune its radio to the channel currently used by the Cellular Proxy and receive the call directly from the cellular network.
[0025] This sequence of activities is illustrated in FIG. 4 .
[0026] Assume that the mobile device has a call in progress as it is moved from the outside world into the enterprise premises. The operational rule is that if there is good cellular coverage within the enterprise premises, the call will be allowed to complete in the cellular network after which the mobile device will register in the enterprise LAN using the procedure described earlier. However, if there is no good coverage within the enterprise premises, the device will initiate a handoff with the Cellular Proxy. The procedure is as follows:
[0027] 1) if the SNR reaches the predefined cutoff value, the mobile device sends a short message service (SMS) message to the Cellular Proxy. The message contains information on the identity of the mobile device, such as its PBX extension and its cellular network telephone number as well as the parameters of the current call. The Cellular Proxy maintains a record of the cellular network that each enterprise mobile device is associated with. Therefore, with the information it received from the mobile device the Cellular Proxy sends a message to the authentication server to expedite the authentication of the mobile device.
[0028] 2) The authentication server will provide emergency registration for the mobile device by broadcasting a Registration Invite message that the mobile device will respond to.
[0029] 3) After locating and authenticating the mobile device, the authentication server forwards the device's location and network configuration parameters like the IP address to the Cellular Proxy.
[0030] 4) After sending the emergency registration request to the authentication server, the Cellular Proxy will start monitoring the channel on which the mobile device was communicating and accumulating information destined for the device until the device has been authenticated and registered in the network
[0031] 5) When the Cellular Proxy receives information on the device's location, it will set up a TCP connection to the device and forward all accumulated packets to the device.
[0032] 6) After this, the operation becomes similar to that described earlier. The Cellular Proxy listens on the channel and relays information between the mobile device and the cellular network until the conversation is over and the connection is terminated. When the current call ends, the Cellular Proxy continues to listen on the cellular network's paging channel for calls destined for the mobile device, as described earlier.
[0033] This sequence of activities is illustrated in FIG. 5 .
[0034] While this invention has been particularly shown and described with references to preferred embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the scope of the invention encompassed by the appended claims. | A scheme that enables seamless roaming between the WLAN and the cellular carrier network by enabling a user that originates a call in the WLAN and happens to go outside the range of the WLAN to automatically switch over to the cellular carrier network without losing connection with the other party. This solution assumes that the mobile device has the capability to operate in at least two modes that include the WLAN mode and one of the cellular carrier modes, such as the GSM, IS-95 CDMA, IS-136 TDMA, and iDEN. | 7 |
DESCRIPTION
This invention relates to a process for the light-intensity balancing of an optical system as well as for a device for the carrying out of the process.
Optical and/or optoelectronic systems have found acceptance in the sensor technology. It is known, for example, to use optical emitters as rotating emitters. These emitters consist of a light source, of a lens installed in the beam path of the light, as well as two photodiodes arranged below the lens. These photodiodes are electrically connected with an amplifier. The amplified signal should be symmetrical.
Because of tolerances and manufacturing irregularities of the components, the optical and optoelectronic systems have shown, however, that even with like designs, different signals are produced for the incident light radiation. Another problem is that the spatial distribution of the light energy in known systems can differ, which could cause an additional deviation from the desired behavior.
Thus, in order to obtain a symmetrical signal, it is necessary to balance the system.
It is known that the balancing of the system with respect to the intensity distribution can be obtained by inserting diaphragms or other non-transparent elements into the light path.
On the other hand, this balancing presents the disadvantage that a precise insertion of the diaphragms or elements is functionally very costly. It is costly because the balancing can be hardly automated. This, of course, results in increased costs for such a system.
It is also known that balancing can be obtained by adapting the signal from the photodetector by modifying it accordingly to the amplification, so that the amplifier amplifies a symmetrical signal.
The electronic balancing in solid-state integrated receiver circuits--the photodiode and amplifier are made out of the same silicon crystal--entails great expense because, in order to achieve this, electronic signals must be led through the crystal. These signals are susceptible to interferences. Direct balancing can also be provided by means of a microchip that must be appropriately designed for the laser beams.
This invention has the object to provide a process for light-intensity balancing, by means of which balancing can be achieved in a simple and reliable manner.
This problem is solved by a process for the light-intensity balancing according to the characteristics of claim 1. A device for carrying out the process according to claim 1 is a feature of the characteristics of claim 4.
Further advantageous embodiments are objects of the subclaims.
Contrary to the state of the art, the light intensity is balanced at the point at which the beam path to the optoelectronic components is originated, namely, at the lens. For this, the process is characterized in that the intensity distribution of the light striking the optoelectronic components is measured and determined in a plane. The intensity distribution at the lens is determined by means of a relevant conversion of the light intensity distribution in the plane. A uniform intensity distribution is obtained by changing the optical properties of the lens at the relevant points, so that the signal at the amplifier is formed symmetrically. This process presents the advantage that no additional elements, such as, e.g., diaphragms or the like, must be used. Also, the signal of an electrical component is not changed by appropriate measures by, e.g., the use of a potentiometer. This presents the advantage that the system consists of a reduced number of components. Another advantage of this process is, that the balancing produces a stable signal at the amplifier because of the absence of an eventual temperature variation at the potentiometer. It was advantageously evidenced that the balancing can be produced fully automatically, so that the manufacturing costs of the optical system can be reduced.
The optical property of the lens is advantageously modified by clouding the lens surface at its relevant point. The clouding of the lens is effected by means of a laser that bombards the appropriate point with photons. The laser beam modifies the structure near the surface.
However, it was also evidenced that the intensity balance can be achieved inasmuch as the structure at deeper layers of the lens can be modified by having the laser beams acting upon the appropriate point over a longer period of time or with increased energy.
For the carrying out of the process is proposed a device that presents a panel consisting of several optoelectronic elements, that are electrically connected with a plotting unit. The device also presents a positioning unit, of which the input is connected with the plotting unit and the output to a laser. The device is characterized by a simple design that can be used for the balancing of different optical systems.
For the radiant exposure of the lens, the wave length of the light emitted by the laser should be within the absorption spectrum of the lens. In this connection, the wave length of the laser must be adapted to the material of the lens in such a manner that the absorbed energy is sufficiently high to produce metabolism.
Practice has shown that CO 2 -laser with 10 μm wavelengths are particularly appropriate for radiating materials, such as, e.g., plexiglas®, methyl methacrylates or other synthetic; materials, because this wavelength is absorbed although the lens is highly transparent for visible light. The transparency of the lens is the premise for its use.
Advantageously, the laser is a pulsed laser, so that the clouding of the lens can be precisely controlled in view of the low penetration depth. Because of the laser's pulsed operation it is possible to control in an extremely precise manner the laser's energy; thus, the penetration depth can be adjusted to a micrometer range.
Further characteristics and advantages can be gathered from the below description of the embodiment of the device illustrated in the accompanying drawing:
The optical system consists of a light source 1, a lens 2 and optoelectronic components 4 arranged on a carrier plate 3. The light source 1 is mounted at the focal point of the lens 2 which can be supported by any supporting means. By way of example, the optoelectronic components can be photoelectric cells. The optoelectronic components 4 are electrically connected with a plotting unit 5. The output of the plotting unit 5 is electrically connected with a positioning unit 6. The positioning unit 6 triggers the laser 7 which is supported by a device (not shown) adapted to revolve the laser around the base to treat the whole lens.
The light source 1 emits light beams 8 that penetrate into the lens 2. The lens 4 is a collimator lens that aligns the light beams 8 of the light source 1 in a parallel manner. The light beams 9 emerging from lens 2 fall on the photoelectric cells 4. The photoelectric cells 4 send signals via an electrical circuit to the plotting unit 5. With a panel of photoelectric cells 4, the photoelectric cells 4 can be successively actuated in the plane by means of the plotting unit 5.
In the plotting unit, or control unit, 5 is determined the intensity distribution of the light in the plane. Based on this intensity distribution, an appropriate conversion is made to the coordinates of lens 2. The signals allocated to the coordinates are transmitted via an electrical circuit to the positioning unit 6, which aligns the laser 7 with the corresponding coordinate at lens 2. This point on the lens is clouded by bombarding it with the laser beam 12. This process is repeated until a uniform intensity distribution is obtained. | Herein is described a process for the light-intensity balancing of an optical system, and a device for carrying out the process. The optical system consists of a light source, a lens installed in the beam path, and optoelectrical components that sends to an amplifier a signal that is proportional to the local light intensity. The intensity balancing is carried out by measuring and determining the intensity distribution in a plane. This local distribution is modified at the relevant points for the local distribution according to the optical properties of the lens until a uniform intensity distribution in the plane is obtained. The lens is attained by radiating its surface or internal structures with a laser. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to EP Application No. 14170346.2, having a filing date of May 28, 2014, the entire contents of which are hereby incorporated by reference.
FIELD OF TECHNOLOGY
[0002] The following relates to a wind turbine, a rotor hub for a wind turbine, an absorber element for a wind turbine and a method for maintaining a clean environment in a wind turbine.
BACKGROUND
[0003] Alternative energy sources have become much more necessary as fossil fuels are depleted and pollute the environment. Wind energy is one of the most cost effective of all types of renewable energy. However, to make wind a viable source of energy or electricity in particular careful design of wind-capturing machines is necessary. A variety of principles of physics are used to create wind turbines that can efficiently capture energy from the wind. Wind turbines can be onshore or offshore.
[0004] A wind turbine typically includes a tower, a nacelle supported by the tower and a rotor mounted to the nacelle. The rotor is coupled via a drive train to a generator housed inside the nacelle. The rotor includes a central rotor hub and a plurality of blades mounted to and extending radially from the rotor hub.
[0005] A wind turbine typically includes many bearings that provide relative movement between adjacent parts in a relatively efficient, low-friction manner. Bearings typically require lubrication like, e.g., oil or grease to operate in with low friction and prolong their lifetime.
[0006] In an exemplary situation of an oil spillage caused by, e.g., leaking blade bearings of a hydraulic blade pitch system, there is a need for absorbing hydraulic oil wasted inside the rotor hub. Thereby, it is a general intention to collect and/or absorb the oil before escaping the rotor hub and before causing environmental damage to the nearest surrounding of the wind turbine.
[0007] WO2012/113402 A1 relates to a sealing system for a wind turbine comprising a first component and a second component positioned proximate the first component and movable relative thereto. An absorbent element is secured to the first component and comprises an oil-absorbent material.
[0008] An alternative exemplary embodiment of oil absorbing would be the utilization of watercut oil absorbing plates, directly mounted at reinforcement plates of the blade bearings. However, the installation of such kind of absorbing plates is expensive and not satisfying with regard to service and maintenance activities. As a further disadvantage, such absorbing plates cannot be secured or mounted during initial installation or production of a wind turbine as they are hindering the installation of rotor blades during, e.g., erection of the wind turbine.
SUMMARY
[0009] An aspect relates to an improved approach for a wind turbine to ensure effective absorbing of oil or grease.
[0010] In order to overcome this problem, a wind turbine is provided, comprising
a rotatable part; at least one absorber element secured to the rotatable part within an interior of the wind turbine; the at least one absorber element at least partly comprising lubricant absorbing material, wherein the absorber element is configured to absorb emerging lubricant inside the wind turbine.
[0014] The absorber element according to the proposed solution has a low complexity and a simple design. The proposed absorber element can be secured/mounted during production of the wind turbine without hindering, e.g., the installation of rotor blades.
[0015] Thus, securing one or a number of absorber elements to a rotatable part within the interior of the wind turbine is a simple and cheap solution for absorbing any lubricant wasted inside the wind turbine. The rotatable part may be able to rotate about the same or approximately about the same rotation axis as a rotor hub or a generator of the wind turbine.
[0016] Due to the ongoing rotation of the rotating part of the wind turbine the lubricant like, e.g., oil spillage will run past the absorber element continuously where it will be collected and absorbed.
[0017] In an embodiment, the lubricant absorbing material comprises oil-absorbent and/or grease-absorbent material.
[0018] In another embodiment, the lubricant absorbing material comprises polypropylene.
[0019] In a further embodiment, the at least one absorber element comprises a container with the lubricant absorbing material located inside the container.
[0020] The at least one absorber element may be also a box or any other element with a shape adjusted to the respective characteristics of the interior within the wind turbine.
[0021] In a next embodiment, the container comprises at least one hole and/or at least one opening.
[0022] Wasted lubricant running past the container will pass through the at least one hole and/or the at least one opening and will be collected and absorbed by the lubricant absorbing material housed by the container.
[0023] It is also an embodiment that the at least one absorber element is secured to the rotatable part of a rotor hub of the wind turbine.
[0024] Pursuant to another embodiment, the at least one absorber element is secured
to at least one reinforcement plate located within an interior of the rotor hub, or to an inner surface of the rotor hub.
[0027] According to an embodiment, at least a part of the at least one hole and/or the at least one opening of the container is located at a side of the container closest to the at least one reinforcement plate or to the inner surface of the rotor hub. This allows easy access of wasted lubricant running past the container to the absorbing material located inside the container.
[0028] According to another embodiment, the absorber element comprises at least one guiding means for guiding the lubricant to the absorber element.
[0029] One embodiment of the at least one guiding means may be, e.g., oil guides in form of plates or shovels, guiding or shoveling the lubricant to the absorber element.
[0030] The problem stated above is also solved by a rotor hub for a wind turbine, comprising
a rotatable part; at least one absorber element secured to the rotatable part within an interior of the rotor hub; the at least one absorber element at least partly comprising lubricant absorbing material, wherein the absorber element is configured to absorb emerging lubricant inside the rotor hub.
[0034] The problem stated above is also solved by an absorber element for a wind turbine, comprising
at least one securing element for securing the absorber element to a rotatable part within an interior of the wind turbine; lubricant absorbing material, wherein the absorber element is configured to absorb emerging lubricant inside the wind turbine.
[0037] In an embodiment, the absorber element comprises a container with the lubricant absorbing material located inside the container.
[0038] In yet another embodiment, the container comprises at least one hole and/or at least one opening.
[0039] The problem stated above is also solved by a method for maintaining a clean environment in a wind turbine, comprising the following steps:
securing at least one a absorber element to a rotatable part of the wind turbine, the at least one absorber element comprising lubricant absorbing material; operating the wind turbine, so that the rotatable part of the wind turbine rotates relative to a static part of the wind turbine; and absorbing emerging lubricant inside the wind turbine with the at least one absorber element.
BRIEF DESCRIPTION
[0043] Some of the embodiments will be described in detail, with reference to the following figures, wherein like designations denote like members, wherein:
[0044] FIG. 1 shows an exemplary schematic overview of a wind turbine;
[0045] FIG. 2 illustrates a schematical view of an interior of a rotor hub thereby showing an exemplary embodiment of the proposed solution;
[0046] FIG. 3 illustrates a more detailed schematical view of an embodiment of the absorber element as shown in FIG. 2 ; and
[0047] FIG. 4 illustrates in an exemplary schematical view of an alternative embodiment of the proposed solution.
DETAILED DESCRIPTION
[0048] With reference to FIG. 1 an exemplary schematic overview of a wind turbine 100 is shown. The wind turbine 100 comprises a tower 110 , a nacelle 120 and a rotor hub 140 . The nacelle 120 is located on top of the tower 110 . The rotor hub 140 comprises a number of wind turbine blades 150 . The blades 150 may be rotatable mounted to the rotor hub 140 by respective blade bearings 155 allowing the blades 150 to be pitched into or out of the wind.
[0049] The rotor hub 140 is mounted to the nacelle 120 such, that it is able to rotate about a rotation axis 105 . A generator 125 is located inside the nacelle 120 . The wind turbine 100 can be, e.g., a direct drive wind turbine.
[0050] FIG. 2 illustrates a schematical view of an interior 200 of a rotor hub thereby showing an exemplary embodiment of the proposed solution. The interior 200 of the rotor hub represents a rotatable part of a wind turbine.
[0051] A hydraulic blade pitch system 210 is located in the interior 200 of the rotor hub, being attached via a first support element 211 to a blade bearing reinforcement plate 240 and via a second support element 212 to a, e.g., casted inner surface of the rotor hub.
[0052] According to the exemplary scenario as shown in FIG. 2 , oil is leaking of the hydraulic blade pitch system 210 causing oil spillage 260 within the interior 200 of the rotor hub like, e.g., on a surface of the blade bearing reinforcement plate 240 .
[0053] To enable absorption of the oil spillage 260 , two absorber elements 220 comprising lubricant absorbing material are secured to the blade bearing reinforcement plate 240 via securing elements 250 . Any shape may be possible for the absorber elements 220 , preferable adjusted to the characteristics (like, e.g., available space) of the interior 200 of the rotor hub. According to the example as shown in FIG. 2 , each absorber element 200 comprises a box or container housing the lubricant absorbing material inside.
[0054] It should be noted, that an arbitrary number of absorber elements or boxes 220 can be placed within the interior 200 of the rotor hub, dependent on, e.g., the characteristics of the interior 200 of the rotor hub.
[0055] As an example, one or several oil absorbing pillows can be used as lubricant absorbing material placed inside each of the boxes 220 . Alternatively, oil absorbing cloth or oil absorbing pulp may be used.
[0056] The boxes 220 may be made of any material like, e.g., metal or composite, being qualified to withstand hydraulic oil.
[0057] According to a further embodiment of the proposed solution, the absorber element may at least partly or purely consist of the lubricant absorbing material which may have, e.g., the shape of a box or container.
[0058] It should be further noted, that the lubricant absorbing material may be directly secured within the interior 200 of the rotor hub like, e.g., secured directly to the blade bearing reinforcement plate 240 or to the inner surface of the rotor hub.
[0059] The lubricant absorbing material may be any material enabling absorption of hydraulic oil like, e.g., polypropylene.
[0060] As shown in FIG. 2 , the boxes 220 are attached to the blade bearing reinforcement plate 240 and therefore being part of a rotatable part of the rotor hub. Hence, during operation of the wind turbine and due to the ongoing rotation of the rotor hub, the oil spillage 260 will run past the boxes 220 .
[0061] According to a preferred embodiment, each of the boxes 220 comprises several holes or openings 230 to enable proper access of the oil spillage 260 to the lubricant absorbing material placed inside the boxes 220 . Preferably, at least a part of the holes or openings (not visible) are located at a side of the box closest to the reinforcement plate 240 allowing easy access of the oil spillage 260 to the lubricant absorbing material.
[0062] According to an advanced embodiment of the proposed solution (not shown), additional oil guides in form of plates or shovels are placed within the interior 200 of the rotor hub, e.g., being attached to the blade bearing reinforcement plate 240 . By the use of theses plates or shovels and due to the ongoing rotation of the rotor hub, the oil spillage 260 will be guided or shoveled to the boxes 220 .
[0063] FIG. 3 illustrates a more detailed schematical view of the absorber elements shown in FIG. 2 . An absorber element 300 comprising a box is secured to a surface of a blade bearing reinforcement plate 310 via securing elements 320 like, e.g., screws. The box 300 comprises several holes or openings 330 .
[0064] By using one or several distance elements 340 , a gap (illustrated by a double arrow 345 in FIG. 3 ) is provided between the box 300 , i.e. a side of the box 300 being closest to the blade bearing reinforcement plate 310 and the surface of the reinforcement plate 310 . Further, a side of the box 300 being closest to the reinforcement plate 310 provides several holes or openings (not visible). According to an alternative embodiment, the box 300 is at least partly open towards the surface of the reinforcement plate 310 .
[0065] Due to the ongoing rotation of the rotor hub, wasted oil spillage 350 can move or pass through the gap 345 and the holes or openings 330 into the interior of the box 300 and thus will be absorbed by lubricant absorbing material (not visible in FIG. 3 ) located inside the box 300 .
[0066] FIG. 4 illustrates in an exemplary schematical view an alternative embodiment of the proposed solution located within an interior 400 of a rotor hub. The interior 400 is part of or representing a rotating part of the rotor hub.
[0067] Contrary to the exemplary embodiment as shown in FIG. 3 , an absorber element 430 comprising or housing lubricant absorbing material (not visible) is secured to the casted inner surface 450 of the rotor hub. According to the exemplary embodiment as shown in FIG. 4 , the shape of the absorber element 430 is adapted to the interior 400 , i.e. the inner surface 450 of the rotor hub like, e.g., fitting between two support elements 410 used for, e.g., mounting components of a hydraulic blade pitch system (not shown) within the interior 400 of the rotor hub.
[0068] The absorber element 430 comprises several holes or openings 440 enabling access of oil spillage to the lubricant absorbing material located inside the absorber element 430 . Due to ongoing rotation of the rotor hub during operation of the wind turbine, occurring oil spillage will be guided through the holes or openings 440 of the absorber element 430 to the lubricant absorbing material placed inside.
[0069] In addition to that, due to the particular shape, the absorber element 430 may be advantageously used as a service platform, allowing comfortable service and maintenance activities within the rotor hub or wind turbine.
[0070] It should be noted, that an arbitrary number of absorber elements may be placed within the interior 400 of the rotor hub, dependent on the size, available space and characteristics of the interior 400 .
[0071] As an advantage, the absorber element according to the proposed solution has a low complexity and a simple design. The proposed absorber element can be secured/mounted during production of the rotor hub or the wind turbine without hindering the installation of the rotor blades.
[0072] Thus, securing one or several absorber elements to the rotating part within the rotor hub or to any rotating part within the wind turbine is a simple and cheap solution for absorbing any lubricant wasted inside the rotor hub or wind turbine. Placing the absorber element within the interior of the rotor hub (like, e.g., at the blade bearing reinforcement plate) or within the interior of the wind turbine and due to the ongoing rotation of the rotor hub (or any other rotating part of the wind turbine), the lubricant like, e.g., oil spillage will run past the absorber element continuously where it will be collected and absorbed.
[0073] Although the present invention has been disclosed in the form of preferred embodiments and variations thereon, it will be understood that numerous additional modifications and variations could be made thereto without departing from the scope of the invention.
[0074] For the sake of clarity, it is to be understood that the use of “a” or “an” throughout this application does not exclude a plurality, and “comprising” does not exclude other steps or elements. The mention of a “unit” or a “module” does not preclude the use of more than one unit or module. | A wind turbine including a rotatable part, at least one absorber element secured to the rotatable part within an interior of the wind turbine, the at least one absorber element at least partly comprising lubricant absorbing material, wherein the absorber element is configured to absorb emerging lubricant inside the wind turbine is provided. Further, a rotor hub for a wind turbine, an absorber element for a wind turbine and a method for maintaining a clean environment in a wind turbine is also provided. | 5 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the priority benefit of Italian patent application number MI2010A001192, filed on Jun. 30, 2010, entitled BACKGROUND POWER CONSUMPTION REDUCTION OF ELECTRONIC DEVICE, which is hereby incorporated by reference to the maximum extent allowable by law.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The solution according to one or more embodiments of the present invention relates to the field of electronic devices. More specifically, the solution relates to the reduction of a power consumption of electronic devices.
[0004] 2. Discussion of the Related Art
[0005] Since some time the market of electronic products is increasingly focusing on products with low power consumption, particularly in the case of mobile products (e.g., computers, mobile phones and personal digital assistants). These mobile products include electronic devices (central processing unit, memory, display, etc.) for performing different operations. In particular, the electronic devices included in a generic mobile product should meet two main specifications. A first specification relates to a physical area occupation, which should be as small as possible in order to ensure the implementation of more electronic devices in the same mobile product or to reduce the size thereof. A second specification relates to a power consumption needed to operate such mobile devices. In more detail, such power is supplied by batteries which have a limited availability of energy. It is therefore desirable to reduce the power consumption of all the electronic devices included in the mobile products in order to increase the autonomy of such portable products with the same batteries used.
[0006] In particular, it is possible to identify two distinct phases of power consumption in an electronic device. A first phase is a phase of active power consumption associated with an operating condition of the electronic device (i.e., a period in which it actively performs an operation for which it was designed). A second phase is a phase of static power consumption associated with a standby condition of the electronic device; in this standby condition, the electronic device performs no operation but it is simply kept on to be ready to switch from the standby condition to the operating condition.
[0007] In general the standby condition of the electronic device may have a very long duration (e.g., several hours) during which the static power consumption unnecessarily dissipates energy stored in the batteries, thus reducing the autonomy of the corresponding portable device.
[0008] In the prior art various expedients have been implemented to reduce power consumption. Substantially these expedients are based on two different approaches. A first approach consists of partially or completely disabling the electronic devices in the standby condition; this dramatically reduces the static power consumption, but at the same time also the performance of the electronic device, as it requires a relatively long time to switch from the standby condition to the operating condition (needed for its bias voltages to reach a desired value thereof in a stable way).
[0009] A second approach involves the implementation of complex systems to manage the supplying of bias voltages in an advantageous way; in this case there is a substantial increase in the required area needed to implement the electronic devices, not always available in portable products; in addition, this enables a smaller reduction of the power consumption than the previous approach does, since such systems in turn consume some power for their correct operation.
[0010] This problem is particularly acute in programmable memory devices of the electrically/erasable type or EEPROM (“Electrically Erasable Programmable Read-Only Memory”). In fact, such memory devices use bias voltages of very high value (generally higher than a supply voltage of the corresponding portable products), which implies non-negligible power consumption.
SUMMARY OF THE INVENTION
[0011] In general terms, a solution according to one or more embodiments is based on the idea of storing the bias voltages in capacitive elements.
[0012] In particular, one or more aspects of a solution according to specific embodiments are set out in the independent claims, with advantageous features of the same solution that are set out in the dependent claims (whose wording is herein incorporated verbatim by reference).
[0013] More specifically, an aspect of a solution according to an embodiment provides an electronic device. The electronic device includes a set of functional blocks (e.g., a read/write unit and memory cells), and a biasing block for generating a set of bias voltages for the functional blocks. In the solution according to an embodiment, the electronic device further includes a holding block coupled between the biasing block and the functional blocks for providing each bias voltage to at least one corresponding functional block. For each bias voltage, the holding block includes a capacitive element (for storing the bias voltage), and a switching element; the switching element is switchable between an accumulation condition (wherein it provides the bias voltage from the biasing block to the capacitive element and to the corresponding at least one functional block), and a release condition (wherein it isolates the capacitive element from the biasing block and provides the bias voltage from the capacitive element to the corresponding at least one functional block). The electronic device further includes a control block for alternately switching the switch elements between the accumulation condition and the release condition.
[0014] Another aspect of a solution according to an embodiment provides a corresponding method (with the same advantageous features recited in the dependent claims for the memory device which apply mutatis mutandis to the method).
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] A solution according to one or more embodiments, as well as additional features and its advantages will be better understood with reference to the following detailed description, given purely by way of a non-restrictive indication and without limitation, to be read in conjunction with the attached figures (wherein corresponding elements are denoted with equal or similar references and their explanation is not repeated for the sake of brevity). In this respect, it is expressly understood that the figures are not necessarily drawn to scale (with some details that may be exaggerated and/or simplified) and that, unless otherwise specified, they are simply intended to conceptually illustrate the structures and procedures described herein. In particular:
[0016] FIG. 1 shows a principle block diagram of an EEPROM memory device wherein an embodiment is applicable;
[0017] FIG. 2 shows a principle circuit diagram of a holding block of the memory device according to an embodiment;
[0018] FIG. 3 shows a principle block diagram of a biasing block and of a control block of the memory device according to an embodiment;
[0019] FIG. 4 shows a principle circuit diagram of a generator block included in the control block according to an embodiment, and
[0020] FIG. 5 shows a principle block diagram of a state machine included in the control block according to an embodiment.
DETAILED DESCRIPTION
[0021] With particular reference to FIG. 1 , there is shown a principle block diagram of a memory device 100 , in which an embodiment is applicable; more specifically, the memory device 100 is an EEPROM-type memory device. The memory device 100 includes a matrix of memory cells 105 (not shown individually in the figure), which is organized into rows and columns. The memory device 100 also includes a row decoder 115 r and a column decoder 115 c. The access to the memory cells 105 of a selected word (in reading and writing) is made by decoding a row address ADRr and a column address ADRc, which are supplied to the row decoder 115 r and to the column decoder 115 c, respectively. The column decoder 115 c selectively connects the memory cells 105 to a read/write unit 120 , which contains circuitry used to read and write the selected memory cells 105 (e.g., driving circuits and comparators). A biasing block 125 provides a plurality of bias voltages Vbias needed for the operation of various blocks of the memory device 100 (and in particular, to be applied to the read/write unit 120 and to be applied to memory cells 105 through the row decoder 115 r ). A micro-controller 128 manages the operation of the entire memory device 100 (in particular, by interfacing with the read/write unit 120 ).
[0022] According to an embodiment, (as described in detail hereinbelow), the biasing block 125 provides the bias voltages Vbias to a holding block 130 , through a plurality of bias lines Lin. The holding block 130 in turn transfers bias voltages Vbias′ corresponding to the bias voltages Vbias, through bias lines Lout, to the read/write unit 120 and to the decoder 115 r . Moreover, the biasing block 125 provides a reference bias voltage (for example, of bandgap) Vbg (included among the bias voltages Vbias) to a control block 135 . The control block 135 also receives an enable signal EN and a register signal Reg from the micro-controller 128 . The control block 135 sends a control signal SH to the holding block 135 , to the biasing block 125 and to itself.
[0023] FIG. 2 shows a principle circuit diagram of the holding block 130 according to an embodiment. For each bias line Lin i (where the subscript i denotes a value between 1 and a number N equal the total number of bias lines Lin) and a corresponding bias line Lout i (belonging to the bias lines Lout), the holding block 130 includes a controlled switch S i and a holding capacitor C i . In more detail, the switch S i has a control terminal receiving the control signal SH (coming from the control block, not shown), a first conduction terminal connected to the bias line Lin i , and a second conduction terminal connected to the bias line Lout i . Such switch S i may include, for example, a PMOS-type transistor and a shifter circuit adapted to receive the control signal SH and convert it to a control voltage adapted to open and close the switch S i according to a logic value of the control signal SH. Moreover, the bias line Lin i is connected to a first terminal of the capacitor C i , while a second terminal thereof is connected to a ground terminal of the memory device for receiving a reference (or ground) voltage.
[0024] The operation of the holding block 130 is the following. The biasing block (not shown in the figure) provides a corresponding bias voltage Vbias i (included among the bias voltages Vbias) to the bias line Lin i .
[0025] When the control signal SH is asserted (e.g., at a high logic value equal to a supply voltage of the memory device) the switch S i is closed thereby coupling the bias line Lin i with the bias line Lout i ; in this way, the bias line Lout provides a corresponding bias voltage Vbias i ′=Vbias i (included among the bias voltages Vbias′) to the corresponding blocks of the memory device (e.g., the read/write unit and the memory cells, not shown in the figure). At the same time, the capacitor C i is charged to the same bias voltage Vbias i ′=Vbias i . When the control signal SH is de-asserted (e.g., at a low logic value equal to the ground voltage) the switch S i is opened thereby decoupling the bias line Lin i from the bias line Lout i . However, the bias line Lout i is maintained at the bias voltage Vbias i ′=Vbias i by the capacitor C i . In such condition, the blocks connected to the bias line Lout i still work correctly since they receive the same bias voltage Vbias i ′ necessary for their operation (even if the biasing block is turned off, as will be described in detail below). In such condition, due to inevitable leakage currents, the capacitor C i will discharge slightly from the bias voltage Vbias i toward the ground voltage, thereby reducing the bias voltage Vbias i ′ correspondingly.
[0026] The control signal SH is then asserted again, so as to recharge the capacitor C i to the bias voltage Vbias i (at the same time turning on again the biasing block that provides the bias voltage Vbias i )—with the same operations above described that are cyclically repeated.
[0027] Consequently, the bias voltage Vbias i ′ (provided to the blocks connected to the bias line Lout i ) will have a value that oscillates slightly over time under the bias voltage Vbias i . However, this ripple has a predetermined maximum width so as not to cause any problem to the proper operation of the memory device.
[0028] In this way, it is possible to achieve a high reduction in power consumption associated with the memory device as a whole. In fact, according to an embodiment there is power consumption (i.e., energy is absorbed by an energy source outside the memory device—e.g., a battery) only during the times when the control signal SH is asserted. Therefore, the power consumption is reduced proportionally to the time when the control signal SH is maintained de-asserted.
[0029] In contrast, an alternative embodiment differs from what has been previously described as follows. In an operating condition of the memory device, the control signal SH is always asserted. In this way, the holding block 130 does not interfere with the operation of the memory device (once the capacitor C i is charged at the bias voltage Vbias i applied to the bias line Lin i , which is directly transferred to the bias line Lout i ). In a standby condition, instead, the control signal SH is cyclically asserted and de-asserted as described above. This alternative embodiment thus allows reducing the power consumption in the standby condition only; it is particularly advantageous in the case wherein the functional blocks (not shown in the figure) require a high power consumption and/or a high precision of the biasing voltage in the operating condition (not sustainable by the capacitors C i ).
[0030] In an embodiment, the capacitors C i are implemented using stabilization capacitors already present on the connecting lines Lout i . These stabilization capacitors are normally used to reduce fluctuations of the voltage/current on the bias lines Lout i . In this way, there is no need to add more capacitors to the bias lines Lout i ; this allows saving area of the memory device and not increasing the total capacity on the bias lines Lout i . Consequently, no delays in the operation of the memory device are introduced (i.e., the performance thereof is not affected).
[0031] The capacitors C i do not have necessarily the same capacity; in fact, they may be advantageously sized according to the value of the corresponding bias voltages Vbias i and according to a maximum value of an operating current (in the operating condition of the memory device) and/or of a leakage current (in the standby condition of the memory device) drawn by the blocks connected to the corresponding bias lines Lout i . For example, the values of the capacities of the capacitors C i may vary from a few pF to a few tens of pF.
[0032] Referring now to FIG. 3 , it illustrates a principle block diagram of the biasing block 125 and of the control block 135 according to an embodiment of the invention.
[0033] The biasing block 125 has a power supply terminal VDD pol , which receives a supply voltage VDD of the memory device (e.g., 1.8-3V). The biasing block 125 includes a functional circuit 305 (e.g., formed by charge pumps and bandgap generators), which generates all the bias voltages Vbias from the supply voltage VDD (e.g., from 1 to 10V).
[0034] According to an embodiment, the biasing block 125 includes a controlled switch S pol having a first conduction terminal connected to the power supply terminal VDD pol , a second conduction terminal connected to an input terminal of the functional circuit 305 , and a control terminal for receiving the control signal SH. Some holding capacitors (all denoted with the same reference C pol ) are connected to corresponding nodes of the biasing block 125 , which are essential for the fast restart thereof (during the charging of the capacitors of the holding block). For example, a capacitor C pol is connected to each of the bias lines Lin (only one shown in the figure), and other capacitors C pol are arranged within the functional circuit 305 (only one shown in the figure).
[0035] The operation of the biasing block 125 is the following.
[0036] When the control signal SH is asserted (high logic value) the switch S pol is closed thereby connecting the input terminal of the functional circuit 305 to the power supply terminal VDD pol . At the same time, each capacitor C pol is loaded to the corresponding voltage.
[0037] When the control signal SH is de-asserted (low logic value) the switch S pol is open thereby decoupling the input terminal of the functional circuit 305 from the power supply terminal VDD pol . However, each bias line Lin is held at the corresponding bias voltage by its capacitor C pol . In this condition, the functional circuit 305 absorbs energy from the capacitors C pol , which then discharge slightly, thereby correspondingly reducing the supplied voltages.
[0038] The control signal SH is then asserted again, in order to recharge the capacitors C pol to the corresponding voltage—with the same operations described above that are cyclically repeated.
[0039] In this way, it is possible to further reduce the power consumption of the memory device (since as hereinabove there is a power consumption only during the times wherein the control signal SH is asserted, so that the power consumption is scaled down with the time wherein the control signal SH is maintained de-asserted).
[0040] The control block 135 instead includes a generator block 310 , which generates a further reference voltage VIref from the reference voltage Vbg received from the biasing block 125 . An oscillator block 315 (implemented in a way known in the art and therefore not described in detail) receives the reference voltage VIref and generates a periodic clock signal Clk with a period T proportional to the value thereof. A state machine 320 receives the clock signal Clk from the oscillator block 315 , and also receives the enable signal EN and the register signal Reg from the micro-controller (not shown in the figure). In particular, the enable signal EN may be either a signal dedicated to enable the control block 135 or a general enable signal commonly used to enable the memory device as a whole. According to the enable signal EN, the register signal Reg and the clock signal Clk, the state machine 320 generates the control signal SH which is supplied to the biasing block 125 and to the holding block 130 , and it is also supplied to the generator block 310 . In particular, following a first assertion of the enable signal EN (corresponding to a start up of the memory device) an initialization phase is started in which the control signal SH is asserted for a predetermined number J of periods of the clock signal Clk to allow the charging of all the holding capacitors of the memory device to the respective voltages. After the initialization phase, the control signal SH is de-asserted for a number N of periods T of the clock signal Clk determined by the register signal Reg (to turn off the biasing block and to open the switches). At the end of the number N of periods T, the control signal SH is asserted for a predetermined number M of periods T of the clock signal Clk (to turn on the biasing block and close the switches). The same operations described above are cyclically repeated (until the enable signal EN is not de-asserted).
[0041] The above-described structure allows programming, by means of the register signal Reg, the duration of a release condition (control signal SH de-asserted) of the holding capacitors (in which they discharge). Such register signal Reg allows varying the duration of the release condition from a minimum value to a maximum value (e.g., from 5 μs to 130 μs with an increment step of 5-20 μs) according to a maximum acceptable ripple of the voltages at the holding capacitors that does not compromise the performance of the memory device. A subsequent accumulation condition (control signal SH asserted) of the holding capacitors (in which they are recharged) has instead a fixed duration, which is chosen so as to ensure a full recharge of the holding capacitors for any duration of the discharge period.
[0042] FIG. 4 illustrates a principle circuit diagram of the generator block 310 according to an embodiment. The generator block 310 includes an operational amplifier 405 having a non-inverting input terminal (+) for receiving the reference voltage Vbg (from the biasing block, not shown in the figure), and an inverting input terminal (−) connected to a ground terminal (for receiving the ground voltage) through a resistor 407 . An output terminal of the operational amplifier 405 is connected to an intermediate node Ni. A PMOS output transistor 415 has a drain terminal connected to the inverting terminal of the operational amplifier 405 , and a gate terminal connected to the node Ni. A controlled switch Sin 1 has a first conduction terminal connected to a power supply terminal VDD gen (for receiving the supply voltage VDD), a second conduction terminal connected to a supply terminal of the operational amplifier 405 , and a control terminal for receiving the control signal SH. Another controlled switch Sin 2 has a first conduction terminal connected to the power supply terminal VDD gen , a second conduction terminal connected to a source terminal of the transistor 415 , and a control terminal for receiving the control signal SH. The generator block 310 also includes a holding capacitor Cin connected between the node Ni and the power supply terminal VDD gen .
[0043] A PMOS transfer transistor 425 has a gate terminal connected to the node Ni, a source terminal connected to the power supply terminal VDD gen , and a drain terminal connected to a first conduction terminal of a controlled switch Sout 1 . The switch Sout 1 has a control terminal for receiving the control signal SH and a second conduction terminal connected to a gate terminal of a NMOS transdiode transistor 440 , which is connected to an output node Nout that provides the reference voltage Viref; the transistor 440 has a source terminal connected to the ground terminal. A further controlled switch Sout 2 has a first conduction terminal connected to the node Nout, a second conduction terminal connected to a drain terminal of the transistor 440 , and a control terminal for receiving the control signal SH. A further holding capacitor Cout is connected between the node Nout and the ground terminal.
[0044] The operation of the generator block 310 is the following.
[0045] When the control signal SH is asserted (high logic value) all the switches Sin 1 , Sin 2 , Sout 1 and Sout 2 are closed thereby connecting the power terminal of the operational amplifier 405 and the source terminal of the transistor 415 with the power supply terminal VDDgen, and the drain terminal of the transistor 425 and the drain terminal of the transistor 440 with the gate terminal of the transistor 440 . As a result of a negative feedback, the operational amplifier 405 reproduces the reference voltage Vbg across the resistor 407 that conducts a reference current Ibg equal to the ratio between the reference voltage Vbg and a resistance of the resistor 407 . Such current Ibg flows completely through the transistor 415 (since the inverting input terminal of the operational amplifier 405 has infinite resistance), so that a corresponding intermediate voltage Vi is set to the gate terminal of the transistor 415 ; the voltage Vi is also set to the node Ni, thereby charging the capacitor Cin to the same. The voltage Vi is also applied to the gate terminal of the transistor 425 , which determines a corresponding current Idout through the transistor 425 , which depends on the relationship between the form factors (e.g., the ratio between width and length in MOS field effect transistors) of the transistors 425 and 415 (for example, with the currents through the transistors 415 and 425 that are equal if they have the same size). The current Idout charges the capacitor Cout until reaching the reference voltage VIref for which the transistor 440 turns on (diverting the current Idout toward the ground terminal). The generator block 310 then allows generating the reference voltage VIref from the reference voltage Vbg, keeping the non-inverting terminal of the operational amplifier 405 (which receives the reference voltage Vbg) decoupled from the node Vout (which generates the reference voltage VIref), thereby isolating the upstream biasing block from the downstream oscillator block (not shown in the figure).
[0046] When the control signal SH is de-asserted (low logic value) the switches Sin 1 , Sin 2 , Sout 1 and Sout 2 are open. Consequently, the operational amplifier 405 and the transistor 415 are turned off (as they do not receive the supply voltage VDD gen any longer). However, the node Ni is maintained at the voltage Vin by the capacitor Cin (apart from a slight discharge thereof). At the same time, the node Nout is maintained at the reference voltage Vlref by the capacitor Cout; in this condition, the oscillator (not shown in the figure) receives the reference voltage VIref through the capacitor Cout, which then slightly discharges.
[0047] The control signal SH is then asserted again, so as to recharge the capacitor Cin to the voltage Vin and the capacitor Cout to the reference voltage Viref—with the same operations described above that are cyclically repeated.
[0048] In this way, it is possible to further reduce the power consumption of the memory device (since there is a power consumption only during the times when the control signal SH is asserted, so that the power consumption is reduced with the time wherein the control signal SH is maintained de-asserted).
[0049] The FIG. 5 illustrates a principle block diagram of the state machine 320 included in the control block (not shown in the figure) according to an embodiment of the invention. The state machine 320 includes a counter 505 and a phase block 510 . Both the counter 505 and the phase block 510 receive the clock signal Clk (from the oscillator, not shown in the figure) and the enable signal EN (from the micro-controller, not shown in the figure). The counter 505 further receives the register signal Reg (from the micro-controller as well), and an accumulation end signal ER from the phase block 510 to which in turn it provides an end of count signal EoC. The phase block 510 generates the control signal SH.
[0050] The operation of the state machine 320 is the following.
[0051] At the end of theinitialization phase of the memory device described above, the phase block 510 impulsively asserts the accumulation end signal ER. In response thereto, the counter 505 is initialized to zero (with the signal EoC that remains de-asserted), and it is incremented at each period of the clock signal Clk; at the same time, the phase block 510 de-asserts the control signal SH—thereby determining the release condition. When the counter 505 reaches the value N determined by the register signal Reg, it asserts the signal EoC. In response thereto, the phase block 510 asserts the control signal SH—thereby determining the accumulation condition—for a predetermined number M of periods of the clock signal Clk. At the end of the M-th period T of the clock signal Clk the phase block 510 de-asserts the control signal SH again (to return to the release condition); at the same time, the phase block 510 impulsively asserts the signal ER, which re-initializes the counter 505 to cyclically repeat the same operations described above (until the enable signal EN is de-asserted).
[0052] Naturally, in order to satisfy local and specific requirements, a person skilled in the art may apply to the solution described above many logical and/or physical modifications and alterations. More specifically, although this solution has been described with a certain degree of particularity with reference to one or more embodiments thereof, it should be understood that various omissions, substitutions and changes in the form and details as well as other embodiments are possible. Particularly, different embodiments of the invention may even be practiced without the specific details (such as the numerical examples) set forth in the preceding description to provide a more thorough understanding thereof; conversely, well-known features may have been omitted or simplified in order not to obscure the description with unnecessary particulars. Moreover, it is expressly intended that specific elements and/or method steps described in connection with any embodiment of the disclosed solution may be incorporated in any other embodiment as a matter of general design choice.
[0053] For example, similar considerations apply if the memory device has a different architecture or includes equivalent components (either separated or combined, in whole or in part). In addition, the memory device may have different operating characteristics; for example, the signals may be asserted and de-asserted at different reference voltages (even reversed to each other).
[0054] Nothing prevents from arranging the holding block to provide bias voltages to other functional blocks of the memory device, such as system oscillators and/or control and driving circuits of the charge pumps.
[0055] Furthermore, the holding block may be distributed instead of concentrated, i.e., a controlled switch and a holding capacitor may be provided directly to a terminal for receiving the respective bias voltage of each functional block of the memory device.
[0056] Obviously, the controlled switches may be implemented differently—for example, by using transistors with different doping, bipolar transistors or pass-gates.
[0057] Alternatively, the control block may alternately switch the switches between the accumulation condition and the release condition in any other condition of the memory device (for example, only in a energy-saving operating condition).
[0058] Nothing prevents from implementing dedicated holding capacitors to be used with or instead of the stabilization capacitors already provided in the memory device.
[0059] In addition, the control block may have an equivalent structure (e.g., without requiring a dedicated oscillator). Alternatively, more control signals may be generated to control different functional blocks in a specific way.
[0060] Nothing prevents from maintaining the biasing block always supplied or to provide more than one switch in the functional block—for example, a switch for each charge pump and bandgap circuit included in the functional circuit.
[0061] Moreover, the generator block may be provided with a greater/lower number of holding capacitors and switches.
[0062] Similarly, also the generator block may have a structure different from the described one.
[0063] Alternatively or in addition, both the accumulation and release conditions may be made programmable or both constant and predetermined.
[0064] Nothing prevents from implementing the solution in a device different from an EEPROM-type memory; for example, an embodiment may be implemented in acquisition devices (such as analog-to-digital converters and samplers).
[0065] The proposed solution lends itself to be implemented by an equivalent method (using similar steps, removing some steps being not essential, or adding further optional steps); moreover, the steps may be performed in different order, in parallel or overlapped (at least in part).
[0066] It should be readily apparent that the proposed solution might be part of the design of an integrated device. The design may also be created in a programming language; in addition, if the designer does not manufacture the integrated device or its masks, the design may be transmitted through physical means to others. Anyway, the resulting integrated device may be distributed by its manufacturer in the form of a raw wafer, as a naked chip, or in packages.
[0067] Moreover, the memory device may be integrated with other circuits in the same chip, or it may be mounted in intermediate products (such as motherboards) and coupled with one or more other chips (such as a processor). In any case, the memory device is adapted to be used in complex systems (such as a mobile phone).
[0068] Having thus described at least one illustrative embodiment of the invention, various alterations, modifications, and improvements will readily occur to those skilled in the art. Such alterations, modifications, and improvements are intended to be part of this disclosure, and are intended to be within the spirit and the scope of the present invention. Accordingly, the foregoing description is by way of example only and is not intended to be limiting. The present invention is limited only as defined in the following claims and the equivalents thereto. | An electronic device including a set of functional block, and a biasing block for generating a set of bias voltages for the functional blocks. The electronic device further includes a holding block coupled between the biasing block and the functional blocks for providing each bias voltage to at least one corresponding functional block, for each bias voltage the holding block including a capacitive element for storing the bias voltage, and a switch element switchable between an accumulation condition wherein provides the bias voltage from the biasing block to the capacitive element and to the at least one corresponding functional block, and a release condition wherein isolates the capacitive element from the biasing block and provides the bias voltage from the capacitive element to the at least one corresponding functional block, and a control block for alternately switching the switching elements between the accumulation condition and the release condition. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority from, and is a 35 U.S.C. §111(a) continuation of, co-pending PCT international application serial number PCT/US01/31667 filed on Oct. 9, 2001 which designates the U.S. and which claims priority from U.S. provisional application Ser. No. 60/239,427 filed on Oct. 10, 2000, incorporated herein by reference.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not Applicable
INCORPORATION-BY-REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISC
Not Applicable
NOTICE OF MATERIAL SUBJECT TO COPYRIGHT PROTECTION
A portion of the material in this patent document is subject to copyright protection under the copyright laws of the United States and of other countries. The owner of the copyright rights has no objection to the facsimile reproduction by anyone of the patent document or the patent disclosure, as it appears in the United States Patent and Trademark Office publicly available file or records, but otherwise reserves all copyright rights whatsoever. The copyright owner does not hereby waive any of its rights to have this patent document maintained in secrecy, including without limitation its rights pursuant to 37 C.F.R. §1.14.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention pertains generally to aerodynamic load control devices, and more particular to a translational device for controlling lift of an airfoil.
2. Description of Related Art
Aerodynamic load control devices are common on lifting surfaces on airplanes, rotorcraft, wind turbines and other lift generating systems. In an airplane, an aileron is a typical aerodynamic control device used to change the lift and drag properties of the airfoil. Despite their lift enhancement properties, however, conventional aileron devices tend to be bulky and heavy and often require complex systems for actuation and support. Also, these devices are prone to flutter and as a result require special attention in the design and development stage. In addition, conventional devices tend to require intensive and costly maintenance throughout the lifespan of the system.
A conventional control surface or simple flap is a separate moveable lifting surface that typically occupies the aft 20% to 30% of the chord of a lifting surface.
As illustrated in FIG. 1 , in a conventional airfoil 10 , rotating the control surface or flap 12 about its hinge point 14 results in a change in surface camber which in turn causes a change in the circulation of the air flow 16 and, thus, the lift 18 of the entire lifting surface. For example, raising flap 12 to position 20 will cause a decrease in lift, while lowering flap 12 to position 22 will cause an increase in lift. It is well known that the optimum location for subsonic lift control in aircraft is at the trailing edge of an airfoil since small changes in the flow field near the trailing edge can result in large changes in the overall flow field. The trailing-edge geometry of a lifting airfoil or surface has a significant influence on the aerodynamic performance of the airfoil at subsonic and transonic flow conditions.
One example of small changes in the flow field near the trailing edge creating large changes in the overall flow field is the trailing-edge blowing concept. Here, large increases in lift are obtainable when tangential surface blowing occurs over a rounded trailing edge. This pneumatic concept can greatly simplify high-lift system complexity and also replace the control surfaces on aircraft. The major problems with this concept are 1) the complexity, weight, and cost associated with the piping of substantial amounts of high-pressure air, (2) the increase in engine size and, hence, weight and cost, necessitated by the loss in engine mass flow for the pneumatic system, or the need for pumps (many small ones or one or two large ones) to generate the required mass flow, and (3) the problem of making this concept reliable and failsafe; i.e., a loss in engine power or an engine failure should not result in a loss of airplane control.
Instead of trailing-edge blowing, it may be easier to deploy a small trailing-edge flap for lift control. An example of such a device is a “Gurney-flap” which consists of a small (approximately 0.01×airfoil-chord), fixed vertical tab mounted perpendicular to the lower (pressure) surface at the trailing edge. FIG. 2 shows the relationship between the coefficient of lift, C L , and angle of attack, α, for a 0.125c Gurney-flap in comparison to a clean airfoil. While Gurney-flaps enhance lift in the linear range as shown in FIG. 2 , they may also cause a significant drag penalty especially at low lift conditions, such as cruise flight. This drag penalty is the main reason why Gurney-flaps are used on only a few aircraft configurations for which high maximum lift is more important than low cruise drag. To avoid the drag penalty, miniature split flaps hinged to the airfoil lower surface have been conceptualized. While these split flaps would be stowed during cruise so as to eliminate drag, their implementation has been hampered by the fact that the aft portion of an airfoil with a sharp trailing edge does not provide sufficient structural support or volume for hinges and deployment hardware based on conventional manufacturing technology.
BRIEF SUMMARY OF THE INVENTION
In accordance with the present invention, the foregoing problems are solved by using small, tab-like, translational elements that are imbedded in the trailing-edge region of the airfoil. When activated, the translational elements deploy outward and have a maximum height of a few percent of the chord length of the airfoil. Downward deflection augments airfoil camber and, hence, lift, whereas upward deflection decreases lift. The effect of these translational elements on lift is as powerful as a conventional flight control surface such as an aileron.
By way of example, and not of limitation, a plurality of actively controlled micro-electro-mechanical (MEM) translational elements are installed in the trailing edge region of lifting surfaces. These MEMs tabs are small (e.g., approximately 1% of chord), are robust and versatile, can range anywhere from microns to centimeters in width, and can extend in length up to several millimeters which is on the order of the boundary layer thickness. In one embodiment, the translational elements are mounted forward of a “sharp” or tapered trailing edge of the airfoil, deploy normal to the surface, and are designed to both extend and retract. In an alternative embodiment, the translational elements are mounted at edge of a blunt trailing edge. Deployment of this type of device in either configuration modifies the camber distribution of the airfoil section, and hence the lift generated.
Application of this rather simple but innovative lift control system based on microfabrication techniques will permit the elimination of conventional control systems and, hence, result in a significant reduction in weight, complexity, and cost. Also due to the miniature size of these tabs, their activation and response times are expected to be much faster than that of conventional trailing edge devices. Further objects and advantages of the invention will be brought out in the following portions of the specification, wherein the detailed description is for the purpose of fully disclosing preferred embodiments of the invention without placing limitations thereon.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)
The invention will be more fully understood by reference to the following drawings which are for illustrative purposes only:
FIG. 1 is schematic side view of an airfoil employing a conventional aerodynamic load control device illustrating the movement of an aileron for increasing and decreasing lift.
FIG. 2 is a graph showing the relationship between coefficient of lift, C L , and angle of attack, α, for a 0.125c Gurney-flap in comparison to a clean airfoil.
FIG. 3 is a schematic side view of an airfoil employing a translational aerodynamic load control device according to the present invention forward of the trailing edge.
FIG. 4 is a detailed schematic view of the translational element of FIG. 3 shown extended upward to decrease lift.
FIG. 5 is a detailed schematic view of the translational element of FIG. 3 shown retracted for cruise.
FIG. 6 is a detailed schematic view of the translational element of FIG. 3 shown extended downward to increase lift.
FIG. 7 is a graph showing the relationship between the coefficient of lift and angle of attack corresponding to the positions of the translational element shown in FIG. 4 through FIG. 6 .
FIG. 8 is a schematic side view of an alternative embodiment of an airfoil employing a translational aerodynamic load control device where the translational elements are installed at the blunt trailing edge according to the invention.
FIG. 9 is a detailed schematic view of the translational element of FIG. 8 shown extended upward to decrease lift.
FIG. 10 is a detailed schematic view of the translational element of FIG. 8 shown retracted for cruise.
FIG. 11 is a detailed schematic view of the translational element of FIG. 8 shown extended downward to increase lift.
FIG. 12 is an exploded schematic view of a translational stage according to the present invention.
FIG. 13 is an assembled view of the translational stage shown in FIG. 12 .
FIG. 14 is a schematic view of a two element array of translational stages shown in FIG. 13 .
FIG. 15 is a perspective schematic view of the underside of an airfoil with an eight element linear array of translational stages shown in FIG. 13 .
FIG. 16 is a schematic side view in cross-section of the trailing edge portion of an airfoil showing a translational stage of FIG. 14 in the retracted position.
FIG. 17 is a schematic side view in cross-section of the trailing edge portion of an airfoil showing a translational stage of FIG. 14 in the extended position.
FIGS. 18A through 18E is a flow diagram showing an example of steps employed in the fabrication of the translational stage shown in FIG. 12 and FIG. 13 .
FIG. 19 is a graph showing the relationship between coefficient of lift, C L , and translational element location in percent of chord from trailing edge for a GU25-5(11)-8 airfoil at an angle of attack α=0 and Re=1.0×10 6 .
FIG. 20 is a graph showing the relationship between coefficient of drag, C D , and translational element location in percent of chord from trailing edge for a GU25-5(11)-8 airfoil at an angle of attack α=0 and Re=1.0×10 6 .
FIG. 21 is a graph showing the relationship between the ratio of coefficient of lift, C L , to coefficient of drag, C D , and translational element location in percent of chord from trailing edge for a GU25-5(11)-8 airfoil at an angle of attack α=0 and Re=1.0×10 6 .
FIG. 22 is a graph showing the predicted relationship between coefficient of lift, C L , and angle of attack, α, for a GU25-5(11)-8 airfoil and Re= 1 . 0 × 10 6 with and without a translational element according to the invention.
FIG. 23 is a graph showing the relationship between force coefficients and translational element height in percent of chord.
DETAILED DESCRIPTION OF THE INVENTION
Referring more specifically to the drawings, for illustrative purposes the present invention is embodied in the apparatus and methods generally shown in FIG. 3 through FIG. 23 . It will be appreciated that the apparatus may vary as to configuration and as to details of the parts, and that the method may vary as to the specific steps and sequence, without departing from the basic concepts as disclosed herein.
Referring first to FIG. 3 , in accordance with the present invention a plurality of translational elements are installed in the trailing-edge region 24 of lifting surfaces of airfoil 10 for load control instead of conventional control systems. FIG. 4 through FIG. 6 depict such a configuration. In FIG. 4 , one such translational element (tab) 26 is shown in an upward extended position to cause a decrease in lift. In FIG. 5 translational element 26 is shown in a fully retracted position which would be the case during aircraft cruise conditions. In FIG. 6 , translational element 26 is shown in a downward extended position to cause an increase in lift. The amount of extension of translational element 26 can be variable or extension can be controlled to simply be “on/off”.
Referring also to FIG. 7 , the effect of these translational elements on lift is shown to be as powerful as a conventional flight control surface. FIG. 7 shows the relationship between the lift coefficient, C L , and angle of attack where:
C L = Lift 1 2 ρ v 2 S , ρ = fluid density , v = flow velocity , and S = platform area of wing .
for translational element with a height of 0.01 c and position of 0.05 c forward of the trailing edge, wherein c=chord. Line 30 shows the characteristics with the translational element deployed downward, line 32 shows the characteristics with the translational element retracted, and line 34 depicts the characteristics with the translational element deployed upward. As can be seen, a translation element with a height of one percent of the chord deployed downward near the trailing edge is demonstrated to increase the lift at zero angle of attack by approximately 35%.
Note in FIG. 3 through FIG. 6 that airfoil 10 employs a tapered or sharp trailing edge 28 and that the translational elements are positioned forward of the trailing edge 28 . Alternatively, airfoil 10 could employ a blunt trailing edge 36 as shown in FIG. 8 through FIG. 11 . In FIG. 9 , translational element 26 is shown in an upward extended position to cause a decrease in lift. In FIG. 10 translational element 26 is shown in a fully retracted position which would be the case during aircraft cruise conditions. In FIG. 11 , translational element 26 is shown in a downward extended position to cause an increase in lift.
It will be appreciated that the specific implementation of the translational elements will vary with the scale of the lifting surface. For example, one embodiment involves the application of micro-electro-mechanical systems (MEMS) technology. In accordance with this embodiment, a plurality of such translational elements would be fabricated in silicon using anisotropic etching and produced in predefined arrays of arbitrary geometry. Each element within an array could be individually actuated to produce a variable trailing-edge geometry for the lifting surface. Furthermore, use of a serrated pattern for the trailing-edge geometry may have a beneficial effect on the performance characteristics of the lifting surface. The translation elements can be actuated mechanically and/or magnetically using known techniques. When activated, the translational elements deploy outward; that is, they attain an extended position. Downward extension augments airfoil camber and, hence, lift whereas upward extension decreases lift. The size of each translational element can range anywhere from microns to centimeters in width and extension with thicknesses up to several millimeters.
Preferably, translational element 26 comprises a sliding component in a “dovetail” microfabricated translational stage 38 having the configuration shown in FIG. 12 and FIG. 13 . The translational stage shown in FIG. 12 and FIG. 13 comprises a base 40 having a plurality of dovetail-shaped receptacles 42 , a slider 44 having a plurality of dovetail-shaped fingers 46 that slidably mate with receptacles 42 , and an extender 48 that is coupled to slider 44 . To assemble the translational stage, extender 48 is bonded to slider 44 using a conventional bonding technique and fingers 46 are slidably inserted into receptacles 42 . The dovetail joint configuration provides a natural interlock to prevent slider 44 and extender 48 , which together form translational element 26 , from falling out of base 40 .
For use with an airfoil, a plurality of translational stages 38 are arranged into a linear array by bonding the stages to a support member 50 as shown in FIG. 14 , thereby forming a modular track. FIG. 15 shows an example of a portion of an airfoil with an array of eight translational stages. Approximately thirty stages are needed to cover a 3-foot airfoil section where the length, height and width of each assembly are approximately 20 mm×5 mm×1.2 mm, respectively. Note also that FIG. 15 illustrates that translational elements 26 can be individually controllable. Each translational stage can be retracted as shown in FIG. 16 or extended as shown in FIG. 17 .
Dovetail translational stages of various sizes can be easily fabricated in this manner ranging in width length from, for example, 100 μm to 12 cm. To be used as a lift control device for an airfoil, an extender translation distance should be on the order of a few millimeters on small chord sections with larger sections requiring a proportional increase in actuation distances. While typical translation limits for conventional MEMs devices are at best a few hundred microns, one of the primary advantages of the dovetail translational stages used here is their relatively large translational capability. In addition, the joint design allows for “packaging” in the small space at the trailing edge of airfoils. This structure thus provides a simple, interconnecting, sliding assembly that is small and lightweight. By using microfabrication techniques, these “microtab” type translational elements can be designed and sized to fit the aerodynamic application.
Referring to FIG. 12 , FIG. 13 and FIG. 18A together, the translational stages are preferably fabricated on a silicon wafer 100 coated with silicon nitride 102 . Conventional chemical etching techniques are used to readily produce the translational stages in predefined arrays of arbitrary geometry. In a typical fabrication process, a chrome mask with the design pattern is created. Taking into account the silicon crystalline orientation, the mask is patterned and transferred to a silicon wafer as shown in FIG. 18B . Next, as depicted in FIG. 18C , silicon is removed in the areas not covered by the photoresist 104 to form the uniform dovetails with 54.7 degree etch angles. This is accomplished using conventional plasma (RIE) and chemical etching (KOH and HF) processes. As shown in FIG. 18D , the etched wafer is then chemically cleaned and fusion bonded to a separate handle wafer 106 , and the bridging portions 108 are removed. A final silicon nitride coat 110 is applied to create a nearly flawless and frictionless surface for the sliding tabs. Base 40 and slider 44 are then diced to size as shown in FIG. 12 and extender 48 is bonded to slider 44 to form an assembly as shown in FIG. 13 . While all pieces are fabricated from silicon coated with silicon nitride, it will be appreciated that the design allows for exchange of materials. Careful processing results in dovetails with very smooth and precise interlocking qualities and tolerances of a few microns. Such tolerances are unachievable using conventional machining tools. The dovetail design is also self-cleaning as any dust or dirt would be removed from the tracks. A typical yield for a four-inch wafer is approximately 20–25 assemblies.
Static load tests on the translational stages assemblies show that these structures can withstand normal loads of approximately 1.7 N. Given that silicon nitride has a coefficient of friction of approximately 0.4, target actuation forces necessary to activate these tabs are estimated to be about 0.7 N.
It will be appreciated that actuation of the translational elements is an important aspect of commercial realization of the invention. Actuation methods not only need to be able to extend distances of millimeters but must also be able to supply the necessary activation energy. The MEMS translational stages are simple to actuate, robust, and lightweight. For micro-devices, electrostatic and electromechanical methods are predominant due to the minute size and application compatibility. Using conventional magnetic actuation methods, dovetail devices of the type described can be accelerated to over 100 mm/sec in 10 msec with less than 700 μN of force. Translational distances between one micron and 8 cm can also be achieved. However, while magnetic actuation is easily achievable in a controlled laboratory environment, it may not be practical for commercial commercially. For flight vehicles, pneumatic, hydraulic, and mechanical systems have been the conventional means of actuation. Since conventional flight controls are exposed to much higher loads and harsher conditions they require greater activation energies and tend to be large and heavy. With target voltage limits, cost, space and weight restrictions, piezo-electric, hydraulic and pneumatic devices were not considered. A design requiring compressed air canisters or hydraulic reservoirs was not desired. High power consumption devices were also considered unsuitable.
Various methods of actuation investigated include a mechanical linear actuator, a rod and motor linkage, and a shape memory alloy (SMA) assembly. A number of push-pull linear actuators were assembled to test their feasibility. Although the actuators provided adequate travel distance, the non-linearity in the activation force of the mechanical actuators proved to be a limitation. Also an estimated eight to ten actuators would be needed to drive twenty to thirty translational elements which increases the weight significantly. A mechanical linkage using rods and radio control (R/C) motors appears to be most feasible for initial prototype testing.
With recent development and commercialization of shape memory alloys (SMA), a possible solution is presented using SMA wire. Since these translational elements are “micro” in fabrication and design but are “macro” in performance and effect, it seems fitting that to actuate such a device a combination of mechanical and electrical methods be utilized. A prototype actuation mechanism using SMA wire was been sized to investigate the feasibility of such a method. Based on manufacturer's data, using Flexinol wire of 0.003″ diameter, the required extension length is achievable. With some wing construction modifications to incorporate length and heat dissipation requirements of the wires, SMA activation shows promise.
EXAMPLE
A GU25-5(11)-8 airfoil was chosen for testing, although numerous other airfoils could have been chosen as well. The GU25-5(11)-8 was selected for its larger trailing edge volume and nearly flat bottom surface. The thick trailing edge provides the volume needed to retract the translational elements. Also, the nearly flat lower surface makes it easy to install translational elements. The GU25-5(11)-8 airfoil was developed at the University of Glasgow as one of a series of high lift, low-drag airfoils.
Experiments were conducted using three, 12-inch chord, 33.5 inch span test airfoil models. One airfoil was used to perform validation tests and to develop a consistent data set for comparison and correction data. The other two GU-like airfoils were fitted with the translational stages. All experiments were conducted in the UC Davis Wind Tunnel Facility (UCD). The facility houses a low-turbulence wind tunnel with a 3×4 ft cross section and 12 ft in length test section built by AeroLab. Tunnel test speeds range from 5 mph to 160 mph and have a six-component force-balance for measuring lift, drag, and side forces and roll, pitch and yaw moments. A 16-bit data acquisition system is used to gather data. The tunnel is also equipped with a turntable for yaw or angle of attack control for 2D or 3D testing and has a moveable XY traverse probe for mounting pitot-static probes or hot-wire anemometers.
Wind tunnel airfoil models were fabricated using foam, fiberglass and epoxy resin. For translational stage installation, a recess was routed in the trailing edge. Based on computational results and volume constraints, the tabs were installed and tested at 5% chord from the trailing edge. This location allowed for sufficient room for retracting the tabs without loosing the lift enhancement benefit. Fully retracted, the tabs were nearly flush with the surface of the airfoil. Fully extended, the tabs extended approximately 3 mm (1% of chord) perpendicular to the surface. This design allowed for minimum changes to current wing design and manufacturing techniques. Over 90% of the airfoil would remained unchanged with only modifications to the trailing edge region.
Analysis using computational fluid dynamics (CFD) codes greatly reduced the number of experimental runs and models needed. By studying the effects with and without the translational elements and the effects of varying height, location and width using simulated data, test model sizes and configurations were finalized.
A typical flow field in the trailing edge region with the separated, recirculating flow behind the translational element was observed. Despite the forward location, the translational element remained effective. The reason is that the point of flow separation for the entire airfoil essentially shifts from the trailing edge to the lower edge of the translational element.
Translational elements were scaled in accordance with model dimensions. Previous work showed that translational elements around 1% of the chord to be a good average size. With that as a starting size, computational simulations were performed using various tab configurations. To have sufficient volume for retraction, it was necessary to test the translational elements at various locations upstream of the trailing edge. It was found that the lift enhancement benefits of the translational elements were retained despite their forward location.
To observe the effect of translational element position on performance, calculations were made with the translational elements positioned at the trailing edge (0%) and moved forward up to 10% of chord from the trailing edge. Note that with the translational elements simply placed at the trailing edge, C L increased from 0.613 to 0.858. FIG. 19 through FIG. 21 show the effect of position for a 1% translational element on lift, drag, and lift to drag ratio for the GU25-5(11)-8 airfoil at an angle of attack α=0 and Re=1.0×10 6 . Based on the results shown in FIG. 19 , an effective zone for placing the translational elements on the test airfoil was determined to range from 2% to 6% of the aft portion of the chord with maximum C L benefit at around 3% chord. As expected, the coefficient of drag (C D ) steadily increases as the translational element is moved forward from the trailing edge) as shown in FIG. 20 ; however, the performance benefit gained terms of C L /C D remains until the translational element was moved past 6% of chord where the drag penalties become significant as shown in FIG. 21 . FIG. 22 shows a predicted shift in the lift curve by ΔC L =0.3 for the test airfoil with a 1% translational element placed at x/c=0.97.
Similar results were generated for translational elements of differing heights as shown in FIG. 23 . Translational elements over 2% chord in height did not seem to derive any further benefit in C L , and in fact resulted in a noticeable increase in C D . Based on simulation results, microfabrication and material properties, a final tab size of 1% (e.g., approximately 3 mm fully extended), positioned at 5% of chord upstream of the trailing edge was determined to be preferable.
Although the description above contains many specificities, these should not be construed as limiting the scope of the invention but as merely providing illustrations of some of the presently preferred embodiments of this invention. Therefore, it will be appreciated that the scope of the present invention fully encompasses other embodiments which may become obvious to those skilled in the art, and that the scope of the present invention is accordingly to be limited by nothing other than the appended claims, in which reference to an element in the singular is not intended to mean “one and only one” unless explicitly so stated, but rather “one or more.” All structural, chemical, and functional equivalents to the elements of the above-described preferred embodiment that are known to those of ordinary skill in the art are expressly incorporated herein by reference and are intended to be encompassed by the present claims. Moreover, it is not necessary for a device or method to address each and every problem sought to be solved by the present invention, for it to be encompassed by the present claims. Furthermore, no element, component, or method step in the present disclosure is intended to be dedicated to the public regardless of whether the element, component, or method step is explicitly recited in the claims. No claim element herein is to be construed under the provisions of 35 U.S.C. 112, sixth paragraph, unless the element is expressly recited using the phrase “means for.” | Micro-electro-mechanical (MEM) translational tabs are introduced for enhancing and controlling aerodynamic loading of lifting surfaces. These microtabs are mounted at or near the trailing edge of lifting surfaces, deploy approximately normal to the surface, and have a maximum deployment height on the order of the boundary layer thickness. Deployment of this type of device effectively changes the camber, thereby affecting the lift generated by the surface. The effect of these microtabs on lift is as powerful as conventional control surfaces such as ailerons. Application of this simple yet innovative lift enhancement and control device will permit the elimination of some of the bulky conventional high-lift and control systems and result in an overall reduction in system weight, complexity and cost. | 5 |
BACKGROUND OF THE INVENTION
The present invention pertains to anchoring devices for securing an object to a cargo bed, such as for a flatbed truck, railroad flatcar or the like.
Flatbed trucks are exemplary of common hauling equipment used across a wide range of businesses. A flatbed truck typically comprises a relatively large, planar mounting or support surface, usually without surrounding sidewalls. Large or bulky items may be easily placed and supported thereon for transport. The bed is primarily comprised of wood, but usually also includes a pair of channel-shaped metal rails attached to opposing sides thereof. The rails are designed to perform a two-fold function including increasing the overall strength of the bed and providing a more durable material to which devices for securing objects on the bed may be attached.
The transportation or hauling of large and bulky objects in particular often engender special difficulties since conventional packing and shipping means are inappropriate. Flatbed trucks have been used extensively for the hauling of such items, due to their capacility of holding a wide range of objects of different shapes and sizes. However, the unencumbered mounting surfaces which make these trucks attractive require special anchoring devices to prevent the object from shifting or falling from the bed. Chains provided with end hooks are normally employed to hold the item in place, although cables or other retaining means may be utilized.
More specifically, the anchoring chains overlie the object to be held in a tight frictional engagement, and are fastened to opposing sides of the trunk bed. Yet, the manner by which the chains are coupled to be bed has been a persistent problem. Typically, square holes have been provided in the siderails of the bed along with corresponding posts that are received therein. The anchoring chains may then be fastened directly to the posts to complete the mounting of the object on the bed.
This arrangement, however, has several disadvantages. First, the holes are generally provided at only a few locations along the side of the bed, which drastically limits the user's options in securing objects on the bed. For instance, a particularly bulky item may, because of the placement of the holes and posts, need to be mounted in the center of the truck thereby precluding the mounting of other items, and in turn, requiring additional trucks. Hence, the efficiency of the flatbed truck may be severaly reduced because of restricted anchoring options. Similarly, the provision of an upright post may occasionally be in the way of a portion of the bulky item to be held or not as advantageously located as the use may need.
Secondly, the square holes concentrate the force at the top surface of the rails which thereby tends to distort and damage the bed.
Thirdly, it is sometimes desirous to provide the flatbed truck with a rigid cover means in an effort to protect the object being hauled from dust and debris or inclement weather. These covers are generally mounted to the rails of the flatbed truck. However, when using the post and chain mounting arrangement it is not possible to employ such a cover.
Lastly, it is noted that many businesses rely on rented trucks for their hauling needs. While rented trucks generally are provided with chains, they typically have no means by which to attach the chains to the truck bed. Consequently, the user normally attached the chains directly to the openings in the truck bed. Again, this not only lacks the desired versatility needed to maximize the truck's efficiency, but also applied a concentrated force which tends to distort and damge the truck bed.
In an effort to solve these problems, prior artisans have developed several alternatives. One alternative has been to fixedly attach tie-down devices to the side of the bed through the use of bolts, rivets, welding, or the like. While this arrangement may distribute the load in a more effective manner, it still has many shortcomings. For example, since the devices are permanently attached to the side of the bed, it still lacks the adjustment versatility needed to maximize mounting efficiency. Also, these arrangements alter the side of the truck in a permanent fashion, and hence are not possible when using rented trucks. Further, these devices have not accommodated the use of a cover means.
It has also been suggested to mount a tie-down device so that it is adjustable along the side of the bed. Such devices do offer a better distribution of the load and, since they are adjustable, they do facilitate mounting efficiency. However, the flatbed trucks employing these devices have been specifically adapted with means to accommodate such a movable device. Furthermore, these devices have been permanently mounted on the flatbed trucks, thereby precluding, for instance, easy removal and positioning of the device on a different side of the flatbed truck. While these devices may operate satisfactorily on such specially adapted vehicles, they provide no advantage to the thoudsands of flatbed trucks already in use without special modifications. Also, the manufacture of flatbed trucks that are specially adapted for the adjustable devices is a more expensive endeavor than the manufacture of a conventional flatbed truck. Moreover, these deivces do not facilitate the use of a rigid cover means.
A third arrangement of tie-down devices that have been suggested are removably mounted and adjustable along the side of a truck bed. However, these devices are normally articulated in such a way so as to clampingly grip the side of the bed when a load is applied through the chain. Hence, these devices are awkward to use, since they require that the chain be immediately fastened thereto in order to be retained on the side of the bed. These devices also do not accommodate the use of a rigid cover means.
Hence, these is a great need for a tie-down device which effectively distributes the load acrosss a portion of the rail to eliminate bending an distortion of the bed, is removably mounted to the side of the bed, and is readily adjustable to an infinite number of locations along the side of the bed. Also, a tie-down device which facilitates the use of a rigid cover would also be highly desirous to many users.
SUMMARY OF THE INVENTION
In the present invention, securing means (such as chains) are fastened to a cargo bed via tie-down devices which are removably and adjustably mounted onto the side of the bed. Preferably, the tie-down device comprises a generally channel-shape structure having a body which extends along the side of the bed between the top and bottom surfaces thereof. A hook means projects from the lower end of the body, and extends around the bottom edge of the siderail of the truck bed to counteract forces generated by the chains. An upper engagement means extends from an opposite end of the body and across the top surface of the bed, so that the device may be retained on the bed solely by its own configuration. Lastely, a coupling means is also attached to the upper end of the body to facilitate attachment of the chains to the device.
In the more preferred embodiments, various alternative coupling means are provided for accommodating the attachement of the securing means. Two of the embodiments utilize a pivotally mounted clevis member which is able to align itself with the direction of force applied through the chain, and thereby reduce the stress generated in the device. The other two embodiments provide rigid tie-down devices which may be constructed solely from a single piece of sheet metal. One of these embodiments is further designed to accommodate the use of a rigid cover means.
The user, by employing this invention, may therefore eliminate unwanted distortion and bending damage to the truck bed without the need for special mounting adaptations or arrangements. The deivce may be easily mounted, positioned, and retained on the truck bed without the need for bolting, welding, or applying the load from the chain immediately thereto. Hence, the devices may be applied to existing trucks, and are particularly advantageous when using rented trucks, since they are easily mounted and removed without altering or damaging the truck bed in any way. Furthermore, once the device is mounted on the bed, it may be inifinitely adjusted therealong so that any variation in the mounting may be readily accomplished.
These and other objects, advantages and features of the present invention will be more fully understood and appreciated by reference to the written specifications and the appended drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of an object mounted to a cargo bed by the use of a securing chain and the first embodiment of the present invention;
FIG. 2 is an enlarged perspective view of the first embodiment of the present invention mounted to the side of the bed and engaged with the end hook of the chain;
FIG. 3 is a side elevational view of the first embodiment of the present invention;
FIG. 4 is a top plan view of the first embodiments of the present invention;
FIG. 5 is a front elevational view of the first embodiment of the present invention;
FIG. 6 is a side elevational view of a second embodiment of the present invention;
FIG. 7 is a fragmented, perspective view of the upper portion of the second embodiment of the present invention;
FIG. 8 is a perspective view of a third embodiment of the present invention mounted to the side of a cargo bed and engaged with the end hook of securing chain;
FIG. 9 is a fragmented cross-sectional view of a truck bed with the third embodiment of the present invention mounted on the side of the bed and engaging an end hook of a securing chain;
FIG. 10 is a top plan view of the third embodiment of the present invention;
FIG. 11 is a side elevational view of the third embodiment of the present invention;
FIG. 12 is a front elevational view of the third embodiment of the present invention;
FIG. 13 is a side elevational view of a fourth embodiment of the present invention;
FIG. 14 is a top plan view of fourth embodiment of the present invention; and
FIG. 15 is a front elevational view of the fourth embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings in greater detail, the tie-down devices of the present invention such as tie-down device 20 are adapted for mounting on the side of a cargo bed 1 for a flatbed truck to secure an object 10 to the bed to be hauled from one location to another (FIG. 1). The various tie-down devices 20, 20', 48 and 65 of this invention each include: a coupling 30, 50 which facilitate engagement with securing chains 11, which in turn, tightly engage and hold object 10 to bed 1; a lower hook 25 which serves to hold devices 20, 20', 48 and 65 to bed 1 upon application of the force applied by chains 11; and an engagement apparatus or structure 40, 60 extending over truck bed 1 in engaging relation, to retain devices 20, 20', 48 and 65 thereto in the initial positioning of the device on bed 1. Various embodiments of the present invention are disclosed below and like parts in the different embodiments will be identified by the same reference numerals.
Flatbed trucks generally comprise a long and broad top or planar mounting surface 2 usually made of wood upon which a large, heavy or bulky object 10 may be placed for hauling. Typically, bed 1 includes along each of its sides 3 a metal siderail 4 fixedly secured thereto by any well known means. Rails 4 provide extra strength for bed 1 and a durable securement to which chains 11 may be attached. Siderail 4 is substantially channel-shaped and provided with top flange 5, mid section 6 and lower flange 7 (FIG. 9). Top flange 5 includes top surface 8 which lies generally in the same plane as mounting surface 2 of bed 1, and hence, extends the width of bed 1. Extending downwardly at a right angle from outside edge 9 of top flange 5 is mid section 6, which forms the sidewall of bed 1. Attached along lower end 13 of mid section 6 is lower flange 7 which projects inwardly in an underlying and parallel relation to top flange 5. Lower flange 7 is mounted in a cantilevered fashion, and therefore is provided with a free end 15 (FIG. 9), which is generally a short distance from mid section 6.
Tie-down device 20 is also substantially channel-shaped and generally wraps around the external surfaces of siderail 4. While tie-down device 20 may be tightly fitted to rail 4, a certain amount of looseness is acceptable, and will even make the mounting of device 20 on rail 4 somewhat easier. Tie-down device 20 includes a body 21 which extends along and substantially parallel to rail mid section 6, and is provided with a first end 22 along its bottom edge and a second end 23 along its top edge. Projecting inwardly from first end 22 of body 21 is lower flange or hook 25 which is generally of an L-shaped configuration. Hook flange 25 includes a first leg 26 which is integral with and extends from body 21 and lies along lower flange 7 of rail 3 in a substantially parallel relationship. A second leg 27 extends upwardly at substantially a right angle to first leg 26, so that it is juxtaposed to free end 15 of lower flange 7. Consequently, the lower portion of tie-down device 20--which includes the lower portion of body 21, first leg 26, and second leg 27--defines a substantially U-shaped structure which wraps around lower flange 7 of rail 4.
As shown in FIGS. 2, 4 and 5, second end 23 of body 21 is provided with a pair of spaced cylindrical ears 31, each provided with a bore 32 whose longitudinal axis is substantially parallel to the longitudinal axis of bed 1. Bores 32 are aligned to receive therethrough a pivot pin 33. Pivot pin 33 is secured in ears 31 via the use of cotter pins 34, or by any other well known means. Coupling 30 comprises a clevis 35 which is pivotally mounted on pivot pin 33. Clevis 35 includes a bight portion 38 and two closed ends 36. Each end 36 is provided with a circular opening 37 shaped to matingly receive pivot pin 33 therethrough. Ends 36 are preferably mounted on pivot pin 33 between ears 31, but clearly may be mounted in any other well known manner. Notches 24 may be provided in body 21 in order to better facilitate the mounting of clevis 35. Clevis 35 is sized to engage and receive hook 12 therethrough in a conventional manner between bight 38 and pin 33. Due to clevis 35 being pivotally mounted, it may easily align with the direction of the tensile force generated along chain 11, to thereby reduce the amount of stress experienced in the tie-down device.
Tie-down device 20 further comprises engagement apparatus 40 which includes tang or flange 41 fixedly attached to second end 23 of body 21 and extending inwardly therefrom at substantially a right angle. Tang 41 is preferably centrally located between ears 31, and is adapted to extend along in engaging relation with top surface 8 of rail 4. Tang 41 enables device 20 to be retained on bed 1 during initial positioning, prior to the fastening of hook 12, and without the need for other fixing means (such as bolts, rivets, etc.). This arrangement advantageously permits the user to preliminarily set up the tie-down devices where needed along the bed without having to immediately attach the chain thereto or utilize a more permanent fixing means which would alter rail 4.
The present tie-down device may be constructed in an easy and inexpensive manner. For instance, much of the device may be formed from a single piece of sheet metal. More specifically, it is clearly seen that a single piece of sheet metal could be bent to form lower hook 25. In the upper portion of the piece of sheet metal, two parallel spaced apart kerfs could be cut therein to define three separate portions. The central portion may be bent downwardly to form tang 41, and the two remaining portions may be curled over to form ears 31 with bores 32 defined therein. Subsequently, pivot pin 33 and clevis 35 may be assembled to the formed piece of sheet metal. Of course, the device may be constructed in any other well known manner.
The second preferred embodiment 20' (FIGS. 6 and 7) is similar to embodiment 20 except for a modification in the mounting of clevis 35. In this embodiment, ears 31 are connected to second end 23 of body 21 via two spaced arms 43. Arms are integral with and extend from second end 23 of body 21 and are positioned on each side of tang 41. Further, arms 43 are inclined upwardly from body 21, such that they are at an acute angle relative to tang 41. In this arrangement, since clevis 35 is raised above tang 41, the user can always easily grasp and hook chain 11 to clevis 35. Note also, that embodiment 20' may be constructed in essentially the same fashion as embodiment 20, except for the addition of the two arms 43, which may also be formed from the one piece of sheet metal.
A third embodiment 48 of the tie-down device (FIGS. 8-12) is of a rigid, non-pivoting construction. Coupling 50 includes a plate number 51 which is integral with and extends from the second end 23 of body 21, and projects inwardly over top surface 8 of rail 4. Plate member 51 is inclined to project upwardly at an acute angle to top surface 8 in order to provide space for hook 12, as will be discussed below. An elongated opening 52 formed centrally of plate member 51 is provided to receive hook 12 therethrough. Hook 12 is secured such that bight 16 of the hook engages distal end 53 of opening 52. Plate member 51 is substantially rectangular in shape but is provided with an arcuate extension 54 projecting beyond opening 52. Extension 54 supplies additional strength to plate member 51 to thereby effectively counteract the force generated through hook 12. Extension 54 is preferably bent downward slightly relative to plate member 51. The forces generated by the attachement of chains 11 typically have a large downwardly directed component which is applied to extension 54. Hence, structing extension 54 with a lesser inclination than plate member 51 tends to reduce the amount of stress created therein.
Engagement apparatus 60 includes a pair of downwardly extending, triangular legs 61 which engage top surface 8 with their lower edges 62. One of the legs 61 is integral with and extends from each of the opposing side edges 55 of plate member 51 at a substantially right angle thereto. Legs 61 not only retain tie-down device 20 on rail 4 until the chain is attached, but also increase the structural integrity of plate member 51 by serving as braces therefor.
Embodiment 48 of the present invention may also be constructed in an easy and inexpensive manner. The entire tie-down device 48 may be constructed of a single piece of sheet metal. More specifically, the sheet metal is cut into its predetermined shape needed for forming. Secondly, elongated opening 52 may be cut into the upper portion of tie-down device 20. Lower hook 25 is formed in the same manner as discussed in regard to first embodiment 20. Coupling 40 and engagement apparatus 60 are then formed by first bending plate member 51 at its predetermined angle to body 21, and then, subsequently bending legs 61 downwardly from each opposing side 55 of plate member 51. Note, that while arcuate extension 54 may be cut or stamped into the original piece of sheet metal, it may also be welded thereon after the bending procedure is accomplished. Of course, the embodiment may be constructed in any other well known manner, such as by welding the different pieces togther.
A fourth embodiment 65 (FIGS. 13-15) is similar to third embodiment 48, in that it employs substantially the same coupling 50 and engagement apparatus 60 as does the third embodiment. Of course, as is illustrated in FIG. 13, the size of the engagement apparatus and the angle of inclination of plate member 51 and extension 54 may be varied. In fourth embodiment 65, plate member 51 is connected to body 21 via an intermediate extension member 70. More specifically, extension member 70 is provided with a first end 71 which is integral with and extends from second end 23 of body 21 such that extension member 70 projects inwardly therefrom at substantially a right angle. An opposite second end 72 of extension member 70 is fixedly connected to outer end 56 of plate member 50. In this way, coupling means 50 and extension means 60 are spaced inwardly from outside edge 9 of bed 1 a sufficient distance to allow the use of a rigid cover such as that shown at C in phantom in FIG. 13. Cover C may be of any well known construction that mounts to bed 1 in a conventional manner. More specifically, this arrangement positions coupling 50 and engagement apparatus 60 within the cover so that chain 11 may be secured thereto without interfering with the cover. While it is true that the cover will engage extension member 70, it is noted that member 70 is of a sufficiently thin construction that no significant interference with result.
Fourth embodiment 65 is constructed in a similar fashion to that disclosed for the third embodiment 48, with the exception that the piece of sheet metal will be longer and the extension member 70 will be included in the bending procedure. Also, as with third embodiment 48, this particular construction is not required, but is merely exemplary of one particular manner of manufacturing the device.
The use of the present tie-down devices facilitate the securing of object of bed 1 in a quick and easy manner. The devices mount readily to the side of the truck bed without the need for applying a load thereto, extra fastening means, or altering the truck bed in any way. Due to the engagement apparatus, the devices may be preliminarily placed on the bed in order to determine the most efficient securing arrangement. As such, devices 20 may be easily adjusted and repositioned as many times as necessary. Furthermore, the devices are adjustable to an infinite number of positions, rather than a few predetermined spaced locations, as is common in the prior art. Devices 20 also effectively distributes the load across a sufficient distance of rail 4 so that bed 1 experiences no distortion or bending damage. Further, in regard to the fourth embodiment 65 of the present invention, a tie-down device is provided which facilitates the use of a rigid cover that may be placed over the object to be hauled.
Of course, it is understood that the above are merely preferred embodiments of the invention, and that various other embodiments as well as many changes and alterations may be made without departing from the spirit and broader aspects of the invention. | A tie-down device for securing an object to a cargo bed comprising a substantially channel-shaped structure which removably mounts along a side of the bed and is infinitely adjustable therealong. The device includes a lower hook which wraps around the bottom surface of the bed adjacent the side, an engagement structure which engages the top portion of the bed to facilitate retention of the device on the bed, and a coupling which receives and engages a chain or the like to facilitate holding the object on the bed. | 1 |
TECHNICAL FIELD
[0001] The present invention relates generally to a cleaning article, and specifically to a dual performance cleaning article comprising two functionally diverse surfaces, wherein said article has an abrasive side that facilitates the process of loosening particulates, such as dust and dirt, and an opposing air permeable, soft, absorbent side, such material being imminently suitable for application in cleaning and cleansing applications.
BACKGROUND OF THE INVENTION
[0002] The general use of nonwoven fabrics as cleaning and cleansing articles is well known in the art. Various end-use articles are commercially available which utilize a combination of topical, performance enhancing additives and/or multi-layered laminate constructions. Enhanced versions of articles used in cleaning hard-surfaces further incorporate an optional cleaning fluid, including but not limited to, disinfectants, polishing solutions, and glass cleaners.
[0003] One such layer commonly utilized in a multi-layer cleaning construct is a meltblown layer. Meltblown layers are often incorporated into cleaning articles in order to provide the article with absorbent and/or abrasive features. A meltblown layer is comprised of micrometer scale filaments, which are drawn and fragmented by a high velocity air stream, and deposited into a self-annealing mass. The meltblowing process is well known in the art and described in U.S. Pat. No. 4,041,203, to Brock, et al., which is hereby incorporated by reference. Combining a meltblown layer along with various other nonwoven layers, allows for an end-use article that can perform multiple tasks.
[0004] It has become desirable, by way of convenience, to be able to utilize a single cleaning article for multiple tasks, wherein a single use wipe can abrade and/or disrupt a build up of dust or dirt, as well as, absorb or collect any resultant particulates and liquids. Past attempts have been made to construct a nonwoven, abrasive and absorbent hard surface cleaning laminate, such as described in U.S. Pat. No. 5,560,794 to Currie, et al., hereby incorporated by reference, wherein the layered abrasive and absorbent construct is comprised of three-dimensional conical protrusions, which taper into an aperture. The aforementioned apertures, however, only exist within the abrasive portion of the construct, limiting the amount of air that may flow through the entire construct. There remains a need for a dual performance cleaning or cleansing laminate that allows for efficient airflow through the entire laminate, so as to provide a product capable of creating a sufficient amount of lather upon the introduction of a cleaning agent.
[0005] The present invention contemplates a dual performance, laminate wipe, wherein one surface is comprised of an abrasive meltblown layer and the opposing surface is comprised of a soft, absorbent, air permeable, nonwoven layer. Further, the wipe of the invention is comprised of bonded regions and distinct pillow regions defined by the bonded regions. Further still, the invention efficiently integrates two separate cleaning articles into a single disposable cleaning article, thus promoting efficient manufacture, while obtaining the desired dual task management.
SUMMARY OF THE INVENTION
[0006] The present invention relates to a dual performance cleaning article, wherein said article is comprised of a first abrasive meltblown surface that facilitates the process of loosening particulates, such as dust and dirt, and an opposing second soft, air permeable surface, which is capable of absorbing and/or picking up particulates and liquids. The meltblown layer comprises coarse discontinuous filamentary elements, formed from adjusting the variable commonly utilized in the traditional meltblown method. Such filamentary elements may be formed from a polymer selected from the group consisting of polyolefins, polyesters, polyetheresters, and polyamide. Suitable absorbent, air permeable webs include, but are not limited to filamentary webs and fibrous carded webs comprised of natural fiber, synthetic fibers, and the blends thereof.
[0007] In accordance with the present invention, the nonwoven cleaning article is comprised of “pillows” or unbonded regions wherein the two layers remain essentially separate from one another. Upon the introduction of a cleaning agent, the pillow regions allow for a maximum amount of air to flow through the laminate, but also, the ability for the separate layers within the pillow regions to come in contact with and pass over one another in an uninhibited manner assists in the formation of a lather. The article is bonded utilizing conventional means, such as adhesive bonding, ultrasonic bonding, and thermal calendaring, so as to form at least two or more enclosed, unique, and distinct pillow regions. It is contemplated that nonwovens embodying the principles of the present invention are especially suitable as a wet wipe substrate for cleaning both domestic and industrial surfaces, and further for use in skin/facial cleaning. The present nonwoven fabric wipe can be provided in forms that are suitable for use as a dry wipe to absorb liquid, and to provide extra scrubbing effect, as needed.
[0008] Further, it is within the purview of the present invention to optionally utilize specific additives or a combination of additives, so as to enhance the performance, visual appearance, or aromatic properties, wherein such additives are meant to include, but not limited to anti-microbial or disinfecting agents, pigments, and/or fragrances. Such enhancing agents may be provided in the form of a melt-additive in the polymer from which the coarse meltblown layer is formed, or may comprise a post surface treatment applied to the laminate itself or deposited into a container or film packaging from which the end-use article may be dispensed.
[0009] Other features and advantages of the present invention will become readily apparent from the following detailed description, the accompanying drawings, and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] [0010]FIG. 1 is a photomicrograph of the abrasive side of the nonwoven cleaning article in practicing the present invention;
[0011] [0011]FIG. 2 is a photomicrograph of the air permeable, absorbent side of the nonwoven cleaning article in practicing the present invention;
[0012] [0012]FIG. 3 is a photomicrograph on a macroscopic scale of the abrasive side of the nonwoven cleaning article in practicing the present invention; and
[0013] [0013]FIG. 4 is a photomicrograph on a macroscopic scale of the air permeable, absorbent side of the nonwoven cleaning article in practicing the present invention.
DETAILED DESCRIPTION
[0014] While the present invention is susceptible of embodiment in various forms, there will hereinafter be described, presently preferred embodiments, with the understanding that the present disclosure is to be considered as an exemplification of the invention, and is not intended to limit the invention to the specific embodiments disclosed herein.
[0015] The nonwoven dual sided cleaning article of the present invention is comprised of coarse denier meltblown filaments, wherein a spunbond resin is utilized with a conventional meltblown process so as to capture thicker filaments. In general, the meltblown process utilizes a molten polymer is extruded under pressure through orifices in a spinneret or die. Traditionally, high velocity air impinges upon and entrains the filaments as they exit the die. Usually the energy of this step is such that the formed filaments are greatly reduced in diameter and are fractured so that microfibers of finite length are produced. Utilizing a spunbond resin with a lower melt flow rate, as well as lowering the air pressure, however, allows the collected filaments to take on a thicker diameter, providing the overall collective web with a desirable coarse texture. The process to form either a single layer or a multiple-layer fabric is continuous, that is, the process steps are uninterrupted from extrusion of the filaments to form the first layer until the bonded web is wound into a roll. Methods for producing these types of fabrics are described in U.S. Pat. No. 4,041,203. The resultant filaments may be of various cross-sectional profiles, which are not considered a limitation to the practice of the present invention.
[0016] In a particular embodiment, a polypropylene spunbond resin, commercially known as PP3155 made available by Exxon Chemical Company was utilized. The aforementioned resin had a 35 MFR and was extruded at an average die temperature of 562° Fahrenheit with an approximate throughput of 7.1 grams/hole/min. Further, the distance between the meltblown die and the collective surface was around the order of 19 inches. The resultant meltblown filaments have a denier between that of 5 and 50 microns. Suitable polymers that may be used in the meltblowing process of the present invention include those selected from the group consisting of polyolefins, polyesters, polyetheresters, and polyamide.
[0017] Optionally, prior to extrusion, the single polymeric resin can be compounded with various melt-additives, so as to assist with the processing conditions, enhance the performance of the web, or enhance the appearance of the web, such additives including, but not limited to thermal stabilizers, colorants, and aromatics.
[0018] The dual purpose cleaning article of the present invention also comprises a soft, air permeable, absorbent layer capable of picking up liquids and particulates. A nonwoven of this nature may be a fibrous nonwoven layer or a continuous filament nonwoven layer. In general, continuous filament nonwoven fabric formation involves the practice of the spunbond process. A spunbond process involves supplying a molten polymer, which is then extruded under pressure through a large number of orifices in a plate known as a spinneret or die. The resulting continuous filaments are quenched and drawn by any of a number of methods, such as slot draw systems, attenuator guns, or Godet rolls. The continuous filaments are collected as a loose web upon a moving foraminous surface, such as a wire mesh conveyor belt. When more than one spinneret is used in line for the purpose of forming a multi-layered fabric, the subsequent webs are collected upon the uppermost surface of the previously formed web. The web is then at least temporarily consolidated, usually by means involving heat and pressure, such as by thermal point bonding. Using this means, the web or layers of webs are passed between two hot metal rolls, one of which has an embossed pattern to impart and achieve the desired degree of point bonding, usually on the order of 10 to 40 percent of the overall surface area being so bonded.
[0019] When staple fibers are utilized to form the air permeable nonwoven layer, the fibers may begin in a bundled form as a bale of compressed fibers. In order to decompress the fibers, and render the fibers suitable for integration into a nonwoven fabric, the bale is bulk-fed into a number of fiber openers, such as a garnet, then into a card. The card further frees the fibers by the use of co-rotational and counter-rotational wire combs, then depositing the fibers into a lofty batt. The lofty batt of staple fibers can then optionally be subjected to fiber reorientation, such as by air-randomization and/or cross-lapping, depending upon the ultimate tensile properties of the resulting nonwoven fabric. The fibrous batt is integrated into a nonwoven fabric by application of suitable bonding means, including, but not limited to, use of adhesive binders, thermobonding by calender or through-air oven, and hydroentanglement.
[0020] Optionally, the air permeable nonwoven layer may be that of a three-dimensionally entangled nonwoven fabric, wherein in the fabric is hydroentangled on a three-dimensional image transfer device. Such three-dimensional image transfer devices are disclosed in U.S. Pat. No. 5,098,764, which is hereby incorporated by reference; with the use of such image transfer devices being desirable for providing a fabric with enhanced physical properties as well as an aesthetically pleasing appearance.
[0021] The two different nonwoven layers may be juxtaposed and continuously bonded so as form a plurality of “pillows”, wherein the two layers within the pillow regions remain essentially unattached. The separate layers of the pillow regions are uninhibited by way of movement during the cleaning process contributing to formation of lather. Subsequent to positioning the abrasive layer and the air permeable absorbent layer, the two layers may be bonded, preferably thermally calendered, wherein the laminate is passed between two metal rolls, one of which is comprised of a pattern. The pattern is imparted into the laminate forming bonded regions. Bonded regions within the laminate in turn define the slightly raised outer most edges of the unbonded “pillow” regions. FIGS. 1 through 4 are indicative of the fabric of the present invention.
[0022] In accordance with the present invention, the dual sided nonwoven article includes the use of various aqueous and non-aqueous compositions. The dual performance article embodying the principles of the present invention is especially suitable for home care cleaning or cleansing articles. The dual sided nonwoven article may be used in various home care applications, wherein the end use article may be a dry or wet hand held sheet, such as a wipe, a mitt formation, or a cleaning implement capable of retaining the dual sided article. The various end uses suitable for cleaning household surfaces such as, kitchen and bathroom countertops, sinks, bathtubs, showers, appliances, and fixtures.
[0023] Cleansing compositions suitable for such end use applications include those that are described in U.S. Pat. No. 6,103,683 to Romano, et al., U.S. Pat No. 6,340,663 to Deleo, et al., U.S. Pat. No. 5,108,642 to Aszman, et al., and U.S. Pat. No. 6,534,472 Arvanitidou, et al., all of which are hereby incorporated by reference. Selected cleaning compositions may also include surfactants, such as alkylpolysaccharides, alkyl ethoxylates, alkyl sulfonates, and mixtures thereof; organic solvent, mono- or polycarboxylic acids, odor control agents, such as cyclodextrin, peroxides, such as benzoyl peroxide, hydrogen peroxide, and mixtures thereof, thickening polymers, aqueous solvent systems, suds suppressors, perfumes or fragrances, and detergent adjuvants, such as detergency builder, buffer, preservative, antibacterial agent, colorant, bleaching agents, chelants, enzymes, hydrotropes, and mixtures thereof. The aforementioned compositions preferably comprise from about 50% to about 500%, preferably from about 200% to about 400% by weight of the dual sided nonwoven cleaning article.
[0024] The dual performance article embodying the principles of the present invention is also suitable for personal cleaning or cleansing articles. Non-limiting examples of such applications include dry or wet facial wipes, body wipes, and baby wipes. Suitable methods for the application of various aqueous and non-aqueous compositions comprise aqueous/alcoholic impregnates, including flood coating, spray coating or metered dosing. Further, more specialized techniques, such as Meyer Rod, floating knife or doctor blade, which are typically used to impregnate cleansing solutions into absorbent sheets, may also be used. The following compositions preferably comprise from about 50% to about 500%, preferably from about 200% to about 400% by weight of the dual sided nonwoven article.
[0025] The nonwoven laminate incorporates a functional additive, such as an alpha-hydroxycarboxylic acid, which refers not only the acid form but also salts thereof. Typical cationic counterions to form the salt are the alkali metals, alkaline earth metals, ammonium, C 2 -C 8 trialkanolammonium cation and mixtures thereof. The term “alpha-hydroxycarboxylic acids” include not only hydroxyacids but also alpha-ketoacids and related compounds of polymeric forms of hydroxyacid.
[0026] Amounts of the alpha-hydroxycarboxylic acids may range from about 0.01 to about 20%, preferably from about 0.1 to about 15%, more preferably from about 1 to about 10%, optimally from about 3 to about 8% by weight of the composition which impregnates the substrate. The amount of impregnating composition relative to the substrate may range from about 20:1 to 1:20, preferably from 10:1 to about 1:10 and optimally from about 2:1 to about 1:2 by weight.
[0027] Further, a humectant may be incorporated with the aforementioned alpha-hydroxycarboxylic compositions. Humectants are normally polyols. Representative polyols include glycerin, diglycerin, polyalkylene glycols and more preferably alkylene polyols and their derivatives. Amounts of the polyol may range from about 0.5 to about 95%, preferably from about 1 to about 50%, more preferably from about 1.5 to 20%, optimally from about 3 to about 10% by weight of the impregnating composition.
[0028] A variety of cosmetically acceptable carrier vehicles may be employed although the carrier vehicle normally will be water. Amounts of the carrier vehicle may range from about 0.5 to about 99%, preferably from about 1 to about 80%, more preferably from about 50 to about 70%, optimally from about 65 to 75% by weight of the impregnating composition.
[0029] Preservatives can desirably be incorporated protect against the growth of potentially harmful microorganisms. Suitable traditional preservatives for compositions of this invention are alkyl esters of para-hydroxybenzoic acid. Other preservatives which have more recently come into use include hydantoin derivatives, propionate salts, and a variety of quatenary ammonium compounds. Preservatives are preferably employed in amounts ranging from 0.01% to 2% by weight of the composition.
[0030] The cosmetic composition may further include herbal extracts. Illustrative extracts include Roman Chamomile, Green Tea, Scullcap, Nettle Root, Swertia laponica, Fennel and Aloe Vera extracts. Amount of each of the extracts may range from about 0.001 to about 1%, preferably from about 0.01 to about 0.5%, optimally from about 0.05 to about 0.2% by weight of a composition.
[0031] Additional functional cosmetic additives may also include vitamins such as Vitamin E Acetate, Vitamin C, Vitamin A Palmitate, Panthenol and any of the Vitamin B complexes. Anti-irritant agents may also be present including those of steviosides, alpha-bisabolol and glycyhrizzinate salts, each vitamin or anti-irritant agent being present in amounts ranging from about 0.001 to about 1.0%, preferably from about 0.01 to about 0.3% by weight of the composition.
[0032] These impregnating compositions of the present invention may involve a range of pH although it is preferred to have a relatively low pH, for instance, a pH from about 2 to about 6.5, preferably from about 2.5 to about 4.5.
[0033] In addition to cosmetic compositions, lotions may be incorporated into the dual sided nonwoven article. The lotion preferably also comprises one or more of the following: an effective amount of a preservative, an effective amount of a humectant, an effective amount of an emollient; an effective amount of a fragrance, and an effective amount of a fragrance solubilizer.
[0034] As used herein, an emollient is a material that softens, soothes, supples, coats, lubricates, or moisturizes the skin. The term emollient includes, but is not limited to, conventional lipid materials (e.g. fats, waxes), polar lipids (lipids that have been hydrophylically modified to render them more water soluble), silicones, hydrocarbons, and other solvent materials. Emollients useful in the present invention can be petroleum based, fatty acid ester type, alkyl ethoxylate type, fatty acid ester ethoxylates, fatty alcohol type, polysiloxane type, mucopolysaccharides, or mixtures thereof.
[0035] Humectants are hygroscopic materials that function to draw water into the stratum comeum to hydrate the skin. The water may come from the dermis or from the atmosphere. Examples of humectants include glycerin, propylene glycol, and phospholipids.
[0036] Fragrance components, such as perfumes, include, but are not limited to water insoluble oils, including essential oils. Fragrance solubilizers are components which reduce the tendency of the water insoluble fragrance component to precipitate from the lotion. Examples of fragrance solubilizers include alcohols such as ethanol, isopropanol, benzyl alcohol, and phenoxyethanol; any high HLB (HLB greater than 13) emulsifier, including but not limited to polysorbate; and highly ethoxylated acids and alcohols.
[0037] Preservatives prevent the growth of micro-organisms in the liquid lotion and/or the substrate. Generally, such preservatives are hydrophobic or hydrophilic organic molecules. Suitable preservatives include, but are not limited to parabens, such as methyl parabens, propyl parabens, and combinations thereof.
[0038] The lotion can also comprise an effective amount of a kerotolytic for providing the function of encouraging healing of the skin. An especially preferred kerotolytic is Allantoin ((2,5-Dioxo-4-Imidazolidinyl)Urea), a heterocyclic organic compound having an empirical formula C 4 , H 6 . N 4 , O 3 . Allantoin is commercially available from Tri-K Industries of Emerson, N.J. It is generally known that hyperhydrated skin is more susceptible to skin disorders, including heat rash, abrasion, pressure marks and skin barrier loss. A premoistened wipe according to the present invention can include an effective amount of allantoin for encouraging the healing of skin, such as skin which is over hydrated.
[0039] U.S. Pat. No. 5,534,265, issued Jul. 9, 1996; U.S. Pat. No. 5,043,155, issued Aug. 27, 1991; and U.S. Pat. No. 5,648,083, issued Jul. 15, 1997, are incorporated herein by reference for the purpose of disclosing additional lotion ingredients.
[0040] The lotion can further comprise between about 0.1 and about 3 percent by eight Allantoin, and about 0.1 to about 10 percent by weight of an aloe extract, such as aloe vera, which can serve as an emollient. Aloe vera extract is available in the form of a concentrated powder from the Rita Corporation of Woodstock, Ill.
[0041] Further, latherants may be incorporated within the dual sided cleaning article. Non-limiting examples of anionic lathering surfactants useful in the compositions of the present invention are disclosed in McCutcheon's, Detergents and Emulsifiers, North American edition (1986), published by allured Publishing Corporation; McCutcheon's, Functional Materials, North American Edition (1992); and U.S. Pat. No. 3,929,678, to Laughlin et al., issued Dec. 30, 1975, all of which are incorporated by reference herein in their entirety. A wide variety of anionic lathering surfactants are useful herein. Non-limiting examples of anionic lathering surfactants include those selected from the group consisting of sarcosinates, sulfates, isethionates, taurates, phosphates, lactylates, glutamates, and mixtures thereof.
[0042] Non-limiting examples of nonionic lathering surfactants and amphoteric surfactants for use in the compositions of the present invention are disclosed in McCutcheon's, Detergents and Emulsifiers, North American edition (1986), published by allured Publishing Corporation; and McCutcheon's, Functional Materials, North American Edition (1992); both of which are incorporated by reference herein in their entirety.
[0043] Nonionic lathering surfactants useful herein include those selected from the group consisting of alkyl glucosides, alkyl polyglucosides, polyhydroxy fatty acid amides, alkoxylated fatty acid esters, lathering sucrose esters, amine oxides, and mixtures thereof.
[0044] The term “amphoteric lathering surfactant,” as used herein, is also intended to encompass zwitterionic surfactants, which are well known to formulators skilled in the art as a subset of amphoteric surfactants.
[0045] A wide variety of amphoteric lathering surfactants can be used in the compositions of the present invention. Particularly useful are those which are broadly described as derivatives of aliphatic secondary and tertiary amines, preferably wherein the nitrogen is in a cationic state, in which the aliphatic radicals can be straight or branched chain and wherein one of the radicals contains an ionizable water solubilizing group, e.g., carboxy, sulfonate, sulfate, phosphate, or phosphonate. Non-limiting examples of amphoteric or zwitterionic surfactants are those selected from the group consisting of betaines, sultaines, hydroxysultaines, alkyliminoacetates, iminodialkanoates, aminoalkanoates, and mixtures thereof.
[0046] Additional compositions utilized in accordance with the present invention can comprise a wide range of optional ingredients. The CTFA International Cosmetic ingredient Dictionary, Sixth Edition, 1995, which is incorporated by reference herein in its entirety, describes a wide variety of non-limiting cosmetic and pharmaceutical ingredients commonly used in the skin care industry, which are suitable for use in the compositions of the present invention. Non-limiting examples of functional classes of ingredients are described at page 537 of this reference. Examples of these functional classes include: abrasives, anti-acne agents, anticaking agents, antioxidants, binders, biological additives, bulking agents, chelating agents, chemical additives, colorants, cosmetic astringents, cosmetic biocides, degreasers, denaturants, drug astringents, emulsifiers, external analgesics, film formers, fragrance components, humectants, opacifying agents, plasticizers, preservatives, propellants, reducing agents, skin bleaching agents, skin-conditioning agents (emollient, humectants, miscellaneous, and occlusive), skin protectants, solvents, foam boosters, hydrotropes, solubilizing agents, suspending agents (nonsurfactant), sunscreen agents, ultraviolet light absorbers, and viscosity increasing agents (aqueous and nonaqueous). Examples of other functional classes of materials useful herein that are well known to one of ordinary skill in the art include solubilizing agents, sequestrants, and keratolytics, and the like.
[0047] The aforementioned classes of ingredients are incorporated in a safe and effective amount. The term “safe and effective amount” as used herein, means an amount of an active ingredient high enough to modify the condition to be treated or to deliver the desired skin benefit, but low enough to avoid serious side effects, at a reasonable benefit to risk ratio within the scope of sound medical judgment.
[0048] In addition to home care and personal care end uses, the nonwoven cleaning article may be used in industrial and medical applications. For instance, the dual sided laminate may be useful in paint preparation and cleaning outdoor surfaces, such as lawn furniture, grills, and outdoor equipment, wherein the low linting attributes of the laminate may be desirable. Aqueous or non-aqueous functional industrial solvents include, oils, such as plant oils, animal oils, terpenoids, silicon oils, mineral oils, white mineral oils, paraffinic solvents, polybutylenes, polyisobutylenes, polyalphaolefins, and mixtures thereof, toluenes, sequestering agents, corrosion inhibitors, abrasives, petroleum distillates, and the combinations thereof.
[0049] A dual side medical cleaning article may incorporate an antimicrobial composition, including, but not limited to iodines, alcohols, such as such as ethanol or propanol, biocides, abrasives, metallic materials, such as metal oxide, metal salt, metal complex, metal alloy or mixtures thereof, bacteriostatic complexes, bactericidal complexs, and the combinations thereof.
[0050] The dual sided cleaning article of the present invention is particularly suitable for dispensing from a tub of stacked, folded wipes, or for dispensing as “pop-up” wipes, in which the cleaning article is stored in the tub as a perforated continuous roll, wherein upon pulling a wipe out of the tub, an edge of the next wipe is presented for easy dispensing. The wipes of the present invention can be folded in any of various known folding patterns, such as C-folding, but is preferably Z-folded. A Z-folded configuration enables a folded stack of wipes to be interleaved with overlapping portions. The dual sided cleaning article may be packaged in various convenient forms, whereby the method of packaging is not meant to be a limitation of the present invention.
[0051] From the foregoing, numerous modifications and variations can be effected without departing from the true spirit and scope of the novel concept of the present invention. It is to be understood that no limitation with respect to the specific embodiment disclosed herein is intended or should be inferred. The disclosure is intended to cover, by the appended claims, all such modifications as fall within the scope of the claims. | The present invention relates to a dual performance cleaning article, wherein said article is comprised of a first abrasive meltblown surface that facilitates the process of loosening particulates, such as dust and dirt, and an opposing second soft, air permeable surface, which is capable of absorbing and/or picking up particulates and liquids. The meltblown layer comprises coarse discontinuous filamentary elements, formed from adjusting the variable commonly utilized in the traditional meltblown method. | 0 |
COMPOSITE METAL AND PLASTIC FENCE
This is a continuation-in-part application of application Ser. No. 239,377, filed Mar. 2, 1981 and now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This application relates generally to fencing material and brackets or similar structures, particularly those which are used to confine livestock.
2. Description of the Prior Art
Fences are the most commonly employed means for confining that which would otherwise escape and excluding that which would otherwise intrude. Fences may vary greatly in both structure and materials of composition. Common fence structures include wire fences, such as barbed wire and chain link, and wood fences such as, picket fences and split rail fences. Common fence materials include metal, wood and stone. Fence structure and composition are selected on the basis of initial and upkeep costs, durability, strength, aesthetic characteristics, and safety desired or required.
One very common form of fencing is barbed wire. The relatively low cost of purchasing, installing, and maintaining barbed wire fencing has made it the preeminent fencing material for enclosing livestock areas. Barbed wire suffers from the disadvantage, however, that its sharp barbs may cut or gouge the hide of valuable livestock. Furthermore, barbed wire has a very thin cross-section so that it is not easy to see; and an animal is correspondingly more apt to contact a barbed wire fence than it would be to contact a more visible barrier. Other types of wire fencing known in this art, such as web wire fencing, and cyclone wire fencing, suffer from similar limitations. These wire fences also tend to have poor aesthetic qualities and they tend to rust or corrode after a few years of service. Fences made entirely of wood, on the other hand, are typically safer and more pleasing to the eye, but are expensive to install and maintain.
In an effort to obtain both the visibility of wood fencing and the low cost and maintenance of wire fencing, some fences have been constructed of wire webbing with wooden boards enmeshed therein. The durability of these fences is limited by the tendency of wood to weather and rot. Another disadvantage is the relative costliness of wood as a fencing material and the constant expense of maintaining wood fences.
It is known in the prior art to use plastic rather than wood to increase durability and decrease cost. For example, U.S. Pat. No. 3,877,140, granted to Topolsek on Apr. 15, 1975, discloses a picket fence composed of metal and plastic. The fence described there, however, seems to be well suited to applications not requiring a great deal of strength, such as for snow fencing, and not applications such as for the confining of livestock.
SUMMARY OF THE INVENTION
The present invention is a composite metal and plastic fence comprised of at least two metal wires having high tensile strength ensheathed in a plastic casing and brackets for installing the fence. The wire may be of any diameter suitable to the strength required in service. For many applications, for example, 8, 121/2 or 16 gauge wire may suffice. Between the wires, the plastic casing assumes the form of a sheet or web, so that the cross-section of a strip of fencing material according to one embodiment of the present invention taken perpendicular to the lengths of any pair of adjacent wires is approximately dumbbell-shaped. In a preferred form, the material encasing the wire protrudes on only one side of the web, the opposite being generally flat. The web itself may have any thickness but is preferably in the range of about 30 mils to 100 mils. When strung on supports, the metal wires run the length of the fence, the plastic casing both enclosing the wires and keeping them at a fixed vertical separation. A fence so constructed has the advantages of high visibility, good strength, and relatively low cost of purchase, installation and upkeep. Also, such a fence will neither cut nor gouge the hides of valuable livestock, and can be used for the close confinement of such animals. This is extremely important when being used as a fencing material to confine livestock such as thoroughbred race horses where any damage to the legs of the animal must be prevented.
A fence constructed according to the present invention is also highly pleasing to the eye, and the plastic may be colored in any fashion to suit the preferences of the user. The color of such a fense is an intrinsic property of the fencing material itself, rather than the result of the application of extrinsic paints or varnishes. Thus, the fence never need be painted, and maintenance is significantly reduced. Phosphorescent material may also advantageously be added to the plastic webbing so as to provide nocturnal visibility for both the animals being confined and the people responsible for the animals.
Installation of fencing material according to this invention are also greatly facilitated using the brackets of the present invention. Installation usually requires no more than one individual, and this individual is not exposed to the danger of harm inherent in the installation of barbed wire fence. Also, the fence comes in continuous lengths as rolls, which can be stored more safely and in less room than prior art fences such as barbed wire fencing. The plastic casing also protects the fencing material from deterioration during storage.
With the fence material of the preferred embodiment, the brackets of the present invention cooperate to facilitate installation as well as enhance the structural strength of the fence once installed. To this end, the present invention provides a novel fence bracket where, with the preferred embodiment of the fencing material, vertical support of a load on the fence is transmitted primarily through the wires encased in protruding portions of the fencing material and thence to the bracket instead of through the webbing between the encased wires.
Fences can be constructed having any number of wires encased in the plastic web material. For example, a fence according to the present invention can be comprised of two, three or even more wires encased in the plastic web with a two-wire fence strand having a width of about 2.5 inches and a three-wire fence strand having a width of approximately 5.5 inches.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other advantages of the invention will become more readily apparent from the following detailed description of the presently preferred exemplary embodiments, taken together with the accompanying drawings, of which:
FIG. 1 is a partial cutaway of the fencing material according to one embodiment of the present invention, as it might be used with a securing staple according to the present invention;
FIG. 2 is a cross-sectional view taken along line 2 of FIG. 1;
FIG. 3 is a front elevation of fencing material according to one embodiment of the present invention as it might be used with another securing staple according to the present invention;
FIG. 4 is a cross-section of the fencing material and securing staple of FIG. 3 taken along line 4;
FIG. 5 is a front elevation of another embodiment of a securing staple according to the present invention;
FIG. 6 is yet another embodiment of a securing staple which might be used with the fencing material according to the present invention;
FIG. 7 is a securing staple of FIG. 6 prior to the final step in the fabrication of the securing staple of FIG. 6;
FIG. 8 is a front elevation of another embodiment of the fencing material according to the subject invention, shown with another securing staple according to the present invention;
FIG. 9 is a front elevation of the fencing material shown in FIG. 7, shown with yet another embodiment of a securing staple according to the subject invention;
FIG. 10 is a front elevation of yet another embodiment of a fence according to the present invention;
FIG. 11 is a side view in elevation of one embodiment of a bracket of the present invention;
FIG. 12 is a sectional view along lines 12--12 of FIG. 11;
FIG. 13 is a side view in elevation of another embodiment of the bracket of the present invention;
FIG. 14 is a side view in elevation of another embodiment of the bracket of the present invention;
FIG. 15 is a view taken along lines 15--15 of FIG. 14; and
FIG. 16 is a top plan view of one illustration of an installation of the fencing and brackets of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring first to FIG. 1, a fence according to the present invention has two metal wires 10 and 12. In the present embodiment, 0.100 inch diameter steel wire (121/2 gauge) is used having a tensile strength of approximately 250,000 pounds per square inch. It will be understood, however, that any wire having suitable characteristics may be used. Wires 10 and 12 are ensheathed in a plastic casing 14. Plastic casing 14 preferably has a thickness between 30 and 100 mils in the gap between wires. In the preferred embodiment, its thickness in the gap is approximately 0.050 inches and its thickness about wires 10 and 12 is such that the outside diameter of wire and sheath is approximately 0.200 inches. The vertical width of wires 10 and 12 and casing 14 is approximately 2.5 inches. In the presently preferred embodiment, casing 14 is composed to polyvinylchloride, although it will be understood that any suitable material may be used.
Casing 14 containing wires 10 and 12 is secured to a support 16 by means of a securing staple 18. Support 16 is typically a wood or concrete post. Securing staple 18 may be made of galvanized steel, and is deformed to follow the contour of plastic case 14. Securing staple 18 has four fasteners 20, 22, 24 and 26. Fasteners 20 and 26 are attached to tongues 21 and 27, respectively, and pierce support 16 respectively above and below casing 14. Fasteners 22 and 24 pierce casing 14 before entering support 16.
As can be seen best in FIG. 2, securing staple 18 presses against casing 14, securing casing 14 firmly in place.
FIG. 3 again shows wires 10 and 12 contained in casing 14. In FIG. 3, a different securing staple 28 is used to secure casing 14 to support 16. Securing staple 18 may be made of galvanized steel or a similar material. Unlike securing staple 18 as illustrated in FIGS. 1 and 2, securing staple 28 has two ringed nails 30 and 32 instead of fasteners 20, 22, 24 and 26. These ringed nails are of the type which are commonly available commercially. In securing staple 28, these nails are arranged horizontally rather than vertically. Also, securing staple 28 has no tongues to accommodate prongs or nails in positions above or below casing 14. Ringed nails 30 and 32 can best be seen in the cross-sectional view along line 4 as illustrated in FIG. 4.
FIG. 5 shows yet another securing staple 34 which might be used to affix a casing 36 shown in phantom to a supporting member. Securing staple 34 has three semicircular bends 38, 40 and 42 to accommodate casing 40 where it assumes a roughly cylindrical shape to contain wires. Securing staple 34 is also provided with holes 44 and 46 to accommodate nails, screws, or other suitable fasteners.
FIG. 6 shows another possible staple which may be used advantageously with the fencing material of the subject invention. The staple 48 of FIG. 6 is stamped from a pre-cut piece of galvanized steel shown in FIG. 7. Staple 48 has four prongs 50 which puncture and anchor in a supporting structure, such as a fence post, when driven by a hammer or other suitable means.
FIG. 8 shows another embodiment of a fence according to the present invention. The fencing material in FIG. 8 has three wires 52, 54 and 56. Wires 52, 54 and 56 may be made of the same materials used to make wires 10 and 12 as shown in FIGS. 1, 2 and 3. A plastic casing 58 encloses all three wires as well as occupies the gap between wires. In the preferred embodiment, casing 58 is made of polyvinylchloride. A securing staple 60 is used to hold casing 58 in place. The securing staple 60 has pairs of integral planar prongs 62, 64, 66 and 68. Prong pairs 62 and 68 bracket casing 58 to either side of its width, while prong pairs 64 and 66 pierce casing 58 to either side of wire 54 before entering the support. It is important to note that staple 60, like staple 48, may be fabricated simply and inexpensively by stamping sheet metal.
FIG. 9 shows an attachment staple 70 similar to staple 60, except that staple 70 has no prong pairs corresponding to prong pairs 64 and 66 of staple 60. Instead, staple 70 has a semicircular channel 72 to accommodate the bulge in the fencing material (shown in phantom) where it distends to accommodate a middle wire.
FIG. 10 shows another embodiment of the present invention which is suitable for use as a highway barrier. A plastic casing 74 constructed of polyvinylchloride or other suitable material encloses seven wires 76. A securing staple 78 secures plastic casing 74 to support 80.
In the foregoing embodiments, much of the vertical support for the fencing is supplied by the bracket or staples 70 particularly where the fasteners pass through the staple and the web of the fencing material. In a preferred embodiment, however, the present invention provides fence brackets where no fastening members are required to penetrate and hold the fencing material in position on a fence post. Further, the brackets of the present invention are provided with openings which cooperate with the raised beads containing the high tensile wire so that any vertical load placed on the web fencing will be transmitted predominantly through the wire to the bracket and not to the webbing extending between the wires of the fencing. It has been found with the use of the brackets of the present invention, the fencing can be suspended between the posts and then subjected to tension to straighten the webbing to a substantially horizontal condition. Further, this arrangement has the advantage that when it is desired to remove the fencing it can be easily taken down and stored for later use at the same or at a different site.
Turning now to FIG. 11, there is shown one embodiment of the bracket of the present invention indicated generally at 84. The bracket 84 includes a first elongated member 82 and a second member having spaced ends 86 and 88 between which a shaft 92 extends and on which is rotatably mounted a roller 90. Member 82 is provided with spaced recesses or notches 94 between which extend smooth rounded surfaces 95 which are spaced from the roller a selected distance to define an opening 91. At its opposite ends, the member 82 is provided with bore holes 96 which are alignable with bore holes 98 in the second member's ends 86 and 88. As shown in the sectional view of FIG. 12, bore hole 98 terminates in a flared outwardly tapering recess 100 into which is inserted a tapering protrusion 102 formed on the face of each end of the first elongated member 82. Similarly, bore holes 96 are also provided in each end of the member 82 and the protrusions 102 serve as aligning means to facilitate alignment of the bore holes 96 and 98.
In FIG. 13, a bracket member similar to that of FIG. 11 is shown but with a section of webbing 111 located in the opening between the roller 90 and the smooth facing surfaces 106 of this bracket member. As can be seen from FIG. 13, the enlarged protrusions 108 and 110 of the webbing 111 fit snugly in the recesses 112 formed in one face of the opening between the roller 90 and surfaces 106. The webbing material 111 in this embodiment has the protruding portions formed such that the reinforcing wires 112 will be offset from the plane of the webbing. The side of the webbing opposite that on which the wires 112 are located is generally flat and smooth. With this arrangement, when the top edge of the webbing 111 is subjected to a load, the wires 112 will transmit the load to the lower surfaces of the recesses 108 and 110 instead of transmitting the load to the web material extending between the wires.
The bracket means utilizing the roller 90 are generally employed as the fence material is led around a corner or bend in the fence arrangement.
In FIG. 14, another type of bracket is illustrated which has a member 114 which is in all respects identical to member 82 of the previous embodiment but which has a simplified mating member 116. Mating member 116 is elongated and between its ends is provided with a smooth generally semicircular surface 118 and a flat backside 119 as can be seen in the sectional view of FIG. 15. The disposition of the webbing 111 is generally the same as that in the embodiment of FIGS. 11 and 13. At each end of the bracket 114, bore holes 120 are provided which are substantially identical to the arrangement shown in FIG. 12.
Turning to FIG. 16, there is shown an arrangement of the brackets and fencing of the present invention where the fence posts 122 are arranged around a corner of an enclosure. Where the webbing is arranged to traverse a straight line, the brackets 114 can be mounted on the inside of the enclosure as illustrated in FIG. 16 up to the point of the turn as at fence post 124 where a bracket such as illustrated in FIG. 11 will be mounted on the outside of the enclosed area with the roller 90 closest to the fence and the member 82 with the notched recesses 94 facing the roller. That is to say, the surfaces labelled A in FIG. 11 will be attached directly to the fence post, while the surface B of FIG. 11 will be facing away from the post 124. The same arrangement would be used for a post 126, although it will be understood that this example is merely for illustrative purposes and more or less posts may be employed in a curve or turn in the fence being installed.
Turning now to FIGS. 17 and 18, another embodiment of the present invention is illustrated wherein the webbing material 128 takes a slightly different form similar to that illustrated in FIG. 2 except that the enlarged portion of the webbing are circular as at 130 with the individual wires 132 generally centered in each enlarged circular portion 130. Correspondingly, the bracket members 140 and 142 are modified wherein the notch means are in the form of enlarged openings 134 and 136 which are generally semicircular in cross-section to receive in a closely fitting relation the enlarged portions 134 of the webbing 128. Each of the bracket members 140 and 142 are, of course, provided with aligned holes 138 for receiving fastening elements such as nails 154. The opening 144 between the facing surfaces of the bracket members 140 and 142 is substantially less than the diameter of the opening formed by the opposed surfaces 134 and 136 so that the enlarged portions 130 containing the wires 132 cannot slip through the opening 144 when a load is placed on the webbing 128.
As shown in FIG. 18 a corner bracket 139 is illustrated which has one element 141 similar to bracket member 140 whereas the second bracket member is provided with spaced end elements 148 having openings for fastening elements and a shaft 146 supporting a roller 150. The roller 150 has spaced grooves 152 opposite the semicircular openings 136' corresponding to the openings 136 in the bracket member illustrated in FIG. 17. The roller bracket 139 will thus accommodate a webbing as illustrated in section at 128 in FIG. 17. The advantage of this arrangement is that, in installing the webbing 128, the webbing can be placed entirely either on the inside or the outside of the fencing relative to the space being enclosed without reversing the position of the support brackets when rounding a bend as illustrated in FIG. 16. This is due to the fact that the webbing 128 is identical on its opposite sides and the bracket members 140, 142 and 139, 150 will accommodate the webbing 128 without regard to the side of the fence post on which the brackets or webbing are disposed.
It has been found that it is easier to subject the fence to tension once installed by wrapping the fence on the rollers 90 as the fence is led around a bend or turn in the enclosure yet, according to the present invention, this is achieved without losing the vertical support for the wires by virtue of the notches 94 formed in the first member 82 of the bracket arrangement.
It will be apparent that any number of wires may be encased in the plastic webbing as in the previous embodiments and a corresponding number of notches will be required for the brackets of this embodiment, with the notches spaced to accommodate the spacing between the wires and plastic material enclosing the wires. It is important, however, that the opening 91 between the members of the bracket have a width such that the webbing cannot be moved to shift the protruding portions of the webbing out of the notches 94. In some arrangements, it may be desirable that the opening be slightly smaller than the thickness of the web so that the webbing 111 and the enlarged portions of the webbing that surround the wires will be squeezed between the two cooperating bracket members. In installing the brackets, the installer will drive a fastening member such as a threaded screw through the holes provided at each end of the bracket members to a limited degree whereupon the webbing will be passed through the openings 91 in each bracket member until the desired length of fencing is in place. Then, the installer will tighten the screws to bring the outer bracket member into firm engagement with the first bracket member to complete the installation.
Although several embodiments of this invention have been described in detail above, those skilled in the art will readily appreciate that many modifications not described in detail above are possible without departing from the novel teachings and advantages of this invention. Accordingly, all such modifications are intended to be included within the scope of this invention as defined by the following claims. | A fence composed of plastic-ensheathed metal wires affixed to posts or poles with clamps. The fence has excellent durability for relatively low cost, and will not harm valuable livestock. The simplicity of securing the fencing material to its supports permits rapid one-person installation. The fence is also aesthetically appealing. | 4 |
[0001] This is a continuation of U.S. application Ser. No. 09/747,164 filed on Dec. 22, 2000, which is a continuation of U.S. application Ser. No. 09/534,432, filed Mar. 23, 2000, which is a continuation of U.S. application Ser. No. 09/366,085, filed Aug. 3, 1999 which claims priority from U.S. Application No. 60/095,313, filed Aug. 4, 1998.
BACKGROUND OF THE INVENTION
[0002] The ability to control hybridization of a nucleic acid strand (a probe) to its complement, while excluding imperfectly base-paired probe hybridization has been central to the advancement of both molecular biological techniques and to design of nucleic acid diagnostic systems. Much attention has been paid to this issue because identification of a particular mutant nucleic acid sequence fully complementary to a probe can permit detection of, for example, the existence of a mutant sequence (genetic disorders) or a particular virulent bacterial or viral strain in a patient. Thus, is studies of the physics of mismatched probe:target energetics has focused on the difference in free energy of such mismatches with the hope that such knowledge will benefit the development of assays in which such mismatches are excluded. For example, in diagnosis of a genetic disorder a mutant probe for targeting a nucleic acid molecule having a sequence containing a single base mismatch associated with such a disorder would produce a false positive result if the probe also hybridizes to the wild-type (unmutated) sequence. In other words, the assay must be sufficiently discriminatory in order for the probe to bind to the molecule having the mutated base and not to the molecule lacking the mutated base. If the probe hybridizes to both molecules, then the hybridization result would indicate the presence of the single base mutated sequence even though it was not, in fact, contained in the tested sample. In general, the environment of the reaction is manipulated to eliminate such mismatch probe:target interactions by modifying the physical conditions for hybridization (e.g., temperature and or time) or composition of the hybridization buffer (e.g., salt, divalent ions denaturing agents, etc.).
[0003] On the other hand, however, it is advantageous, in some applications, to have a probe which is known to hybridize with molecules containing particular mismatched sequences (a “marginally indiscrimninant” probe) within a desired degree of homology to the probes' perfect complement. This would permit a single probe to be used in an assay for determining the presence of nucleic acid molecules containing any of the mismatched sequences. Such an assay would thus reduce, or possibly even eliminate, the need for more than one probe, each containing a nucleic sequence precisely corresponding to a sequence of a target molecule. Achievement of such a probe could be useful as a “multiplex” (multiple assays from one probe) probe. To date, for example, conventional multiplexing has relied upon the inclusion of multiplex specific probes into one cocktail reaction (e.g., multiplex polymerase chain reaction (PCR)), rather than just one probe.
[0004] There are always going to be constraints on an indiscrimninant probe. It would be generally acceptable for a probe to hybridize to any nucleic acid molecule whether complementary or not (although there may be limited use for such a probe in detecting the presence or absence of any DNA). This type of probe and/or conditions for hybridization of the probe would detect even sequences which shared no homology with the probes' complement. At the other end of the spectrum, it is desirable that when designing a marginally indiscrimninant probe for detecting viral nucleic acid sequences, for example, to design a probe such that a single probe will pick up all known of sequence within a limited degree of homology (say 10, 20, 30, 40 or 50% homology).
[0005] There are known approaches for detecting target nucleic acids by hybridization of a probe having a nucleic acid sequence fully complementary to or substantially complementary to a sequence of a target nucleic add. Methods have thus been developed to detect viral nucleic acid sequences and their variants by hybridization using probes fully complementary to or substantially complementary to the viral nucleic acid sequences, as exemplified by U.S. Pat. Nos. 5,008,182; 5,079,351; 5,268,268; 5,567,603; 5,594,122; 5,594,123; 5,599,662; and 5,733,781, the text of which is incorporated herein by reference.
[0006] The specifications of these patents disclose methods and compositions of nucleic acids for as probes for detecting nucleic acid sequences of the family of Human T-cell Leukemia Viruses (HTLV) and the Human Immunodeficiency Virus (HIV). HIV and its variants are thought to be responsible for the acquired immunodeficiency syndrome (AIDS). The probes and methods disclosed in these patents for detecting the presence or absence of the viral DNA utilize probes to conserved regions of these viruses, but the disclosed approaches have limited applicability. This is because of the now well-known genetic variability of human immunodeficiency viruses. Genetic variations arise with high frequency. This variability has complicated the development of assays for detecting the presence of their genetic material. Further, while a comparison of various HIV-1 isolates has revealed, regions of the genome that are reasonably well conserved, it is possible that even the conserved regions, regions to which the probes have been designed to hybridize, may at mutate in the future. If so, probes designed for detecting the conserved regions may not hybridize to the one is conserved region as a result of base mismatches.
[0007] As a further example, U.S. Pat. No. 5,567,603 describes probes for detecting HIV-3 that hybridize neither with the sequences of HIV-1 nor with the sequences of HIV-2 under stringent hybridization conditions. Thus, the ability to design a single nucleic acid probe and a method that will allow hybridization of the probe to all HIV strains and their variants but not to other non-target partially complementary nucleic acid sequences or other non-related viral nucleic acid sequences would have advantages over current approaches.
SUMMARY OF THE INVENTION
[0008] The present invention describes how a nucleic acid probe with mismatches to a target may be forced to hybridize to a target without hybridizing indiscriminantly with other non-target partially complementary nucleic acids. The methods of the invention require that nucleic acid duplex ligands as well as nucleic acid single-strand ligands be titered in concentration against one another to achieve the required degree of mismatch target hybridization without obtaining non-target hybridization.
[0009] In one aspect of the invention, a method of providing a nucleic acid molecule for potential use as a probe for a family of nucleic acid molecules in the present of a nucleic acid sequence binding ligand which will promote hybridization of the probe to all the member of the family of target sequences and not to non-target partially complementary sequences is provided. The method includes the steps of providing the family of first nucleic acid molecules wherein each member of the family is related to all other members of the family by a consensus sequence. A second nucleic acid molecule complementary to the consensus sequence is synthesized by methods well known in the art. It is highly preferable that the homology of this complementary sequence to other viral nucleic acid sequences as well as other sequences in general be determined by comparing its nucleotide sequence against those listed in a database (e.g., GenBank, DDBJ, EBI, or GSDB) to ensure that it does not by chance happen to have significant homology to other non-target partially complementary sequences. In addition, the homology of The complementary sequence should also be searched against all members of the family of target sequences to determine if the probe might hybridize to a region(s) other than it was originally intended to. Once it is determined that the complementary sequence will most likely not hybridize to a region(s) of the target sequence and all its family members other than it was intended to or to other non-target partially complementary nucleic acid sequences, the nucleic acid sequence complementary to the consensus sequence can be used as a probe. The ability of the probe to hybridize to the consensus region of the target nucleic acid sequence and all members of the family is then determined in the presence of a certain concentration of nucleic acid sequence binding ligand known to affect hybridization of the probe to the complementary region of the target sequence. This is repeated at several different concentrations of ligand, such that the concentration of ligand at which the probe is able to bind to the target nucleic acid sequence and all its family members equally well without affecting the hybridization of the probe to other non-target partially complementary nucleic acid sequences is the concentration of ligand that will be used for subsequent methods of the invention for that particular probe in detecting the presence of the its target nucleic acid sequence and its genetic variants.
[0010] In yet another aspect, hybridization of the probe to the target nucleic acid sequence and its family members can be further improved in the presence of two different nucleic acid binding ligands.
[0011] In a preferred embodiment, a method of promoting the hybridization of a nucleic acid capture moiety comprising a nucleic acid sequence complementary to a consensus sequence of a target single-stranded nucleic acid sequence and all its family members without hybridizing to a plurality of other non-target partially complementary nucleic acid sequence suspected of being present in a sample is provided. The method includes the steps of identifying at least one consensus sequence to a region of the target duplex nucleic acid sequences and all its genetic variants suspected of being present in a sample; synthesizing a nucleic acid sequence complementary to the consensus sequence (probe); providing a nucleic acid capture moiety comprising the probe; a nucleic acid binding ligand, wherein the ligand has been selected to promote hybridization of the probe to the corresponding complementary region of the target nucleic acid and all its family members; the sample suspected of containing the target nucleic acid sequence and all its family members; and allowing the target single-stranded nucleic acid sequence and all its family members to the nucleic acid capture moiety comprising the probe without promoting the hybridization of other non-target partially complementary nucleic acid sequences.
[0012] In yet another preferred embodiment, a consensus sequences of the target sequence and all its family members can be amplified by PCR if it is suspected that direct detection of the target nucleic acid sequences and all its family members may be different or impossible. In this case, the nucleic acid primers used for detecting the target nucleic acid sequences and all its family members should be designed such that the primers will allow amplification of the region of target nucleic acid sequence and all its family members (i.e., the consensus sequence) to be detected without simultaneous amplification of non-target partially complementary nucleic acid sequences from other viral nucleic acid sequences or human genomic nucleic acid sequences. The hybridization of the amplified region of the target sequence and all its family members to a nucleic acid capture moiety comprising the probe can then be performed under conditions in which the presence of a nucleic acid sequence binding ligand will promote hybridization of the target single-stranded nucleic acid sequence and all its family members to the nucleic acid capture moiety without promoting the hybridization of other non-target partially complementary nucleic acid sequences.
[0013] In a preferred embodiment, the invention described herein can be used to detect nucleic acid sequences of the AIDS virus and all of its family members without detecting other non-target viral nucleic acid sequences or human genomic DNA.
[0014] In yet another preferred embodiment, the invention described herein can be used to detect nucleic acid sequences associated with infectious diseases, genetic disorders, or cellular conditions such as cancer in which the gene responsible for the pathological condition is known to be caused by several mismatch variant nucleic acid sequences. Examples of such genes include but are not limited to p53, ras, BRCA1, BRCA2, or APC.
[0015] In another embodiment, the invention herein relates to a multi-container kit for detecting target nucleic acid sequences and their mismatch nucleic acid sequences suspected of being present in a sample, which kit comprises:
(a) a nucleic acid capture moiety comprising a labeled probe nucleic acid sequence substantially complementary to a consensus sequence of the target duplex nucleic acid sequence and all its family members variants suspected of being present in a sample; and (b) at least one nucleic acid sequence binding ligand, wherein the ligand promotes hybridization of the target single-stranded nucleic acid sequence and all its family members to the nucleic acid capture moiety comprising the labeled probe sequence without promoting the hybridization of other non-target partially complementary nucleic acid sequences.
[0018] Preferably, the kit also contains nucleic acid sequences primers for amplifying the region of the target nucleic acid sequence and all its family members to be detected, an agent for polymerization and four different nucleosides. It is also preferable that the kit contain the relevant positive and/or negative controls.
[0019] In preferred embodiments, the label of the labeled probe nucleic acid sequence is then selected from the group consisting of antibody, antigens, radioisotopes, fluorescent, enzyme, lecithin or biotin.
[0020] In a preferred embodiment, the components of the kit are designed to detect the AIDS virus and all its family members without detecting non-target viral nucleic acid sequences and other non-target nucleic acid sequences.
[0021] In another preferred embodiment, the components of the kit are designed to detect nucleic acid sequences associated with infectious diseases, genetic disorders, or cellular conditions such as cancer in which the gene responsible for the pathological condition is known to be caused by several mismatch variant nucleic acid sequences.
[0022] Examples of such genes include but are not limited to p53, ras, BRCA1, BRCA2, or APC.
BRIEF DESCRIPTION OF THE FIGURES
[0023] FIG. 1 shows the effect of titrating of four DNA binding ligands in a DNA hybridization reaction in which the target molecules were labeled with the radioisotope 32 P. Dark bands indicate unbound target (i.e., higher band intensity=less bound target). The control lane shows the total intensity of unbound target. Hybridization was allowed to occur under the conditions described herein. At the end of the specified time period for hybridization, the amount of unbound target was determined by gel electrophoresis.
[0024] FIG. 2 shows the effect of titrating combinations of four DNA binding ligands in a DNA hybridization reaction in which the target molecules were labeled with 32 P. Distamycin A was held constant at 1 mM for those sets with drug combinations. Hybridization was allowed to occur under the conditions described herein. At the end of the specified time period for hybridization, the amount of unbound target was determined by gel electrophoresis.
[0025] FIG. 3 a shows the time dependence of target-probe hybridization in the presence and absence of distamycin A and ethidium bromide. The arrow indicates the perfect matched probe. The hairpin and target sequences are listed in the inset. At the end of the specified time period amount of unbound target was determined by gel electrophoresis.
[0026] FIG. 3 b shows graphs of normalized binding curves from the data obtained in FIG. 3 a. Gray circles indicate hybridization without DNA ligands. Black circles indicate hybridization in 1 mM distamycin and 0.001 mM ethidium bromide.
[0027] FIG. 4 shows the effect of salt concentration dependence of denaturation of target:probe hybrids of 40% (v/v) formamide. The buffer was 10 mM phosphate, pH 7.2 and the specified concentration of NaCl. Wash incubation time was held constant at 1 hr. The amount of unbound target at the end of the wash incubation time was determined by gel electrophoresis.
[0028] FIG. 5 a shows the effect of formamide concentration when cross-tittered with distamycin A in the wash buffer on denaturation of target probe hybrids. Darker bands indicate a higher degree of dissociation. At the end of the wash period, the amount of 32 P labeled target was determined by gel electrophoresis.
[0029] FIG. 5 b shows graphs of binding curves from the data obtained in FIG. 5 a with each of the constructs shown.
[0030] FIG. 5 c shows graphs of the fraction of target:probe hybrids remaining after denaturation as a function of formamide at different concentrations of distamycin A with each of the constructs shown.
DETAILED DESCRIPTION OF THE INVENTION
[0031] The methods and unique compositions of the invention are useful in the detection of nucleic acid sequences and all related family members without detecting non-target partially complementary nucleic acid sequences. The methods of the invention can be performed with nucleic acid capture moieties immobilized on a solid support such as multi-well plates, membranes or gene chips. The methods of the invention can also be automated, in part, to speed screening and improve economy.
[0032] The term “single-stranded nucleic acid”, as used herein, refers to a duplex nucleic acid which has been denatured resulting in two single-stranded nucleic acid sequences of DNA or RNA. Methods of denaturing duplex nucleic acid sequences are well known to those skilled in art. Single-stranded nucleic acid can also mean a mixed DNA-RNA strand, or nucleic acid-like compounds such as peptide nucleic acids. A nucleic acid strand can also include modified (e.g., chemically or biochemically modified) DNA or RNA bases, of which many are known in the art.
[0033] The terms “target nucleic acid sequence”, “target nucleic acid” or “target strand” refer to a nucleic acid sequence which is to be detected, sequenced, immobilized, or manipulated. The target nucleic acid sequence can be any nucleic add strand, as defined above, and in general will be single-stranded or will be made single-stranded by methods known to those skilled in the art. The target nucleic acid sequence can be obtained from various sources including plasmids, viruses, bacteria, fungi, yeast, plants, and animals, including humans or the target nucleic acid sequence can be obtained from non-natural sources. The target nucleic acid sequence can be obtained from various organisms or tissues, including fluids such as blood, semen, urine and the like. The target nucleic acid sequence is preferably extracted or purified to remove or reduce contaminating or interfering materials such as proteins or cellular debris. Procedures for such purification or extraction of target nucleic acids sequences are known in the art, including, for example, those described in Maniatis et al., “ Molecular Clorung: A Laboratory Manual”, Cold Spring, Harbor Laboratory (1989), or in Bell et al., Proc. Nat Acad. Sci. USA (1991), 78:5759-576. The methods and compositions of the inversion are particularly useful in the detection of nucleic acid sequences associated with infectious diseases, genetic disorders, or cellular conditions such as cancer.
[0034] In one aspect, the invention features a nucleic acid capture moiety which has at least one nucleic acid sequence complementary to at least one consensus sequence of a target nucleic acid sequence and having at least two nucleic acid sequence regions which are capable of forming an intramolecular duplex. The capture moiety can be immobilized on the solid support before, simultaneous with, or after capturing the single-stranded target nucleic acid sequence. A nucleic acid capture moiety can “capture” a target nucleic acid sequence by hybridizing to the target nucleic acid sequence and thereby immobilizing the target nucleic acid sequence and all its family members. In preferred embodiments, the nucleic acid capture moiety comprises a nucleic acid sequence strand which has at least one nucleic acid sequence which is complementary to a consensus sequence of the target nucleic acid and all its family member. One example of a nucleic acid capture moiety is a nucleic acid hairpin. A “hairpin” is a double-helical region in a single DNA or RNA strand formed by the hydrogen bonding between adjacent inverse complementary sequences along the nucleic acid strand. The use of a nucleic acid hairpin as a nucleic acid capture moiety has been described in detail in U.S. Pat. No. 5,770,365 issued to the current applicants, the disclosure of which is incorporated herein by reference. In certain embodiments, the nucleic acid sequence capture moiety, whether a single-stranded nucleic acid sequence or a nucleic acid hairpin, may be labeled as with, e.g., a radioisotope, a fluorescent moiety, an antibody, an antigen, a lecithin, an enzyme, biotin or other labels well known in the art. Alternatively, the target sequence may also be labeled or labeled secondary probes may be employed. A “secondary probe” is a nucleic acid sequence which is fully complementary or substantially complementary to a region of the target nucleic acid sequence or to a region of the nucleic acid capture moiety. “Substantially complementary” as used herein means that the sequence must be sufficiently complementary to the nucleic acid being detected such that hybridization will take place under the conditions employed. Alternatively, a nucleic acid capture moiety can also be a linear nucleic acid sequence such as a single stranded DNA or RNA nucleic acid comprising at least one nucleic add sequence which sequence is complementary to the consensus sequence to the consensus sequence to all members of the family of target sequences.
[0035] As used herein, the term “consensus sequence” means an idealized sequence that represents the nucleotides most often present at each position in a given segment of all members of the family of target sequences. One method of determining a consensus sequence is to use a computer program to compare the target nucleic acid sequence and all its family member sequences for which a consensus sequence is desired. For this purpose, a commercial program with the underlying computer algorithm provided by the National Biomedical Research Foundation using a dot matrix may be conveniently employed. The program involves inputting the nucleic acid sequences of the target nucleic acid sequence and all its generic variants and defining a window size for base pair homology. The program employs graphics to compare the sequences on different axes, and a dot appears where there is at least substantial homology. As used herein, the term “target nucleic acid sequence and all its genetic variants” refers to the wild-type nucleic acid sequence and all base mismatch variants of the wild-type sequence. Once the consensus sequence has been determined a nucleic acid sequence complementary to the consensus sequence is synthesized by methods well known in the art. It is preferable, however, that prior to synthesizing the complementary sequences, the complementary sequence be searched against a plurality of nucleic acid sequences listed in one or more of the nucleic acid sequence databases which include but is not limited to the DNA Data Bank of Japan (DDBJ), the European Bioinformatics Institute (EB), GenBank, or the Genome Sequence Database (GSDB) to determine if the complementary sequence has significant homology to other non-target partially complementary nucleic acid sequences. If the consensus sequence happens by chance to have significant homology to another non-related viral nucleic acid sequence or to an unrelated human sequence, a new consensus sequence to another region of all members of the family of target sequences can be selected and the above process repeated. By doing this, false positives can be eliminated. It is also preferable that the complementary sequence be searched against all members of the family of target sequences to determine if the complementary sequence might hybridize to a region(s) other than it was originally intended to. Once it is determined that the complementary sequence will most likely not hybridize to a to a region(s) of the target sequence and all its family members other than it was intended to or to other non-target partially complementary nucleic acid sequences, the nucleic acid sequence complementary to the consensus sequence can be synthesized and used as a probe. Otherwise, a new consensus sequence should be selected and the above process repeated.
[0036] “Sequence identity or homology”, as used herein, refers to the sequences similarity between two nucleic acid molecules. When a position in both of the two compared sequences is occupied by the same base, e.g., if a position in each of two DNA molecules is compared by adenine, then the molecules are homologous or sequence identical at that position. The percent of homology or sequence identity between two sequences is a function of the number of matching or homologous identical positions shared by the two sequences divided by the number of positions compared×100. For example, if 6 of 10, of the positions in two sequences are the same, then the two sequences are 60% homologous or have 60% sequence identity. By way of example, the DNA sequences ATTGCC and TATGGC share 50% homology or sequence identity. Generally, a comparison is made when two sequences are aligned to give maximum homology. Unless otherwise specified “loop out regions”, e.g., those arising from deletions or insertions in one of the sequences are counted as mismatches.
[0037] The comparison of sequences and determination of percent homology between is two sequences can be accomplished using a mathematical algorithm. Preferably, the alignment can be performed using the Clustal Method. Multiple alignment parameters include GAP Penalty=10, Gap Length Penalty=10. For DNA alignments, the pairwise alignment parameters can be Htupla=2, Gap penalty=5, Window=4 and Diagonal saved=4. For protein alignments, the pairwise alignment parameters can be Ktuple=1, Gap penalty=3, Window=5, and Diagnosis Saved=5.
[0038] Additional non-limiting example of a mathematical algorithm utilized for the comparison of sequences is the algorithm of Karlin and Altachu (1990) Proc. Natn. Acad. Sci. USA 87:2264-68, modified as in Karlin and Altachu (1993) Proc. Natn. Acad. Sci. USA 90:5873-77. Such an algorithm is incorporated into the NBLAST and XBLAST programs (version 2.0) of Altachu, et al., (1990) J. Mol Biol. 215:403-10. BLAST nucleotide searches can be performed with the NBLAST program, score=100 wordlength=12 to obtain nucleotide sequences homologous to nucleic acid molecules of the invention. BLAST protein searches can be performed with the XBLAST program, score=50, wordlength=3 to obtain amino acid sequences homologous to protein molecules of the invention. To obtain gapped alignments for comparison purposes, Gapped BLAST can be utilized as described in Altachu et al., (1977) Nucleic Acids Research 25(17):3389-3402. When utilizing BLAST and Gapped GLAST programs, the default parameters of the respective programs (e.g., XBLAST and NBLAST) can be sued. See http://www.nebi.nlm.nih.gov. Another preferred non-limiting example of a mathematical algorithm utilized for the comparison of sequences is the algorithm of Myers and Miller, CABIOS (1989). Such an algorithm is incorporated into the ALIGN program (version 2.0) which is part of the GCG sequence alignment software package. When utilizing ALIGN program for comparing amino acid sequences, a PAM120 weight residue table, a gap length penalty of 12, and a gap penalty of 4 can be used.
[0039] The compositions and methods of the invention generally feature the use of at least one base-preferring binding ligand (or, in some cases, sequence-specific ligand) to promote hybridization of a probe nucleic acid sequence to promote hybridization of the target single-stranded nucleic acid sequence and all its family members to the is nucleic acid capture moiety without promoting the hybridization of other non-target partially complementary nucleic acid sequences. The methods and compositions of the invention can also include one or more additional binding ligands, which can be base-preferring or sequence-specific ligands, or non-specific ligands, and can bind duplex nucleic acid sequences or single-stranded nucleic acid sequences. The term “nonspecific binding ligand”, as used herein, refers to a nucleic acid binding ligand that does not substantially preferentially bind to nucleic acid sequences in which one or more specified bases predominate. That is, a “nonspecific binding ligand” binds to all, or a large variety of, bases or sequences approximately equally well. The choice of appropriate ligands will be routine to the skilled artisan in light of the teachings herein, as explained in more detail below.
[0040] Ligands suitable for use in the present invention are capable, in general, of binding to nucleic add single strands and/or duplexes. In general, it is necessary to provide at least one base-preferring ligand in the reaction mixtures of the invention.
[0041] A variety of base-preferring ligands have been described. For example, the duplex-binding ligand distamycin A has been reported to bind preferentially to AT-rich sequences. Other base-preferring, duplex-binding ligands include certain restriction enzymes, drugs such as actinomycin D (which has a primary binding site of 5′-GC-3′, and a secondary preference for GT sites) and intercalators such as ethidium bromide (as described below).
[0042] Similarly, base-preferring single strand-binding ligands can be employed in the invention.
[0043] The method of the invention is particularly useful for detecting genetic variants of a target nucleic acid sequence by hybridization using a single probe in the presence of a pre-selected nucleic acid binding ligand under conditions such that the nucleic acid binding ligand will promote hybridization of the target nucleic acid and all its genetic variants with the probe but not to other non-target partially complementary nucleic acid sequences. Specifically, the method of the invention can be used to detect the presence of the AIDS virus nucleic acid sequence and all its genetic variants. A candidate consensus sequence to a particular region of the viral nucleic acid sequence and all its family members is first selected. A second nucleic acid sequence complementary to the consensus sequence, the probe, can then be synthesized by methods well known in the art. It is preferable that the nucleic acid sequence of the probe be compared to a plurality of nucleic acid sequences in a database to rule out the possibility that other non-related viral nucleic acid sequences or other nucleic acid sequences with significant homology may hybridize to the probe, resulting in false positives. The conditions under which a nucleic acid ligand will promote hybridization of the probe sequence to the AIDS virus nucleic acid sequence and all its family members is then determined. A second nucleic acid ligand different from the first can also be used to further improve hybridization of the probe to the AIDS virus nucleic acid sequence and all its genetic variants without promoting hybridization of the probe to other non-target partially complementary sequences. If it is suspected that the amount of AIDS viral nucleic acid sequence present is below the level of direct detection of the method herein, the consensus sequence van be amplified by PCR using consensus sequence primers immediately adjacent to the region to be detected.
[0044] Similarly, the method of the invention can be used to detect the presence of any nucleic acid sequences associated with infectious diseases, genetic disorders, or cellular conditions such as cancer in which the gene responsible for the pathological condition is known to be caused by several mismatch variant nucleic acid sequences. Examples of such genes include but are not limited to p 5 3, ras, breast cancer antigen 1 (BRCA1), or breast cancer antigen (BRCA2).
[0045] The present invention will now be illustrated, but is not intended to be limited by the following examples:
[0000] General Methods
[0000] A. Constructs Used
[0046] The biotinylated DNA capture hairpin (hairpin) was purchased from a commercial supplier (Oligos Therapeutics), wit the following structure:
TTCCTGGTGCAGCTGATC-5′ / U* \ TTGGACCACGTCGACTAGGGCTCCTCTGCGATCCATA-3′
[0047] The duplex region will henceforth be referred to as the “stem.” The 5 bases forming a single-stranded loop on one end of the hairpin will be referred to as the “hairpin loop” or “loop.” “U” refers to biotinylated U, used for attaching the hairpin to a solid support (in this case, streptavidin-coated microtiter plates). The single-stranded region (shown above in bold-face) will be referred to as the “dangling end.”
[0048] Single-stranded DNA molecules fully or partially complementary to the dangling end (referred to as “probe”) were also purchased from the same supplier. These molecules were of different lengths to allow them to be separated and visualized by PAGE. The sequences are:
15-mer perfect match: 5′-TAT GGA TCG GCA GAG-3′ 17-mer mismatch: 5′-AT TAT GGA TCG GCA GAT-3′ 19-mer mismatch: 5′-AAAT TAT GGA TCG GCG GAG-3′ 21-mer mismatch: 5′-TAAAAT TAT GGA TCT GCA GAG-3′ 23-mer mismatch: 5′-TTTAAAAT TAT GGG TCG GCA GAG-3′
[0049] Note that the mismatches are longer than the 15-mer perfect-matched sequence on the 5′-end.
[0050] The duplex molecules formed are:
1. TTCTGGTGCAGCTGATC-5′ GAGACGGCTAGGTAT-5′ / U* \ TTGGACCACGTCGACTAGGGCTCCTCTGCGACCATA-3′ 2. TTCTGGTGCAGCTGATC-5′ TAGACGGCTAGGTATTA-5′ / U* \ TTGGACCACGTCGACTAGGGCTCCTCTGCGATCCATA-3′ 3. TTCTGGTGCAGCTGATC-5′ GAGGCGGCTAGGTATTAAA-5′ / U* \ TTGGACCACGTCGACTAGGGCTCCTCTGCGATCCATA-3′
B. Reaction Conditions
1. 32 P Labeling of the Target Molecules
[0051] The five target molecules were labeled with 32 P following a standard kinasing protocol. The labeled bands were isolated from the reaction solutions by denaturing PAGE (8 M. urea, 20% actylamide). 32 P activity was determined by scintillation counting.
[0000] 2. Capture Hairpin Immobilization on Microtiter Plates
[0052] A solution of the capture hairpin at 10 pmol/50□1 in PBS (150 mM NaCl, 10 mM phosphate, pH 7.2) was prepared. 50□1/well was loaded on streptavidin-coated microtiter plates (Boehringer-Mannheim #1645692) and allowed to incubate for 30 min at room temperature. After the incubation period, the wells were washed 6 times with PBS, and blotted on clean Kimwipes.
[0000] 3. General Procedure for Hybridization
[0053] A cocktail of the labeled targets was prepared by adding a sufficient amount of each target to the hybridization mixture to give a final concentration of −20,000 cpm/target/25□1. The final composition of hybridization mixture is 1M NaCl, 10 mM phosphate, pH 7.2, and the specified concentration of the ligand. 25□1 of the target cocktail was loaded into each well and the plate was incubated for the specified amount of time. After incubation, each reaction mixture as quantitatively transferred to a 0.2 ml tube (Costar 6547).
[0054] The samples were analyzed by denaturing PAGE as follows: 10□1 of loading dye (8 M urea, 5 mM Tris-HC1, pH 7.5, 100 mM EDTA, 0.01% bromophenol blue, 0.01% xylene cynol) was added to the tube, and the whole sample was loaded onto a 15% acrylarnide/1×TBE/7 M urea gel. PAGE was run at 20 mA/gel for 2 hours. After electrophoresis, the gels were visualized by autoradiography.
[0000] 4. General procedure for denaturation
[0055] The hybridization mixture was incubated typically for 2 hours, under the specified conditions (i.e., hybridization buffer+ligands). After incubation, the reaction mixture was removed, and the wells washed once with 100 μl 1M NaC1 phosphate, pH 7.2. The plate was blotted on Kimwipes, and 50 μl of the specified denaturation buffer was added and allowed to incubate for the specified amount of time. The mixture was then quantitatively transferred to 0.2 μl of loading dye was added, and the sample analyzed by PAGE as above.
[0056] The autoradiograms were done by exposing X-ray films (Kodak X-OMAT) to the gels overnight, using an image intensifying screen. In some cases, there is a lane marked “control.” This is a reference lane loaded with an equal volume (25 μl) of unhybridized target cocktail. Also, in each denaturation set of experiments, there is a lane marked “initial.” This lane was loaded with the reaction mixture after hybridization, which indicates how much of the target has bound.
EXAMPLE 1
Effect of Single Ligands of Hybridization
[0057] An hybridization experiment was done where the following binders (see Table 1) were titrated: actinomycin D. distamycin A, ethidium bromide, and single-strand DNA binding protein (SSB). Incubation time was held constant at 2 hours. The results are shown in FIG. 1 .
Results
[0000]
1. Addition of actinomycin D to the hybridization reaction decreased the extent of hybridization in all cases. It acted as a single-strand binder (i.e., denaturant), with the activity proportional to the concentration.
2. Distamycin A improved binding up to a concentration of 0.016 mM, but did not improve binding (compared to the control with no ligands) at higher concentrations.
3. Ethidium bromide died not seem to affect the extent hybridization up to a concentration of 0.001 mM, and it inhibited hybridization of the longer mismatches (19-21, 23-mer sequences) from a concentration of 0.004 mM and higher. There are no bands at 1 mM. However, there was a strong band at the top of the gel (data not shown).
4. SSB did not have an effect on the hybridization up to a concentration of 0.78 μg/ well. However, a decrease in the extent hybridization was observed at the higher SSB concentrations.
EXAMPLE 2
Effect of a Ligand Combination of Hybridization
[0062] In this experiment, different combination of ligands were used. The titration of distamycin A was repeated (see above), and in three other sets, distamycin A concentration was fixed at 1 mM and the other ligands were titrated. The results are sown in FIG. 2 .
Results
[0000]
1. The distamycin A titration experiment showed nearly identical results with the first run. An improvement in the extent of hybridization was observed up to a concentration of 0.016 mM, with no improvement at higher concentrations.
2. Titration of actinomycin D in the hybridization mix with a constant amount of distamycin A showed markedly different results than when actinomycin D was used alone. A comparison of the two experiments (II-1 and III-2) showed that when actinomycin D was used alone, a decrease in the extent of hybridization was apparent even at the lowest concentration used (0.00025 mM). When actinomycin D was used in combination with distamycin A, a decrease in the extent of hybridization was noted at 0.004 mM or higher, an approximately 16-fold higher concentration.
3. A combination of distamycin A and ethidium bromide showed a similar effect While there was a decrease in the hybridization at >0.001 mM ethidium bromide when it was used alone, there was no decrease in hybridization when it was used in combination with distamycin A. Similar to the previous experiment, at 1 mM ethidium bromide, all the unhybridized target was noted at the top of the gel (data not shown).
4. Distamycin A apparently did not have an effect on the activity of SSB. The results of the distamycin A/SSB combination are similar to the results when SSB alone was titrated.
EXAMPLE 3
Effect of a Ligand Combination on Hybridization Time
[0067] The previous experiment showed that a combination of ligands (i.e., distamycin A and ethidium bromide) may improve the extent of DNA hybridization. A hybridization kinetics experiment was performed where the extent of hybridization in the absence of ligand (i.e., hybridization buffer only) and with a combination of ligands (1 mM distamycin A+1 μM ethidium bromide) were compared as a function of time.
Results
[0068] The results are shown in FIG. 3 a. A comparison of the band intensities at 40 and 60 minutes shows an improvement in the hybridization in the presence of ligand. This trend is more clear when the intensities are measured (NIH Image) and plotted as shown in FIG. 3 b.
EXAMPLE 4
Effect of Denaturation on Hybridization
[0069] In this set of experiments, we used various combinations of salt concentration, distamycin A, and the formamide (a denaturant), to control the extent of duplex to single-strand dissociation. The same set of molecules as in the previous section was used.
[0070] Hybridization of the target cocktail to the capture hairpin was carried out following the procedure described in General Methods. The final composition of the hybridization buffer was 1M NaC1, 10 mM phosphate, pH 7.2. The samples were incubated for approximately 2 hours at room temperature, and washed once with the hybridization buffer.
[0071] The denaturation buffer was 10 mM NaCl, 10 mM phosphate, pH 7.2, and NaCl tittered from 0 to 1M. The results are shown in FIG. 4 . The amount of target dissociating from the capture hairpin decreased with an increase in the salt concentration with the 15-mer perfect match showing the greatest change.
Results
[0000]
1. Salt Concentration Dependence of Denaturation
[0073] The wash buffer consisted of 40% formamide, 10 mM phosphate pH 7.2, and NaC1 tittered from 0 to 1M. The results are shown in FIG. 4 . The amount of target dissociating from the capture hairpin decreased with an increase in the salt concentration, with the 15-mer perfect match showing the greatest change.
2. Formamide and Distamycin A Concentration Effect on Dissociation
[0075] FIG. 5 a shows a denaturation experiment where formamide was cross-tittered with distamycin A. The buffer concentration was kept constant at 10 mM NaCl, 10 mM phosphate pH 7.2 Formamide was tittered from 20-35% at 2.5 increments, while distamycin A was tittered from 0.062 mM to 1 mM in 4-fold increments. With no distamycin A, the stabilities of the mismatched targets increased, as shown by the decrease in their respective band intensities. This effect becomes more clear when the bands are quantified and plotted, as shown in FIG. 5 b (with distamycin A independent variable), and in FIG. 5 c (with formamide as the dependent variable).
3. Time Dependence of Dissociation as a Function of Distamycin A Concentration
[0077] An experiment was fun where the extent of dissociation over time was measured as a function of distamycin A concentration in the wash buffer. The formamide concentration was kept constant at 40% (v/v), and distamycin A was tittered in 4-fold increments, at 0,0,62 mM, 0.25 mM, and 1 mM. Time points were from 0 (wash buffer was added and pulled out) to 60 min. The results are shown in FIG. 6 . With 0-0.062 mM distamycin A, denaturation dissociate to the same extent as in the previous drug concentration. At 1 mM distamycin A, all target molecules show a lower extent of dissociation, with the perfect match showing a marked increase in stability.
[0000] Equivalents
[0078] Those skilled in the art will recognize, or be able to ascertain using no more than routine experimentation, numerous equivalents to the specific procedures described herein. Such equivalents are considered to be within the scope of this invention and are covered by the following claims. The contents of all references, issued patents, and published patent applications cited throughout this application are hereby incorporated by reference. | The invention relates to the field of molecular biology, nucleic acid chemistry and medical diagnostics. More specifically, it relates to methods and compositions for promoting the hybridization of a nucleic acid probe with a target nucleic acid sequence which is not perfectly matched to the probe. | 2 |
CROSS REFERENCE TO RELATED APPLICATION
This application claims the priority of German Application Nos. 100 03 994.4 filed Jan. 29, 2000 and 100 51 998.9 filed Oct. 20, 2000, which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
This invention relates to an apparatus integrated in a carding machine or a roller card unit for forming a sliver from a fiber web. The apparatus has a roll assembly, formed of a doffer, a stripping roll and a crushing roll pair. The apparatus further has a web gathering and advancing unit as well as a sliver trumpet followed by a calender (pull-off) roll pair. The sliver trumpet densifies the web and discharges a sliver. The sliver exiting the trumpet is introduced into the calender roll pair.
In practice, in the fiber batt processing industry, roller card units and carding machines are used which, for forming a fiber web, have a transitional guide plate (open web triangle), a standing roll pair and a downstream-arranged calender unit. It is a disadvantage of these known arrangements that the cross section of the produced sliver significantly deviates from a rectangular shape. It is also a drawback that the fiber material is not uniformly distributed over the sliver cross section. The thus-produced intermediate product (sliver) leads to irregularities during further processing to obtain the final product, such as a hygiene item.
German patent document 22 50 834 describes a transverse web gathering device which has a conveyor belt and a conveyor roll, followed by a sliver trumpet to form a sliver from a fiber web. The fiber web, after being densified in a closed zone, leaves the transverse gathering device and runs through a sliver trumpet and calender rolls and is thereafter deposited into a sliver can. The roll nip in the transverse gathering device is narrow and the inlet of the trumpet is at a substantial distance from the outlet of the transverse gathering device. The outlet of the trumpet has a circular cross section, and thus the exiting sliver assumes a circular cross section as well. The trumpet outlet is situated at a distance upstream of the bight defined by the calender roll pair. Such an apparatus is not adapted to form a sliver having a rectangular—particularly sharp-edged—cross section. It is a further disadvantage of the known arrangement that because of the distances of the trumpet inlet from the transverse web gathering device, on the one hand, and the trumpet outlet from the calender nip, on the other hand, the processing of the fiber material having a significant amount of short fibers is not possible. Also, the above-noted relatively large distances do not allow a high delivery speed.
SUMMARY OF THE INVENTION
It is an object of the invention to provide an improved apparatus of the above-outlined type from which the discussed disadvantages are eliminated and which, in particular, produces an improved sliver having a rectangular cross section and which further permits a production rate higher than heretofore.
This object and others to become apparent as the specification progresses, are accomplished by the invention, according to which, briefly stated, the fiber sliver producing apparatus includes an arrangement for making a running fiber web; a transverse web gathering device gathering the fiber web; and a sliver trumpet through which the gathered fiber web passes for being densified and discharged thereby as a running sliver. The sliver trumpet has a cross-sectionally rectangular outlet opening which has a width that is at least 10 times greater than its height. The apparatus further has a calender roll pair formed of two calender rolls through which the sliver passes after being discharged by the sliver trumpet. The calender roll pair defines a bight in which the outlet opening of the sliver trumpet is disposed.
By virtue of the measures according to the invention a sliver having a rectangular cross section may be produced which has a more uniform fiber distribution and a significantly increased output speed (at least 100 m/min) compared to prior art arrangements. In particular, the processing of the fiber material with a higher short-fiber proportion is advantageously feasible.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a schematic side elevational view of a carding machine incorporating the invention.
FIG. 2 is an enlarged schematic side elevational view of one part of the structure shown in FIG. 1 .
FIG. 3 is a perspective view of a preferred embodiment of the sliver trumpet according to the invention.
FIG. 3 a is a front elevation of the sliver trumpet, showing an adjustable wall element in the outlet region.
FIG. 3 b is a cross-sectional view of the sliver exiting the sliver trumpet.
FIG. 4 a is a schematic front elevational view of a preferred embodiment of the invention in which a crushing roll pair (only one roll is visible), a transverse gathering device, a sliver trumpet and a calender roll pair (only one roll is visible) are in a vertical arrangement.
FIG. 4 b is a side elevational view of the construction illustrated in FIG. 4 a.
FIG. 5 is a schematic front elevational view of another preferred embodiment of the invention, including a conveyor belt and a conveyor roll, calender rolls arranged parallel to the conveyor roll and a deflecting roll.
FIG. 6 is a schematic front elevational view of a further preferred embodiment of the invention having calender rolls oriented perpendicularly to the conveyor roll.
FIG. 7 a is a schematic front elevational view of the gap region between the web conveyor belts which have an after-connected web spreading element.
FIG. 7 b is a sectional view taken along line VIIb—VIIb of FIG. 7 a.
FIG. 7 c is a schematic side elevational view of the structure shown in FIG. 7 a including an after-connected sliver trumpet and calender rolls.
FIG. 8 is a schematic front elevational view of a variant of the structure illustrated in FIG. 4 a.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 illustrates a carding machine CM which may be, for example, a high-performance DK 903 carding machine manufactured by Trützschler GmbH & Co. KG, Mönchengladbach, Germany. The carding machine CM has a feed roll 1 , a feed table 2 cooperating therewith, licker-ins 3 a, 3 b, 3 c, a main carding cylinder 4 , a doffer 5 , stripping rolls 6 , cooperating crushing rolls 7 , 8 , a web guiding element (transverse web gathering device) 9 , a sliver trumpet 10 , calender rolls 11 , 12 and a travelling flats assembly 13 having slowly circulating flat bars 14 . The rotary direction of the carding machine rolls is indicated by curved arrows drawn thereinto. At the output of the carding machine a coiler device 16 is provided which deposits the sliver into a coiler can 15 . The working direction, that is, the advancing direction of the fiber material in the carding machine is designated with the arrow A.
Turning to FIGS. 2 and 3, the transverse web gathering element 9 , the sliver trumpet 10 and the calender rolls 11 and 12 rotating in the direction indicated by the arrows 11 a and 12 a, are arranged downstream of the crushing rolls 7 and 8 which rotate in the direction indicated by the arrows 7 a and 7 b, respectively. The sliver trumpet 10 and the calender rolls 11 , 12 are mounted on a holding device 17 which may turn in the direction of the arrows B and C about a fixed shaft 18 . The inner passage of the sliver trumpet 10 converges in the working direction A. The height c of the inlet opening 10 b is greater than the height b of the outlet opening 10 a. The height b of the outlet opening 10 a of the sliver trumpet 10 is approximately 2-3 mm. The width a of the outlet opening 10 a of the sliver trumpet 10 is between approximately 20-100 mm, preferably 60-90 mm. The width a may be changed—as shown in FIG. 3 a —by a wall element 10 c in the region of the outlet opening 10 a by shifting it in the direction of the arrow D or E. The outlet opening 10 a is rectangular and is bounded by sharp edges. As a result of this construction the flat sliver 19 exiting the sliver trumpet 10 has, as shown in FIG. 3 b, a sharp-edged rectangular cross-sectional shape. As shown in FIG. 2, the outlet opening 10 a of the sliver trumpet 10 is situated in the intake bight 11 ′ defined between the calender rolls 11 and 12 . The inlet opening 10 b of the sliver trumpet 10 is chamfered and has an elongate shape. The inner trumpet walls 10 d and 10 e extending in the region of the trumpet outlet opening 10 a along the width thereof, are parallel to one another.
As shown in FIGS. 4 a and 4 b, the axially parallel crushing rolls 7 and 8 are horizontally arranged and are followed perpendicularly downward by the transverse web gathering element 9 , the sliver trumpet 10 and the calender rolls 11 and 12 .
The transverse web gathering element 9 has two endless flexible conveyor belts 9 a, 9 b supported by end rolls 9 1 , 9 2 and, respectively, 9 3 , 9 4 . In each instance, one end roll for each belt, for example, the end rolls 9 1 and 9 3 are driven by a respective shaft 9 * (shown in FIG. 2) by a non-illustrated, preferably common driving device. The belt flights of the conveyor belts 9 a, 9 b move in directions illustrated by the arrows F, G and H, I.
The calender roll 12 is biased by a compression spring 20 and is radially movably supported relative to the radially stationary calender roll 11 , whereby the width d of the nip between the calender rolls 11 and 12 as well as the pressure on the sliver may be adjusted. The force of the spring may be adjusted, for example, by inserting washers 20 a, 20 b of suitable thickness between a spring end and a spring support. If a subsequent doubling of the fiber web is effected prior to further processing, an excessive pressing of the calender rolls 11 , 12 may cause damage whereas if an immediate further processing is carried out, then a greater compression force is desirable.
Turning to FIG. 5, the transverse web gathering element 9 is composed of a conveyor belt 9 a and a conveyor roll 9 c defining together a nip (exit gap) having a width e which has a clearance of preferably approximately 10 mm. The web material passes through the nip in direct contact with the conveyor belt 9 a and the conveyor roll 9 c. The axes of the end rolls 9 1 , 9 2 (supporting the belt 9 a ), the conveying roll 9 c and the calender rolls 11 , 12 are arranged in a parallel orientation. By virtue of the parallel arrangement of the calender rolls 11 , 12 , the web material lying on the belt 9 a is packed in an even more pronounced manner into the rectangular cross-sectional shape of the web by the transverse web gathering element 9 . Downstream of the calender rolls 11 , 12 a sliver deflecting roll 23 is arranged.
According to FIG. 6, in contrast to FIG. 5, the width of the sliver trumpet 10 and the axes of the calender rolls 11 , 12 are perpendicular to the axes of the end rolls 9 1 , 9 2 and the conveying roll 9 c. The advantageous arrangement of the sliver trumpet 10 with respect to the transverse web gathering element 9 also depends from the width a of the outlet opening 10 a and from the processed fiber material.
To obtain an optimal web structure for the consecutive material distribution in the rectangular trumpet 10 , the width e of the outlet nip according to FIGS. 4 a, 5 and 6 between the end roll 9 2 on the one hand and the end roll 9 4 or the conveying roll 9 c on the other hand, has to have a minimum dimension, for example, at least 10 mm to avoid a premature compression of the web at that location.
Turning to FIGS. 7 a, 7 b and 7 c, subsequent to leaving the web gathering device 9 , a web widening prior to its entering the rectangular sliver trumpet 10 may be advantageous for a desired width a of the exiting sliver 19 (final sliver width). For this purpose an arcuate web spreading element 21 is provided which is arranged between the transverse web gathering element 9 and the inlet 10 b of the sliver trumpet 10 . The web spreading element 21 is a bent bar having an approximately semicircular cross section as shown in FIG. 7 b. The sliver 22 exiting the outlet nip of the web gathering device 9 runs over the upper, convexely bent region of the web spreading element 21 and is thus laterally spread thereby. The gathered web 22 subsequently passes through the sliver trumpet 10 and is pulled off the outlet opening 10 a by the calender rolls 11 , 12 as a flat sliver 19 having a rectangular, uniform cross section.
In a variant shown in FIG. 8, the conveyor belts 9 a and 9 b of the web gathering device 9 ′ are arranged at an oblique angle α 1 and α 2 with respect to the axis of the crushing rolls 7 and 8 (only the crushing roll 7 is visible). The oblique angle is approximately between 30° and 45°.
It will be understood that the above description of the present invention is susceptible to various modifications, changes and adaptations, and the same are intended to be comprehended within the meaning and range of equivalents of the appended claims. | A fiber sliver producing apparatus includes an arrangement for making a running fiber web; a transverse web gathering device gathering the fiber web; and a sliver trumpet through which the gathered fiber web passes for being densified and discharged thereby as a running sliver. The sliver trumpet has a cross-sectionally rectangular outlet opening which has a width that is at least 10 times greater than its height. The apparatus further has a calender roll pair formed of two calender rolls through which the sliver passes after being discharged by the sliver trumpet. The calender roll pair defines a bight in which the outlet opening of the sliver trumpet is disposed. | 3 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a National Stage of International Application PCT/FR2011/051617 (“PCT '617”) filed Jul. 7, 2011 and published as WO 2012/004537 on Jan. 12, 2012. PCT '617 claims priority to French Application No. 1002902 filed Jul. 9, 2010. All of the applications are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The invention relates to image synthesis.
BACKGROUND
[0003] In modern computer processing, computation capacities have increased exponentially, to the point that immersion in three dimensional universes is now possible.
[0004] Managing these universes and seeking to make them increasingly more realistic for users nevertheless conflicts with the time necessary to create these universes, as well as the technical limitations particularly relative to capacity and memory access.
[0005] To manage this problem, systems have been designed that use limited inventories of images that are manipulated to give an illusion of variety, for example by applying those images on the three-dimensional surfaces to give them a varied appearance.
[0006] However, the quality of the resulting images is unsatisfactory if the images are reused on varied surfaces. Furthermore, if one wishes to adapt each image to its substrate surface to improve the quality, it is necessary to store all of the resulting images individually, which is a clear waste of storage space.
[0007] The invention aims to improve the situation.
SUMMARY
[0008] To that end, the invention relates to an image processing device including an analyzer capable of calculating associated cutting data and difference data from image data, the cutting data comprising coordinates of the image and designating a pair of parallel paths in the image, and the difference data representing a difference between attributes of the image data along each pair of parallel paths, a selector receiving input data from a working node and cutting data and configured to obtain therefrom so-called successor node data on the basis of a selection rule, the data of a node including cutting data, cost data, and position data, and an assembler receiving input data from working nodes and data from a predecessor node and capable of calculating updated node data as a function of the cost data on at least some of the working nodes, the cost data of the predecessor node and the difference data associated with the cutting data of the working nodes. Further, a driver configured to call the analyzer with image data of an input image, call the selector with an input node as the working node and with the cutting data calculated by the analyzer, call the assembler with at least some of the successor nodes determined by the selector as working nodes and with the input node as a predecessor node, and repeatedly call the selector and the assembler using one of the updated nodes as a working node for the selector, using the successor nodes resulting from said call as working nodes and the updated node as a predecessor node for the assembler, until a condition relating to the cutting data and the position data of an updated node is satisfied.
[0009] This device and method are novel, as they make it possible to generate new images similar to the reference images, but the sizes of which are adapted to their substrate surface.
[0010] For example, if a three-story façade image is applied on a surface of a four-story building, a distortion can be observed. Owing to the invention, a new façade image, resembling the original but having the right number of floors, can be generated.
[0011] Furthermore, its storage and display can be done in a very compact form. The invention is not, however, limited to façades, but applies to any image having enough repetitions along horizontal or vertical translations.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] Other features and advantages of the invention can better appear upon reading the following description, drawn from examples provided as an illustration and non-limitingly, drawn from the drawings, in which:
[0013] FIG. 1 is a schematic diagram of a device according to an example of the invention,
[0014] FIG. 2 shows a schematic overview diagram of an image with the device of FIG. 1 ,
[0015] FIG. 3 shows an example of operations carried out by the device of FIG. 1 according to FIG. 2 ,
[0016] FIG. 4 shows a flowchart of the implementation of another part of FIG. 2 by the device of FIG. 1 ,
[0017] FIG. 5 shows an example of cuttings according to an example of the invention,
[0018] FIG. 6 shows an alternative of the diagram of FIG. 3 , and
[0019] FIG. 7 shows an alternative of FIG. 1 in which the device is used to create a set of images to simulate a three-dimensional town.
DETAILED DESCRIPTION
[0020] The drawings and descriptions below essentially contain elements of a definite nature. They may therefore not only serve to better understand the present invention, but may also contribute to the definition thereof if necessary.
[0021] The present invention involves elements subject to copyright protection. The holder of the rights does not object to the identical reproduction by anyone whosoever of this patent document or its description, as it appears in official documents. For the rest, it reserves all of its rights.
[0022] FIG. 1 shows a schematic diagram of a device 2 according to the invention.
[0023] In the example described here, the device 2 receives an input image of size M×N as well as a target width W, and produces an output image of size W×N resembling the input image.
[0024] The device 2 includes an analyzer 4 , a selector 6 , an assembler 8 , a rule base 10 , and a driver 11 to control them.
[0025] As shown in FIG. 2 , the device 2 receives an input image 12 . In a first operation, the device 2 calls the analyzer 4 with the input image 12 . At the end of the operation, the analyzer 4 produces a file that comprises data defining a cutting plane of the input image.
[0026] The cutting plane comprises a list of series of coordinates in the image, each series defining a path in the input image. To embody that cutting plane, an image 14 is shown in which the paths of the cutting plane are shown superimposed on the input image 12 .
[0027] Each broken line has a least one other broken line parallel to it: they may be superimposed exactly. This correspondence is stored in the file produced by the analyzer 4 .
[0028] These broken lines are hereafter referred to as “cuttings,” and in the example described here, they are oriented vertically relative to the display of the image: each cutting separates the image into two left and right parts.
[0029] FIG. 3 shows an example embodiment of the analyzer 4 .
[0030] The analyzer 4 looks for pairs of paths between the upper edge and lower edge of the image, such that the two paths are strictly parallel and have similar colors.
[0031] The two sought paths being parallel, it is possible to superimpose them exactly by a translation T. These paths are called “cuttings” because it is possible to cut the image along these two paths so as to remove or repeat a piece thereof.
[0032] The cost (or quality) of the paste, i.e., the possibility for a user to perceive a visual defect, depends on the similarity between the colors along the pair of paths.
[0033] There are a large number of possible pairs of cuttings separated by different distances and offering varying paste qualities.
[0034] Although it is possible to use cuttings with any shapes, the Applicant has chosen to restrict the search for cuttings to paths with a simple shape, so as to simplify the storage thereof. In particular, a cutting always advances strictly from top to bottom and cannot move by more than one pixel on the x-axis for each pixel descended on the y-axis.
[0035] The search for cuttings is an important step: too many cuttings would weigh down the processing needlessly, while too few cuttings would prevent the assembler 8 from producing good quality synthesized images.
[0036] The analyzer 4 of the example described here is a compromise between obtaining good quality parallel cuttings (i.e., having a small color difference) and obtaining a good distribution of cuttings in the image, so that the assembler 8 has enough choices.
[0037] The analyzer 4 receives an input image Img of size M×N and produces, as output, a plurality of parallel cuttings in a file Cuts.
[0038] The analyzer 4 implements an algorithm that executes a global loop whereof each iteration runs a plurality of local loops. To that end, an index of width T varying between 1 and M−1 is initialized in an operation 300 .
[0039] In an operation 302 , it is verified whether T is equal to M−1, which would mean that all of the possible widths have been tested. If that is the case, then the algorithm ends in an operation 304 .
[0040] The operations 306 to 316 describe the execution of an iteration of the global loop. Each iteration of the global loop finds, for each possible width T, a set of parallel cuttings that do not intersect for that width. It can, however, be noted that cuttings associated with two different widths, and therefore determined in iterations distinct from the global loop, may intersect.
[0041] The principle of discovering a pair of parallel cuttings is to use a difference map Diff, and therefore to find a unique path on that map. To that end, the map Diff is calculated in the operation 306 as the color difference between the pixels of the image Img and those of its translation by T pixels to the right. Alternatively, other attributes of the data of the image may be used, such as the chrominance, brightness, or saturation.
[0042] A path in the map Diff therefore corresponds to two paths in the image Img:
[0043] a first path that has the same coordinates as the path of Diff, and
[0044] a second path, shifted by T pixels to the left in the image Img.
[0045] These two paths are parallel by construction. The color matching between these paths corresponds to the sum of the color values of the pixels along the path in the map Diff. This sum concretely corresponds to the some of the differences between the pixels along the path, i.e. the cost of the path.
[0046] Each local loop is formed by the operations 308 to 314 , and chooses a path P in the map Diff, and stores the corresponding cuttings in the file Cuts.
[0047] To determine whether cuttings remain to be found for the current width T, a function Pth( ) is called in the operation 308 . This function looks in the map Diff for all possible paths according to the rule described above, i.e. always strictly from top to bottom and without moving by more than one pixel along the x-axis for each pixel descended on the y-axis, and only retains the paths that do not have a so-called infinite cost. The notion of infinite cost is clarified below.
[0048] If the function Pth( ) does not find any path, then the global loop has finished its current iteration, and the index T is incremented in operation 316 , then the global loop starts again in 302 .
[0049] Otherwise, in the operation 310 , the function Min( ) returns the path P of the map Diff that has the lowest cost. Then, in an operation 314 , cuttings corresponding to the path P are stored in the file Cuts, with the associated cost of the path P.
[0050] Lastly, in the operation 316 , a function Kill( ) modifies all of the pixels of the map Diff comprised between the path P and the path P shifted by T pixels to the right and left to yield a value indicating an infinite cost. This value may be chosen arbitrarily or may be a particular sign.
[0051] The role of the function Kill( ) is to guarantee that all of the local loops after the current local loop produce cuttings not secant to those previously determined. Additionally, since in the worst case, the path P is T pixels wide, the T pixels following P are eliminated from the following local loops, while assigning them an infinite cost.
[0052] This makes it possible to avoid needlessly accumulating too many parallel cuttings in the same region of the image. The operation 310 guarantees that only the best possible pair of cuttings is retained for the width T, i.e., that with the smallest cost.
[0053] The algorithm therefore finds that the compromise between the quality and quantity objectives of the cuttings.
[0054] As seen above, the cost corresponds to the sum of the differences between the colors of pixels associated with the two parallel paths (more generally the difference in image attribute if an attribute other than the color is selected). Two non-parallel cuttings are not superimposable, and therefore not comparable.
[0055] Furthermore, as can be seen hereafter, associating two non-parallel cuttings does not cause a visual difference. For that reason, the cost associating two non-parallel cuttings is defined as zero.
[0056] In the example described here, cost data only exists for parallel cuttings, and all of the other cutting associations have an implicit zero cost. Alternatively, this may be explicit.
[0057] It is assumed that the parallel cuttings never have a zero cost (i.e., there is no perfect match). This may be guaranteed by adding a low non-zero value to the match cost of all of the pairs of parallel cuttings. In practice, this case is very rare, except on artificial images. Other strategies are possible to avoid this problem.
[0058] A secant cutting here refers to the fact that there is a portion of the original image in which the x-axis of the first cutting is smaller than that of the second cutting, and another portion of that image in which the x-axis of the second cutting is smaller than that of the first cutting. In other words, when one looks at the “paths” associated with these cuttings, they intersect.
[0059] For a given cutting, there is a set of cuttings that is particularly interesting. The set comprises so-called “frontal” cuttings. A cutting is said to be frontal with respect to a given cutting if the frontal cutting is situated all the way to the right of the given cutting and if there is no other cutting that is completely situated between it and the given cutting. “Completely situated between” means that there are no cuttings whereof all of the points are strictly situated between those of the given cutting and those of the frontal cutting.
[0060] Several cuttings secant with respect to one another may be frontal with respect to a given cutting. As can be seen below, the selection of frontal cuttings is important to find the solution more effectively. In fact, they can make it possible to reduce the number of possibilities examined, while their definition guarantees that no possible solution is dismissed.
[0061] FIG. 5 makes it possible to better understand the notion of a frontal cutting. As can be seen in the figure, the given cutting is the leftmost cutting.
[0062] In that figure, the two cuttings that have their x-axis on the upper edge closest to that of the given cutting are frontal cuttings, and not the third. In fact, for each of these, there is no cutting between them and the given cutting.
[0063] However, the last (rightmost) cutting is not frontal relative to the given cutting because the frontal cutting having the x-axis on the rightmost upper edge is completely contained between the given cutting and that cutting.
[0064] Alternatively, it would be possible to look for paths by threes or fours instead of looking for them by pairs. Furthermore, as seen relative to the description of FIGS. 3 and 5 , one may use the term path or cutting equivalently inasmuch as a path has been selected in a local loop. A frontal cutting may thus also be called a frontal path.
[0065] Once the analyzer 4 has calculated the cuttings in the input image 12 , a loop is launched in which the selector 6 , the assembly 8 and the rule base 10 interact to produce a set 16 of synthesized image pieces.
[0066] Lastly, the set 16 of synthesized image pieces can be assembled to form a synthesized image 18 .
[0067] FIG. 4 shows an example embodiment of the loop that produces the set 16 . In this example, the synthesized image is enlarged or reduced along the horizontal dimension.
[0068] The operating concept used by this loop is now described.
[0069] In order to simplify image generation, and to be able to store the images at a lower cost, the Applicant resolved to use the advantages related to the cuttings. As seen above, a cutting is a path in the image in a direction, here between the upper and lower edges of the image, that has at least one “parallel path” having similar colors in that image all along it.
[0070] Thus, if one pastes the part of the original image following the “parallel cutting” after a given cutting, the human eye can not see the difference in most cases. It then becomes possible to enlarge or reduce the size of a base image while considerably reducing artifacts, and while adding variety.
[0071] This is done by the juxtaposition of the series of cuttings of the original image, which are filled between them by the content corresponding to the original image. This for example appears with the set 16 .
[0072] This example is very advantageous, as it becomes possible to create a multitude of synthesized images from a single base image, and to describe them only with that image, the cuttings it contains, and a plurality of lists of successive cuttings for each image.
[0073] The work to reconstruct a synthesized image from its list of cuttings is in fact not very greedy in terms of calculation time. It is nevertheless necessary to choose the cuttings wisely.
[0074] Furthermore, in modeling a three-dimensional building, it is necessary for the corners to match, which requires keeping the left and right edges of the original image. In other applications, this limitation may be ignored, and the start and end edges may be chosen in the image by the user.
[0075] The Applicant's work has therefore led to studying the most effective way to choose the list of successive cuttings in the image so as to obtain a final image of the selected size.
[0076] As can appear with the following description of the loop for generating the set 16 , the Applicant has implemented an adapted version of the Dijkstra algorithm. Here, the aim is to start from the left edge of the image, and to reach the right edge of the image, while selecting the cuttings between the two to obtain the desired length of the synthesized image.
[0077] To that end, the selector 6 chooses, at each iteration, the list of cuttings that can be used from among the following list:
cutting(s) “parallel” to the cutting in progress, the set of so-called “frontal” cuttings.
[0080] These selection conditions form a first selection rule that is stored in the rule base 10 . Other rules are described later.
[0081] It can be noted that selecting the cutting(s) “parallel” to the cutting in progress makes it possible to “go backwards” or “jump forwards” in the original image to form the synthesized image, which makes it possible to generate enlarged or reduced synthesized images with the smallest possible quantity of visual artifacts.
[0082] Furthermore, this set is reduced, which simplifies the complexity of the algorithm, while not ignoring any possible combinations, owing in particular to the frontal cuttings.
[0083] The Dijkstra algorithm is implemented as follows:
when one of the cuttings “parallel” to the cutting in progress is chosen, the cost is increased by the difference between those cuttings, and the length of the synthesized image is not increased. The distance between the cuttings refers to the error, the difference between the pixels of the original image along the cuttings. This information is available directly from the work of the analyzer 4 : when a frontal cutting is selected, the cost is not increased, as that amounts to reproducing part of the original image, and the length of the synthesized image is increased by the length that separates the current cutting from the selected frontal cutting; the algorithm stops when the right edge of the image is chosen, and the length of the synthesized image is equal to the desired length. All that remains is then to go up the list of “precedents” established by the algorithm to see the list of cuttings, up to the left edge.
[0087] However, the algorithm operates not based on the cuttings, but based on nodes. A node here refers to the pair formed by a cutting identifier and a position of that cutting in the synthesized image.
[0088] As can be seen below, a current node has several attributes:
the predecessor of that node, i.e., the node that is considered the least costly to reach the current node, the cost that is associated with that node, i.e. the sum of the differences between all of the cuttings encountered before reaching that node.
[0091] The loop starts in operation 400 by calling a function Init( ) by the driver 11 .
[0092] The role of the function Ink) is to initialize the variables and global parameters of the synthesis loop of the image.
[0093] These parameters include the desired length W for the synthesized image. As can be seen with FIG. 6 , this length may be specified by the user for each image he wishes to synthesize. It may also be generated automatically as a function of other parameters specified by the user and/or distribution models.
[0094] Another parameter is the file Cuts, which receives the set of cuttings identified in the image 12 by the analyzer 4 , and which serves as a starting point for the algorithm. In the file Cuts, the cuttings are described by the list of coordinates of the points that define them, and the cuttings are ordered by increasing x-axes, i.e., the left edge of the image is the first cutting, followed by the cutting that contains the point for which the x-axis is lowest, and so forth.
[0095] In an operation 402 , the cutting that corresponds to the left edge of the image is chosen as the starting point. The corresponding node here is denoted N 0 and has a zero x-axis in the synthesized image, a zero associated cost, and no predecessor. The node N 0 is stored in a list Pot.
[0096] Once this is done, the initialization of the loop is complete, and the loop, as such, runs.
[0097] In a first operation 404 , the list Pot is opened using a function Pop( ) As can be seen below, this always involves the node having the lowest cost. The result of this opening is stored in a current node Nc, and that node is entered into a list of already optimized nodes.
[0098] Then, in an operation 406 , a test verifies whether the algorithm is complete, i.e., whether the cutting of the node Nc is the right edge of the image, and whether the length of the image is the desired length.
[0099] If that is the case, the loop ends in 408 . Otherwise, in operation 410 , the driver calls the function Select( ) with the current node Nc. The result of that call is stored in a list NXT.
[0100] In the function Select( ) the selector 6 selects the list of cuttings from the file Cuts that correspond to the cutting of the current node Nc according to the selection criteria explained above. Then, those cuttings are arranged in the form of nodes in the list Nxt, as a function of the length associated with each cutting.
[0101] Thus, if the position of the cutting of the current node Nc is p, and I is the length of the transition of the cutting of the current node Nc toward a cutting c from the file Cuts, then a node is created in the list Nxt that has the cutting c as cutting, and a position q=p+1 as position.
[0102] In the case where such a node has already been encountered and is in the list Pot, then the attributes of that node are copied from the list Pot, i.e., its predecessor node and the cost of that node. Otherwise, that node is new, and the predecessor is not initialized, while the cost associated with that node is initialized with an “infinite” value. An infinite value refers either to data indicating that the cost has never been calculated, or data corresponding to a very high cost.
[0103] The function Select( ) is provided to arrange the list Nxt ordered by increasing transition costs. The transition cost here refers to the cost associated with the difference between the cutting of the node Nc and the cutting of each node of the list Nxt. Alternatively, the function Select( ) can perform a sort by another attribute.
[0104] Then, the driver 11 calls the assembler 8 in a series of operations 412 to 420 to update the cost attributes of the nodes according to the Dijkstra algorithm.
[0105] This series of operations is a loop that begins in step 412 by opening the list Nxt in a node Ntmp. If the node Ntmp is in the list of nodes already optimized, then that node is ignored and the operation 410 is repeated, since the cost of that node cannot be improved.
[0106] When Ntmp exists, a test 414 uses a function Cost( ) to verify whether the cost of the node Ntmp can be decreased. To that end, the function Cost( ) compares the cost of the node Ntmp with the addition of the cost of the current node Nc to the cutting of the node Ntmp.
[0107] If the cost of the node Ntmp is higher, that then indicates that it is possible to reach that node more economically by passing through the current node Nc.
[0108] Then, the cost of the node Ntmp is updated in operation 416 by adding the transition cost of the cutting of the current node Nc toward the cutting of the node Ntmp to the cost associated with the current node Nc. As seen above, this passage cost is zero when the cutting of the node Ntmp is not a parallel cutting. Then, in an operation 418 , the current node Nc is indicated as the predecessor of the node Ntmp.
[0109] Then, the list Nxt is opened again in the operation 412 . Before that, the node Ntmp is put back in the list Pot in an operation 420 . This operation is carried out in an ordered manner, i.e., the node Ntmp is introduced into the list Pot as a function of the cost associated with it. In the case where the node Ntmp is already in the list Pot, its cost and predecessor attributes are updated and the list Pot is sorted accordingly.
[0110] When the operation 412 determines that the list Nxt is empty, the loop is reiterated in step 404 with a new opening of the list Pot.
[0111] In the preceding, it appears that each node of the list Pot associated with its predecessors represents one possible partially synthesized image alternative. The algorithm is optimized to stop once the most faithful synthesized image, i.e., with the lowest cost and the right length, is found. The right length means that the position of the last node is equal to the desired length of the synthesized image, and the cutting of that node is the right edge.
[0112] The algorithm described in FIG. 4 is therefore very high-performing and makes it possible to produce, with a low calculation cost, a representation, which in turn has a low weight, of a synthesized image with very few artifacts.
[0113] However, this algorithm is perfectible. In fact, as a function of the distribution of the costs associated with the parallel cuttings and due to the fact that a shorter path is always made up of shorter paths in turn, the synthesized image may include a high repetition of a particular pattern from the original image.
[0114] To avoid this problem, the function Select( ) may be modified to implement a plurality of selection rules in addition to the first rule mentioned above.
[0115] The first rule described above may be varied by making it possible to choose, as non-parallel cuttings, the cuttings situated to the left of the current cutting, i.e., one making it possible to go backwards with all of the cuttings, and not only the parallel cuttings. In that case, the copied image piece is reversed, as it is copied from right to left.
[0116] A second rule may be based on the limitation of the number of repetitions of a column of the input image 12 in any portion of the synthesized image of a certain length. In this way, it is possible to ensure that the synthesized image does not contain visually displeasing repetitions.
[0117] To that end, it is necessary to maintain a table of occurrences for each column of the input image. That table is updated in the operation 404 from predecessors of the node Nc. That table contains the number of occurrences of the columns of the original image in the portion of the preceding partially synthesized image Nc and with the chosen length.
[0118] During the selection of the nodes in the operation 406 , if the cutting of a given candidate node for the addition into the list Nxt is a frontal cutting, then a piece of the original image can be added to the synthesized image in progress. The table of occurrences is then consulted to verify that the increase in the number of occurrences due to that copy can not exceed a certain threshold. If the threshold is exceeded, the node is not added into the list Nxt.
[0119] A third rule operates similarly, but taking the entire synthesized image into account, instead of a selected length.
[0120] In the example described here, the columns used in its rules each describe a width of 1 pixel. In other alternatives, this width may be greater, or may vary.
[0121] A fourth rule may require variety between successively synthesized images. To that end, the selector 6 receives or has access to a list of synthesized images described by their cuttings, and thus therefore to the position of each of the columns of the original image in each already synthesized image.
[0122] The fourth rule may be not to allow the selection, as the following node, of the nodes whereof inclusion would cause a copy of the synthesized image of columns of the original image in a position close to that already done in the already synthesized images.
[0123] This may be done by going through the list Nxt produced by applying the first rule, combined or not combined with the second or third rule, and eliminating the nodes that do not meet this fourth rule.
[0124] Furthermore, to apply the second, third, and fourth rules, the calculations of tables of occurrences done for a given synthesized image may be reused for a subsequent synthesized image, as the algorithm is the same for all of the synthesized images. This makes it possible to avoid repeating a large number of calculations.
[0125] A fifth rule may require the reproduction of part of the original image at a specific location of the synthesized image, for example using a copy-paste interface. The area to be reproduced identically therefore has known coordinates in the synthesized image.
[0126] To apply this rule, the operation 406 must manage two situations:
[0000] a. a node added in the list Nxt has a cutting that, with the cutting of the current node, defines an area of the original image that is situated before the area to be reproduced identically in the synthesized image, or when the current node has a position situated after the area to be reproduced identically in the synthesized image,
b. a node added in the list Nxt has a cutting that defines, with the cutting of the current node, an area of the original image that passes through the area to be reproduced identically in the synthesized image.
Cases a. and b. may be detected by comparing the coordinates in the synthesized image of the points associated with the cutting of the added node and those of the area to be reproduced identically.
[0127] In case a, the operation 406 is unchanged.
[0128] In case b, the selector must determine whether the cutting of the added node reproduces the area to be reproduced identically at the right coordinates. If yes, then that node is kept. If not, the added node is removed from the list Nxt. In the case where the added node is kept, the choice of the following node is very restricted, as its cutting must reproduce the rest (in whole or in part) of the area to be reproduced identically starting from that cutting.
[0129] A sixth rule consists of encouraging the columns to appear with shifts that follow the one-dimensional auto-correlation function of the original image. The auto-correlation function measures the distance of the image from its copy shifted by x pixels, for any value of x.
[0130] To that end, the transition cost is modified between two cuttings by adding an additional cost thereto that varies as the inverse of the correlation value for x equal to the shift (modulo W) between the position of the current cutting in the original image and its position in the image being synthesized, all multiplied by the deviation between the two cuttings relative to which the transition cost is considered.
[0131] In general, the fact that the shortest paths are themselves made up of shorter paths of a smaller size makes it possible, in the case where the rules applied do not depend on previous operations, to achieve significant gains in the calculations.
[0132] In fact, if the solution is calculated for a size W, the calculations done may be reused in full, and it is possible to obtain the solution for a size W+X more quickly.
[0133] In light of the state of the art, it appears to one skilled in the art that the algorithm previously described is a shortest path algorithm (Dijkstra algorithm) applied on a graph. Although the graph is not explicitly built, it is implicitly defined by the selection rules for the following nodes.
[0134] Any other shortest path algorithm, including A* or random approximate algorithms, may therefore be used equivalently.
[0135] Likewise, the graph corresponding to the rules described above may be built in memory explicitly, so as to perform various processing operations therein. Defining the graph implicitly as described above nevertheless allows more effective implementation of the synthesis of a new image.
[0136] The example described above was described in relation to a synthesis in the horizontal direction of an image. However, a synthesis in the vertical direction can be identical, with the exception that the cuttings can be horizontal in that case. Another possibility can be to impose a 90° rotation on the image, and to apply identical resizing to it.
[0137] When one wishes to perform two-dimensional resizing of an image, it is possible to:
calculate the vertical cuttings, perform a horizontal synthesis to obtain an intermediate image, calculate the horizontal cuttings in the intermediate image, perform a vertical synthesis to obtain the final image.
[0142] However, this requires recalculating the horizontal cuttings for each intermediate image. However, this is detrimental, since these cuttings can vary as a function of the horizontal resizing done first. The result therefore takes more time to generate.
[0143] The Applicant therefore established an algorithm shown in FIG. 6 , which makes it possible to produce multiple synthesized images with a different bidirectional enlargement or shrinkage, while keeping only a single set of horizontal and vertical cuttings, which is that of the original images.
[0144] In the example described here, the invention receives an input image of size M×N, a target width W, and produces an output image of size W×N resembling the input.
[0145] The invention proceeds through two steps: given a target size of W×H pixels and an original image of size M×N, the invention first produces an intermediate image of size W×N from the image M×N, then secondly an image of size W×H from the intermediate image of size W×N.
[0146] It should be noted that the order of the operations is of little importance and that the operations performed horizontally and vertically are strictly equivalent. The rest of this example is limited to the horizontal case followed by vertical.
[0147] To that end, a horizontal synthesis operation is performed in an operation 600 . This operation is identical to all of FIG. 4 . The result is a list of vertical cuttings.
[0148] Then, in operation 610 , the driver 11 calls the assembler 8 to apply a transformation to each horizontal cutting of the original image that corresponds to the list of vertical cuttings resulting from the operation 600 .
[0149] Lastly, in an operation 620 , the driver 11 performs a vertical synthesis operation, which is based on the transformed horizontal cuttings resulting from the operation 610 .
[0150] This results in a list of horizontal cuttings that is stored with the list of vertical cuttings to form the synthesized image.
[0151] Thus, to reconstitute the synthesized image, one need only apply the horizontal synthesis defined by the list of vertical cuttings to the original image and the horizontal cuttings, then apply the vertical synthesis defined by the resulting horizontal cuttings to the resulting image.
[0152] FIG. 7 shows a universe synthesis system in which a server 70 is a user interface GUI and a device 2 as described above.
[0153] This server may be made in the form of a specialized integrated circuit, or a computer running a code that executes all of the functions and has all of the characteristics of the device 2 .
[0154] Using the interface GUI, a user has the possibility of massively generating varied synthesized images, in batches.
[0155] To that end, the user has access to an original image database 72 , and can program the device 2 to produce, for each image of the database 72 , a desired number of synthesized images stored in the synthesized image database 74 .
[0156] This production may be done by randomly or systematically applying a certain number of the rules from the rule base 10 , and randomly or systematically varying the parameters of those rules.
[0157] The interface GUI also allows the user to create synthesized images having particular characteristics, for example by requiring the presence of a cutting of the original image at a specific location of a synthesized image.
[0158] To that end, the device 2 calculates two synthesized images, one starting from the left edge of the image and stopping at the concerned cutting, and the other image starting from the concerned cutting and stopping at the right edge of the image. Of course, this may be repeated by requiring several cuttings at several target locations.
[0159] Alternatively, the user may also require the reproduction of a target part of the original image in a target area of the synthesized image. This makes it possible to use a “drag and drop” of part of the original image, which simplifies the user experience. To that end, the device 2 may in particular apply the fifth rule.
[0160] Above, the second, third, fourth, and fifth rules have been described to improve the quality of the image synthesis. To that end, these rules limit the cuttings that may be used in the Dijkstra algorithm. They have been defined from a node that has first been added, then is removed as a function of these rules.
[0161] This means that the function Select( ) that implements them first operates as described relative to the first rule, then executes a second passage over the list Nxt to remove the nodes that have been added and do not meet the second and/or third and/or fourth and/or fifth rules.
[0162] Alternatively, the function Select( ) may be provided to implement all of the first to fifth rules in a single pass, i.e., a node is only added to the list Nxt if it meets all of the rules, through a priori tests.
[0163] To conclude, it appears that the synthesized images may be stored in two equivalent formats.
[0164] According to a first format, the original image and the list of cuttings are provided, and the synthesized images are formed from the list of cuttings of which they are made up.
[0165] When they must be used, the synthesized images are built by pasting the pieces of the original image situated between each pair of cuttings from the list of cuttings end to end.
[0166] This is particularly advantageous since the list of cuttings contains only one cutting identifier, and one identifier for the original image. Thus, when there are many synthesized images, this format takes up very little storage space relative to the storage of raw images.
[0167] It is also possible to determine the color of a point situated at the coordinates (x,y) of the synthesized image very quickly from the list of cuttings. To that end, a dichotomous search is done in the list of cuttings that are sorted by increasing order of position (the cuttings forming a synthesized image never intersecting).
[0168] This makes it possible to display the images on the screen or applied on three-dimensional objects by attaching textures without ever explicitly having to form the synthesized image in memory.
[0169] According to a second format, the synthesized images are stored directly in the form of images, i.e., after the list of cuttings has been established, the corresponding synthesized image is generated and stored.
[0170] This format may be useful when the calculation power is limited, and prevents on-the-fly generation of synthesized images from their respective lists of cuttings.
[0171] The approach that has been described above may be applied directly even on video data and volumes (in fact 3D images).
[0172] The approach also applies to 1D signals such as sounds, in which case the cuttings are reduced to a single coordinate and the matching cost may for example be given by a similarity matrix.
[0173] The paths then become layers that separate the volume in two in a direction, but the rest of the operation is globally unchanged.
[0174] In that case, it may be interesting to extend the algorithm described in FIGS. 4 and 6 to account for the number of dimensions of the layers, repeating the operations according to each of those dimensions.
[0175] More generally, it is possible to extend the algorithm of FIG. 6 to any number of directions. | An image processing device, including an analyzer calculating cutting data and difference data from image data, a selector receiving data from a working node, the data including cutting data, cost data, and position data, an assembler receiving data from working nodes and from a predecessor node and calculating updated node data as a function of the cost data, a driver configured to call the analyzer with image data of an input image, call the selector with an input node and with the cutting data calculated by the analyzer, call the assembler with the successor nodes determined by the selector as working nodes and with the input node as a predecessor node, and repeatedly call the selector and the assembler using one of the updated nodes as a working node for the selector, until a condition relating to the cutting data and the position data of an updated node is satisfied. | 6 |
RELATED APPLICATIONS
This application claims priority under 35 U.S.C. 119(e) from Provisional U.S. Patent Applications No. 60/916,207 filed May 4, 2007, No. 60/938,622 filed May 17, 2007, and No. 60/939,167 filed May 21, 2007, the contents of which are incorporated herein by reference.
TECHNICAL FIELD
The present disclosure is directed to a transport package for a temperature sensitive payload and a method of use within hostile environments having temperatures outside a desired temperature range for payload protection.
BACKGROUND OF THE INVENTION
Shipping containers for transporting temperature sensitive payloads typically include insulation materials, such as foam peanuts, expanded foams, etc. Various other containers have employed phase change materials to protect the payload from hotter or colder ambient temperatures during shipping. There is an urgent need for an environmentally friendly or “green” container and method of use for maintaining the payload temperature within a narrow band and which can operate without an electrical power source.
Many packages and methods are currently employed to ship temperature sensitive products. Often, these packages and methods require specified thermal preparation. For example, known methods of temperature sensitive material product recovery require on site thermal preparation, or just in time delivery of properly thermally prepared packaging. Methods also exist in which a mechanical device is activated, such as a device that evaporates water into a vacuum and uses the latent heat of vaporization to chill and maintain the temperature of a payload. Such systems are complex and expensive. A passive shipping package with no moving parts is particularly needed.
Temperature sensitive materials such as vaccines are sent to remote locations for use. Often unused materials are wasted for lack of adequate temperature control equipment at the remote location. As the temperature sensitive materials may initially be in usable condition, a method to recover remotely located temperature sensitive materials is urgently needed.
BRIEF SUMMARY OF THE INVENTION
A transport package is described herein which efficiently maintains payload temperature within a predetermined temperature range during delivery through regions having ambient temperatures outside the desired range. The transport package is used for transporting temperature sensitive materials and thermally protecting the materials from cold and hot ambient temperatures in a manner that does not require a power source or other mechanical devices.
Aspects of the invention relate to a temperature maintaining packaging system having an outer container, thermal insulation materials and two or more different phase change materials. Methods of using such packages within hostile environments are disclosed.
Aspects of the present invention also include a package having at least two different phase change materials, with one or more phase change material being thermally conditioned prior to insertion into the container. In some examples of the invention, one or more of the other phase change materials act as a thermal buffer to maintain the payload temperature within a desired temperature range. Prior to package assembly, a phase change material may be cooled or heated to temperatures outside the desired temperature range. With proper selection of the phase change materials, the package can maintain the payload temperature within the desired temperature range throughout the delivery process. Methods of assembling a container and methods of using such a container are also disclosed herein.
The foregoing has outlined rather broadly the features and technical advantages of the present invention in order that the detailed description of the invention that follows may be better understood. Additional features and advantages of the invention will be described hereinafter which form the subject of the claims of the invention. It should be appreciated by those skilled in the art that the conception and specific embodiment disclosed may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes of the present invention. It should also be realized by those skilled in the art that such equivalent constructions do not depart from the spirit and scope of the invention as set forth in the appended claims. The novel features which are believed to be characteristic of the invention, both as to its organization and method of operation, together with further objects and advantages will be better understood from the following description when considered in connection with the accompanying figures. It is to be expressly understood, however, that each of the figures is provided for the purpose of illustration and description only and is not intended as a definition of the limits of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of the present invention, reference is now made to the following descriptions taken in conjunction with the accompanying drawing, in which:
FIG. 1 is a perspective illustration of one embodiment of a package utilizing a phase change material combination in accordance with the present invention.
FIG. 2 is a perspective illustration of a second embodiment of a package utilizing a phase change material combination in accordance with the present invention.
FIG. 3 is a temperature vs. time diagram showing heat transfer to and from a package in accordance with the present invention during a delivery period.
DETAILED DESCRIPTION OF THE INVENTION
A phase change material is a substance with a high heat of fusion which, melting and solidifying at certain temperatures, is capable of storing or releasing large amounts of energy. Initially, solid-liquid phase change materials perform like conventional heat storage materials; their temperature rises as they absorb heat. Unlike conventional heat storage materials, however, when phase change materials reach a phase change temperature, i.e., melting point, they absorb large amounts of heat without a significant rise in temperature. When the ambient temperature around a liquid material falls, the phase change material cools and solidifies, releasing its stored latent heat. Certain phase change materials store 5 to 14 times more heat per unit volume than conventional heat storage materials such as iron, masonry, or rock.
Phase change materials can be broadly grouped into two categories: “Organic Compounds”, including but not limited to propylene and/or ethylene glycols and “Salt-based Products”, including but not limited to Glauber's salt. The most commonly used phase change materials are salt hydrides, fatty acids and esters, and various paraffins, such as octadecane. Certain ionic liquids have also been identified as promising phase change materials.
One embodiment of the present invention provides an efficient method of packaging realizing a reduction in the use of higher-priced phase change materials. Desirably, the packaging includes water-based phase change materials, which are among the least expensive phase change materials in current use. Water has a transition temperature close to 0 degrees C. Water-based phase change materials are often not suitable for certain temperature sensitive products. Other, generally more expensive, phase change materials may be necessary to avoid thermal damage to the temperature sensitive product. For example, red blood cells are temperature sensitive and should not be subjected to temperatures below 1 degree C. The temperature of sub-cooled water-based phase change materials may be significantly lower. As a result, if water based phase change materials are employed, sufficient insulation is typically needed between the temperature sensitive payload and the water based phase change material.
Embodiments of the present invention employ a second phase change material to act as a thermal buffer between a water based phase change material and the temperature sensitive payload. In one example, the second phase change material solidifies while protecting the payload from the temperature of the colder or hotter water based phase change material. In one example, the second phase change material is initially in solid form and then used as a heat sink to protect the payload from heat.
In another embodiment the thermally conditioned phase change material is heated to a temperature above the desired range of protection for the payload. In such an embodiment, the second phase change material again acts as a thermal buffer so as to maintain the payload temperature within the desired range. As a result, it is envisioned that embodiments of the present invention will be utilized to protect a payload against ambient temperatures that are hotter or colder than the payload's desired temperature range.
Embodiments of the present invention may also protect the payload from ambient temperatures that are both colder and hotter than the desired payload protection temperature range. If the ambient temperature is colder than the desired protection temperature range during one period of the package delivery, some period of time may be necessary in order to precondition the liquid phase change materials.
The present invention also promotes efficient packaging methods for thermally acclimating phase change materials. For example, a water based phase change material can be placed into the package directly from the freezer or other suitable preparation device. For example, the phase change material can be stored in solid or liquid form and then, along with the temperature sensitive payload, be packaged without having to wait for the phase change material to arrive at a desired packaging temperature.
The present invention is also directed to a package and method for encasing a payload cavity with phase change materials and insulation. In one example, a water based phase change material is combined with another phase change material to provide thermal protection for the payload. By properly selecting the phase change materials, a package can be configured to provide maximum thermal protection for a temperature sensitive product during delivery. Employing a combination of solid and liquid phase change materials in the container can provide protection from both hotter and colder ambient temperatures during delivery, and a beneficial reduction in the amount of phase change materials can result.
With reference to FIG. 1 , there is shown an exploded perspective view of a package 10 for shipping a temperature sensitive payload 12 . As depicted, package 10 is prepared for transport by inserting the components and payload 12 into the outer container 14 . The components of package 10 include insulation contained within or defined by an insulation panel 16 and phase change material contained within separated panels 18 . Six phase change material panels 18 and six insulation panels 16 are employed in the package 10 of FIG. 1 . The temperature sensitive payload 12 is received within a payload cavity, defined generally as the interior volume contained within the walls of panels 18 . In the illustrated embodiment, container 14 assumes a generally cubic form. In other embodiments, container 14 may assume alternative forms, including but not limited to cylinders, etc. Container 14 may be corrugated paper or corrugated plastic or other suitable material.
Insulation panels 16 can include vacuum insulation panels and/or foams and fiber-based materials. A combination of different insulation materials may be used to form the panel 16 .
While panels 16 , 18 are shown in rectangular form, each panel can assume a variety of different shapes and forms in alternative embodiments of the invention. For example, panels 16 , 18 may be defined as open cylinders with one panel being inserted into the other in a nesting manner. In other examples, panels 16 , 18 may be shaped in relation or allowed to conform to the payload 12 . Panels 16 may be defined by plastic and/or metal shells for containing phase change material therewithin. Phase change material panels 18 may assume different shapes or forms in alternative embodiments. Examples of phase change material panels 18 can include HDPE containers, form fill and seal films, or any other suitable containers sized to be inserted into the package 10 .
Selection of the phase change materials may include consideration of multiple factors including, but not limited to, the desired protected temperature range, anticipated ambient temperatures during shipment, thermal properties of the different phase change materials, thermal properties of the container and/or insulation panels, and thermal properties of the temperature sensitive product being shipped. The design and sizing of containers for the phase change material panels and the insulation panels would vary depending on these factors as well.
FIG. 2 illustrates another embodiment of the present invention. In this example, package 10 includes a pair of phase change material panels 18 , 20 placed above and below payload 12 . The payload cavity is thus defined between the four walls of insulation panels 16 and two inside walls of phase change material panel 18 . In this embodiment, the primary heat transfer occurs through the top and bottom portions of package 10 .
An exemplary package 10 in accordance with the present invention includes phase change materials in different layers relative to the payload. Prior to shipment one or both of the phase change materials can be preconditioned into liquid or solid form. Depending on the anticipated ambient temperature profile during transport of package 10 , an effective combination of solid and liquid phase change materials can be selected. If additional protection is needed, auxiliary phase change materials in solid, liquid, or solid and liquid phase can be added to augment the thermal capabilities of the package 10 .
In another embodiment, the payload cavity may initially contain a phase change material form that is thermally prepared to be solid, liquid, or solid and liquid based on anticipated ambient temperatures during delivery and the protection requirements of the payload. In yet another embodiment the functions of container 14 and phase change panel 18 may be combined into an integrated structure. In such an example, the container 14 and phase change panel 18 would together be thermally conditioned prior to package 10 assembly. Similarly, the insulation panels 16 and one or more of the phase change material panels 18 , 20 may be combined into one or more structures.
One embodiment of the present invention includes an outer container into which one or more insulation panels and multiple different phase change material panels are inserted. A payload cavity within the container is sized to receive a temperature sensitive product. In one example, a water based phase change material is combined with another phase change material. The two phase change materials cooperate to provide thermal protection for the temperature sensitive product even, for example, if the water-based phase change material is sub-cooled. For example, a package 10 for shipping blood products may include a first water based phase change material and a second phase change material which is liquid near 4 degrees C. A method of shipping such package 10 would include cooling the water-based phase change material below zero degree C prior to insertion into package 10 .
The temperature sensitive payload can be wrapped, encased, or placed adjacent a phase change material and together covered with another phase change material. During shipping, one of the phase change materials may initially solidify the other phase change material without thermal damage to the payload.
Other embodiments of the present invention include two or more different phase change materials. In one embodiment, a water-based phase change material is utilized along with a non-water-based phase change material. In another embodiment, a phase change material panel protects a temperature sensitive payload against thermal damage from a colder or hotter water-based phase change material. Depending on the desired temperature range, a variety of different phase change materials may be utilized to keep a temperature sensitive product warm or cold during shipment through an environment having substantially different temperatures than desired.
While the embodiments of FIG. 2 illustrates a water-based phase change material separated from the temperature sensitive payload by an intermediate phase change material, in other embodiments of the present invention a water-based phase change material is positioned between an outer phase change material and the temperature sensitive product.
FIG. 3 depicts a change of payload temperature during a hypothetical delivery process of a package 10 in a hostile environment. During the delivery process the ambient temperature, shown as line AT, changes to be outside the desired product protection range. In this example, package 10 maintains the payload temperature, shown as line PT, within the desired temperature range for product protection, defined between temperatures, T 1 and T 2 . During a time period between t 1 and t 2 , the ambient temperature of package 10 is higher than the desired range. During such period a solid phase change material panel absorbs heat without a substantial increase in the payload temperature. Similarly, during a time period between t 3 and t 4 , with the ambient temperature lower than the desired range, the phase change material panel would transfer heat to the payload.
The invention further relates to a method for shipping temperature sensitive products from a first location to one or more remote locations including: preparing at a first location a container having insulation materials and phase change materials; receiving the container at a second location; thermally conditioning and replacing at least one of the phase change materials of the package; and inserting a temperature sensitive product into a payload cavity prior to shipment from the remote location to yet another location. The phase change materials may initially include two different phase change materials.
Other examples of the invention provide a method for transporting a temperature sensitive product including: receiving a container including multiple phase change materials and insulation, the phase change materials being thermally preconditioned prior to and/or during delivery; thermally conditioning one of the phase change materials to a temperature outside of a desired temperature range for protection of the thermally sensitive product; and placing the temperature sensitive product into the payload cavity prior to shipping the container to another site. In a preferred form, one of the phase change materials is utilized to buffer the temperature of the temperature sensitive product during shipment. As a result, the temperature sensitive product can be protected against thermal damage caused by a phase change material having a temperature outside of the desired temperature range for product protection.
The present invention is also directed to a transport method where the payload cavity is initially filled with a phase change material prior to transport to a remote location and the payload cavity is cleared prior to delivery from the remote location. In one example, some or all of the phase change material is removed from the payload cavity at a remote location. A temperature sensitive product is then placed into the payload cavity and the container is resealed and delivered to another location. Such an example provides a method for recovering temperature sensitive material from a remote site that does not have adequate thermal control equipment. For example, a remote site may have a small refrigerator but not a freezer. When the package arrives at such a remote location, a flu vaccine clinic for example, some amount of the phase change material is removed from the container and the temperature sensitive material is placed into the container for shipping to another location.
Another embodiment of a package of the present invention provides phase change materials in different states on different sides of the payload. For example, a phase change material panel 18 in solid form is placed on one side of the payload and phase change material panels 20 are placed on the other sides of the payload. In other examples, two sides can be in solid form while four sides are in liquid form, three sides can be in solid form while three sides are in liquid form, four sides can be in solid form while two sides are in liquid form, and five sides can be in solid form while one side is in liquid form. The panels 18 , 20 on each side of the configuration can be made into two or more panels placed together to make many other combinations of panels possible. Depending on the anticipated ambient temperature profile, the most effective combination of solid and liquid phase change material can be selected. If additional protection is needed and space is available within the payload cavity, auxiliary phase change material in solid, liquid, or solid and liquid phase can be added to augment the encasement phase change materials.
Although the present invention and its advantages have been described in detail, it should be understood that various changes, substitutions and alterations can be made herein without departing from the spirit and scope of the invention as defined by the appended claims. Moreover, the scope of the present application is not intended to be limited to the particular embodiments of the process, machine, manufacture, composition of matter, means, methods and steps described in the specification. As one of ordinary skill in the art will readily appreciate from the disclosure of the present invention, processes, machines, manufacture, compositions of matter, means, methods, or steps, presently existing or later to be developed that perform substantially the same function or achieve substantially the same result as the corresponding embodiments described herein may be utilized according to the present invention. Accordingly, the appended claims are intended to include within their scope such processes, machines, manufacture, compositions of matter, means, methods, or steps. | The present invention is directed to a transport package which efficiently maintains payload temperature within a predetermined temperature range during delivery through regions having ambient temperatures outside the desired range. The transport package is used for transporting temperature sensitive materials and thermally protecting the materials from cold and hot ambient temperatures in a manner that does not require a power source or other mechanical devices. Aspects of the invention relate to a temperature maintaining packaging system having an outer container, thermal insulation materials and two or more different phase change materials. | 5 |
FIELD OF THE INVENTION
This invention relates to equipment for generating a force in a wellbore and more particularly but not limited to setting and retrieval tools for use in oil and gas wells.
BACKGROUND OF THE INVENTION
The structure of a wellbore of an oil or gas well generally consists of an outer production casing and an inner production tubing installed inside the production casing. The production tubing extends from the surface to the required depth in the wellbore for production of the oil or gas. Various tools such as plugs, chokes, safety valves, check valves, etc. can be placed in landing nipples in the production tubing to allow for different production operations or the downhole control of fluid flow. Also, tools like bridge plugs, packers and flow control equipment are placed in the production casing to control production or stimulation operations. Force generating tools are needed both to exert a pushing force to set the tools in the landing nipples and to provide a pulling force to retrieve the tools. It is preferable to have the force generating tools pressure balanced so that the same force may be applied both in pulling and in pushing operations, irrespective of the pressure in the wellbore.
A downhole force generator is disclosed in U.S. Pat. No. 6,199,628. A downhole force generator is disclosed in U.S. Pat. No. 5,070,941. A locator and setting tool is disclosed in Canadian Patent No. 2,170,711. These 3 patents describe virtually the same technology, in different variations. None of these prior art tools are pressure balanced to provide equal force in pulling and pushing operations. As detailed in the article published by Halliburton Energy Services in the June 1996 edition of the SPE Drilling & Completion magazine, “Any pressure differential increases the available force with the DPU in tension and decreases the setting force in the extension mode. This is because (1) the DPU is sealed to the well pressure through redundant sealing elements maintaining internal parts at near-atmospheric pressure, and (2) the well pressure acts on the power rod's sealed diameter.” This is a disadvantage, especially in high-pressure wells. A high enough downhole pressure will render these tools unusable. Additionally, none of these tools provide a simple mechanical tool, particularly for the retrieval of downhole tools.
SUMMARY OF THE INVENTION
According to one broad aspect, the invention provides a well tool for applying a pulling or a pushing force to an object in an interior of a well bore comprising: a) a drive mandrel; b) an engaging mandrel; c) an actuation means; d) a housing sealing a portion of the drive mandrel and a portion of the engaging mandrel within an interior space, the drive mandrel and the engaging mandrel extending from opposite ends of the housing; e) a drive mandrel piston area defined at a drive mandrel end portion of the housing between a outside diameter of the housing and a sealed diameter of the drive mandrel; and f) an engaging mandrel piston area defined at an engaging mandrel end portion of the housing between the outside diameter of the housing and a sealed diameter of the engaging mandrel; wherein the actuation means is adapted to reversibly move the housing longitudinally relative to the drive mandrel and the engaging mandrel and wherein the drive mandrel piston area and the engaging mandrel piston area are substantially equal and external pressure acting on these two piston areas, generates two opposing forces that are substantially balanced during relative movement.
According to another broad aspect, the invention provides a well tool for applying a pulling or a pushing force to an object in an interior of a well bore comprising: a) an inner elongated member; b) an outer elongated member; c) a sealed interior defined between the inner elongated member and the outer elongated member; and d) an actuation means defined at least partially within the sealed interior; wherein the actuation means is adapted to reversibly move the outer elongated member longitudinally over the inner elongated member and wherein the inner elongated member and the outer elongated member are arranged such that a volume of the sealed interior occupied by the inner elongated member remains substantially constant as the inner elongated member and the outer elongated member move relative to each other.
According to a further broad aspect, the invention provides a well tool for applying a pulling or a pushing force to an object in an interior of a well bore comprising: a) an inner elongated member; b) an outer elongated member encircling an intermediate segment of and longitudinally moveably engaged with the inner elongated member; c) a screw component of the inner elongated member, the screw component being coupled for rotation about a longitudinal axis; and d) a threaded component of the outer elongated member engaged with the screw component; wherein rotation of the screw component reversibly moves the outer elongated member relative to the inner elongated member.
According to a still further broad aspect, the invention provides a well tool for applying a pulling or a pushing force to an object in an interior of a well bore comprising: a) an inner member comprising a first elongated member, a second elongated member and an actuation means axially interconnecting the first elongated member and the second elongated member; b) an outer elongated member longitudinally moveably engaged with the inner member; c) a first seal defined between the first elongated member and the outer elongated member; d) a second seal defined between the second elongated member and the outer elongated member; e) a first piston area defined at a first end portion of the outer elongated member between an outer diameter of the outer elongated member and a sealed outer diameter of the first elongated member; f) a second piston area defined at a second end portion of the outer elongated member between the outer diameter of the outer elongated member and a sealed outer diameter of the second elongated member; and g) a sealed chamber defined between the first seal and the second seal, the sealed chamber including a fluid at a fluid pressure; wherein operation of the actuation means axially reversibly moves the outer elongated member relative the inner member while the fluid pressure remains constant; and wherein the first piston area and the second piston area are substantially equal and external pressure acting on these two pistons areas, generates two opposing forces that are substantially balanced during relative movement.
BRIEF DESCRIPTION OF THE DRAWINGS
Preferred embodiments of the invention will now be described with reference to the attached drawings in which:
FIG. 1 is a partial schematic cross-sectional view of a first embodiment of the invention.
FIGS. 2A , 2 B and 2 C are detailed top, middle and bottom cross-sectional views, respectively, of the first embodiment of the invention in a first position;
FIGS. 3A , 3 B and 3 C are detailed top, middle and bottom cross-sectional views, respectively, of the embodiment of FIGS. 2A , 2 B and 2 C in a second position;
FIGS. 4A , 4 B and 4 C are detailed top, middle and bottom cross-sectional views, respectively, of the embodiment of FIGS. 2A , 2 B and 2 C in a third position; and
FIGS. 5A , 5 B and 5 C are detailed top, middle and bottom cross-sectional views, respectively, of a second embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a cross-sectional view of a simplified embodiment of the invention. A tool 10 has an inner elongated member which includes a drive mandrel 50 , a screw 62 and an engaging mandrel 66 . The engaging mandrel may be a setting or a retrieving mandrel. The drive mandrel 50 and the screw 62 are axially coupled for both rotational and longitudinal movement. The engaging mandrel 66 and the screw 62 are preferably coupled for longitudinal movement only. The cross-sectional area of the drive mandrel 50 is substantially equal to the cross-sectional area of the engaging mandrel 66 .
The tool 10 also includes an outer elongated member or main housing 64 . The outside diameter of the main housing 64 is preferably constant. Fixed to the interior of the main housing 64 is a threaded component or nut 58 . The nut 58 is threaded on the screw 62 . One end of the main housing 64 is sealed to the drive mandrel 50 by a seal 48 . The other end of the main housing 64 is sealed to the engaging mandrel 66 by a seal 70 . The sealed interior of the main housing 64 is preferably equalized with the wellbore pressure. The connection between the screw 62 and the nut 58 is not fluid tight, i.e. chambers 65 and 67 on either side of the nut 58 are enclosed by the main housing 64 and are in fluid communication through gaps between the screw 62 and nut 58 and/or channels milled on the outside of the nut 58 .
The drive mandrel 50 is coupled at its other end to a motor 24 . The motor 24 is contained within a motor housing 14 . A connector 12 is provided at the other end of the motor for electrically and mechanically connecting the tool 10 . Cap screws 44 are provided in a guide sleeve 38 formed at the end of the motor housing 14 which encircles the drive mandrel 50 and an electronics seal 46 is provided around the drive mandrel 50 which seals the guide sleeve to the mandrel 50 to protect the inside of the motor housing 14 from the environment. A guide housing extension 40 of the main housing 64 slidably encompasses a portion of the guide sleeve 38 . The cap screws 44 travel in slots in the guide housing extension 40 and prevent rotation of the main housing 64 .
In operation, the connector 12 is electrically and mechanically connected to a wireline. The motor 24 rotates the drive mandrel 50 . Rotation of the drive mandrel 50 causes the screw 62 to rotate. The main housing 64 is held against rotation so that rotation of the screw 62 causes the main housing 64 to move longitudinally over the inner elongated member. At all times, the volume of the drive mandrel entering/exiting the interior space is the same as the volume of the engaging mandrel exiting/entering the interior space so that the free volume, and therefore also the pressure, in the interior space remains constant. The seals 48 and 70 , define two hydraulic pistons between the outside diameter of the main housing 64 and the outside diameter of the drive mandrel 50 and the outside diameter of the engaging mandrel 66 respectively. The two piston areas have the same area. Any outside well pressure acting on these two hydraulic piston areas will create two equal opposing forces that cancel each other. The constant volume in the interior and the matched piston areas enable the same force to be applied by the tool in both the pushing and the pulling operations. The main housing 64 and/or the engaging mandrel 66 are coupled to engaging tools for setting or retrieval of downhole tools.
In greater detail, FIGS. 2A to 2C depict a well tool, in particular a wireline retrieving tool for applying a pulling force to an object in the interior of a wellbore. The wireline retrieving tool 110 is generally tubular in shape. A connector 112 is located at the proximal end of the wireline retrieving tool 110 . The connector 112 allows for mechanical and electrical connection of the wireline retrieving tool 110 to a wireline. The connector 112 connects to a proximal end of a tubular electronics housing 114 . Seals 116 are provided at the interface between the connector 112 and the electronics housing 114 to seal the interior of the electronics housing 114 from the environment. The electronics housing 114 houses an electronics carrier 118 , a printed circuit board 120 , a digital positioning encoder 122 and a gear motor 124 . The electronics carrier provides mechanical support for the printed circuit board 120 . The connector 112 is connected to the printed circuit board 120 to provide power to the printed circuit board from the wireline. The printed circuit board 120 provides control for the operation of the digital positioning encoder 122 and the gear motor 124 . The digital positioning encoder 122 is connected at one end of the gear motor 124 . The digital positioning encoder 122 counts the rotation of the gear motor 124 to allow precise calculation and control of the movement of the distal end of the wireline retrieving tool 110 .
A distal end of the electronics housing 114 is connected to a guide sleeve 138 . The guide sleeve is generally tubular. Seals 116 are provided between the guide sleeve 138 and the electronics housing 114 to seal the interior from the environment. A drive mandrel 150 extends at least partially through the guide sleeve 138 . The drive mandrel 150 is generally an elongated solid member with a circular cross-section. The drive mandrel 150 is interconnected to the gear motor 124 through a spline adapter 130 . The spline adapter 130 interconnects the gear motor 124 to the drive mandrel 150 through axial splines so that rotation of an output of the gear motor 124 results in rotation of the drive mandrel 150 at the same speed. The spline adaptor 130 is threaded to the drive mandrel 150 . Set screws 136 hold the drive mandrel 150 in position relative to the spline adapter 130 .
Thrust bearings 134 are provided at support ends of the spline adapter 130 to facilitate smooth rotation of the drive mandrel 150 relative to the guide sleeve and the electronics housing. A drive mandrel lock nut 132 is provided to retain the bearings 134 and the spline adaptor in the guide sleeve 138 and cap screws 128 are provided to fasten the gear motor to the distal end of the electronics housing 114 .
Cap screws 144 are provided at a distal end of the guide sleeve 138 . Heads of the cap screws 144 project outward from the surface of the guide sleeve 138 . An upper guide housing 140 slidably encompasses a portion of the guide sleeve 138 . Longitudinal slots are defined in the upper guide housing 140 . The cap screws 144 travel within the longitudinal slots in the upper guide housing 140 when the upper guide housing 140 slides relative to the guide sleeve 138 . The cap screws 144 rest against the ends of the longitudinal slots to retain the upper guide housing 140 in contact with the guide sleeve 138 at the limits of relative travel and prevent relative rotation between the guide housing 138 and the upper guide housing 140 .
A glide ring 142 is also provided adjacent the cap screws 144 between the guide sleeve 138 and the drive mandrel 150 to facilitate the smooth rotation of the drive mandrel 150 . An electronics seal 146 is provided around the drive mandrel 150 at the distal end of the guide sleeve 138 . The electronics seal 146 seals the electronic section from external contaminants and keeps it at atmospheric pressure.
The distal end of the upper guide housing 140 mates with a proximal end of an upper housing 152 . The upper housing 152 is also generally tubular. The upper guide housing 140 and the upper housing 152 are retained relative to one another by a threaded connection. An upper interior area seal 148 is provided at a proximal end of the upper housing 152 and seals the upper housing 152 to the drive mandrel 150 . The upper internal area seal 148 seals the interior of the upper housing 152 . The electronics seal 146 and the upper internal area seal 148 allow for rotation of the drive mandrel 150 .
A distal end of the upper housing 152 is coupled to a proximal end of an actuator housing 160 . The actuator housing 160 is generally tubular. An actuator nut 158 is non-rotatably held within the actuator housing 160 . An actuator screw 162 extends through the actuator nut 158 . The actuator screw 162 is coupled to a distal end of the drive mandrel 150 . The coupling is provided by an anti-rotational lug so that the actuator screw 162 rotates with the drive mandrel 150 . A drive mandrel retainer 154 is provided within the upper housing 152 which maintains the drive mandrel 150 in contact with the actuator screw 162 . Glide rings 156 are provided around the circumference of the drive mandrel retainer 154 to allow smooth rotation of the drive mandrel retainer 154 within the upper housing 152 .
Upper chambers 165 A and 165 B ( FIG. 3 ) are defined within the upper housing 152 which accommodate the drive mandrel retainer 154 when the upper housing 152 moves longitudinally relative to the drive mandrel 150 . Upper chambers 165 A and 165 B are in permanent communication.
Seals 116 are provided at the interface of the upper housing 152 and the actuator housing 160 to protect the interior of the upper chambers from the environment. A bottom housing 164 connects to the distal end of the actuator housing 160 . Seals 116 are provided between bottom housing 164 and the actuator housing 160 to protect the interior from the environment.
The actuator screw 162 extends through the bottom housing 164 . The actuator nut 158 is engaged with the actuator screw 162 such that rotation of the actuator screw 162 moves the actuator nut 158 relative to the actuator screw 162 . Other screw components and threaded components may be utilized.
The distal end of the actuator screw 162 is coupled to a retrieving mandrel 166 . The retrieving mandrel 166 is generally an elongated solid member with a circular cross-section of substantially the same diameter as the drive mandrel 150 . The actuator screw 162 is coupled to the retrieving mandrel 166 by a retrieving mandrel retainer 168 . The proximal end of the retrieving mandrel 166 adjacent to the actuator screw 162 has a shoulder 177 . On either sides of the shoulder 177 are thrust bearings 134 . The thrust bearings 134 allow longitudinal movement of the actuator screw 162 to be transmitted to the retrieving mandrel 166 but rotational movement of the actuator 162 is not transmitted to the retrieving mandrel 166 such that retrieving mandrel 166 moves longitudinally but does not rotate. Glide rings 156 are positioned between the retrieving mandrel retainer 168 and the bottom housing 164 to allow smooth longitudinal and rotational movement of the retrieving mandrel retainer 168 relative to the bottom housing 164 .
Bottom chambers 167 A and 167 B are defined within the bottom housing 164 which accommodate the retrieving mandrel retainer 168 when the bottom housing 164 moves longitudinally relative to the retrieving mandrel 166 . The bottom chambers 167 A and 167 B are in permanent communication.
A distal end of the bottom housing 164 is coupled to a setting cone 174 . Seals 116 are provided between the bottom housing 164 and the setting cone 174 . A lower internal area seal 170 is provided between the setting cone 174 and the retrieving mandrel 166 . A lower secondary interior area seal 172 is provided between the bottom housing 164 and the retrieving mandrel 166 . The lower internal seal 170 provides a primary seal to seal the interior of the bottom housing 164 from the external environment. The lower secondary interior seal 172 provides a backup seal.
A slip cage 178 holds a set of slips 180 on the setting cone 174 . Cap screws 176 connect the slip cage 178 to the setting cone 174 . The slip cage 178 is moveable relative to the setting cone 174 by movement of the cap screws 176 in slots defined in the slip cage 178 . The slips 180 are biased inward by springs 182 .
A C-ring 190 is provided which sits in a circumferential recess in the retrieving mandrel 166 . The C-ring 190 sits inside a C-ring housing 186 which is connected to the setting cone 174 by cap screws 184 . The C-ring 190 is retained within the C-ring housing 186 by a C-ring retainer 192 . A segment of the production tubing or casing 188 is shown to facilitate the explanation of the operation of the wireline retrieving tool 110 .
The drive mandrel 150 and the retrieving mandrel 166 are of substantially the same diameter so that the volume of either mandrel entering the sealed interior defined by the upper housing 152 , the actuator housing 160 , and the bottom housing 164 is substantially the same as the volume of the other mandrel exiting the sealed interior so that the free volume within the sealed interior remains substantially constant. A hydraulic piston defined between the outside diameter of the upper housing 152 and the outside diameter of the drive mandrel 150 and a hydraulic piston defined between the outside diameter of the bottom housing 164 and the outside diameter of the retrieving mandrel 166 are equal in area. Any outside well pressure acting on these two hydraulic piston areas will create two equal opposing forces that cancel each other. This provides the same power availability for pushing and pulling.
The operation of the wireline retrieving tool 110 is explained with reference to FIGS. 2 , 3 and 4 which shows the wireline retrieving tool 110 in three different positions. The same reference characters are used in all three figures to refer to the same elements. In operation, the wireline retrieving tool 110 is connected by connector 112 to a wireline, both electrically and mechanically. The wireline retrieving tool is lowered into a segment of the production tubing or casing 188 to a desired location. At that location, the gear motor 124 is operated via the printed circuit board 120 . The digital positioning encoder 122 counts the rotations of the gear motor 124 so that an exact position of the retrieving mandrel 166 can be obtained. Rotation of the gear motor 124 is translated to the drive mandrel 150 to provide rotation of the drive mandrel 150 .
In the initial position depicted in FIG. 2 , only chambers 165 A and 167 A are open. The drive mandrel 150 is coupled to the actuator screw 162 as noted above so that rotation of the drive mandrel 150 provides rotation of the actuator screw 162 at the same rate of rotation. Rotation of the actuator screw 162 moves the actuator nut 158 downward along the actuator screw 162 as seen in FIG. 3 . This opens up chambers- 165 B and 167 B at the same rate that chambers 165 A and 167 A are closed. The movement of the actuator nut 158 in turn moves the upper guide housing 140 , the upper housing 152 , the actuator housing 160 and the bottom housing 164 downward. The bottom housing 164 in turn pushes the setting cone 174 downward.
The C-ring housing is held against downward movements by the C-ring 190 seated in the recess on the retrieving mandrel 166 . This also holds the slips 180 stationary relative to the retrieving mandrel 166 . The setting cone 174 slides relative to the slips 180 . The setting cone 174 has a narrower end initially within the slips 180 and expands along a shoulder 181 to a wider section. As the shoulder 181 is forced through the slips 180 , the slips are moved outward, the springs 182 are compressed and the slips bite into the segment of production tubing or casing 188 and hold the slips stationary relative to the production tubing or casing 188 (see FIGS. 3A to 3C ). Further rotation of the actuator screw 162 no longer moves the housing downwardly, instead, further rotation of the actuator screw 162 will force the expansion and release the C-ring 190 from the retrieving mandrel 166 and the proximal end of the wireline retrieving tool 110 moves upwardly to the upper limit of travel shown in FIGS. 4A to 4C . In this final position, chambers 165 A and 167 A are completely closed and chambers 165 B and 167 B are completely open.
All of chambers 165 A, 165 B, 167 A and 167 B are in fluid communication through gaps between the actuator screw 162 and the actuator nut 158 and gaps between the coupling assemblies interconnecting the actuator screw 152 to the mandrels 150 and 166 and the housings 152 and 164 . The mandrels 150 and 166 have substantially the same cross section. As a result, the combined free volume of the chambers 165 A, 165 B, 167 A and 167 B remains substantially constant throughout the relative movement of the housings so that the pressure within the sealed interior of the tool 110 remains constant. Also, because the mandrels 150 and 166 have the same cross section, any outside well pressure acting on the two opposing hydraulic pistons defined by the outside diameter of the housings 152 and 164 and the outside diameters of the mandrels 150 and 166 , would generate two equal opposing forces that would cancel each other and would not affect the function of the tool in pushing or pulling operations.
In operation, a fishing tool is attached to the distal end of the wireline retrieving tool 110 . The further rotation of the actuator screw 162 pulls the fishing tool upward against the holding force of the slips against the segment of production tubing or casing 188 . Thus, the pulling force is not provided by the wireline but instead by the action of the retrieving mandrel 166 against the slips 180 .
To reset the tool, the actuator screw 162 is rotated in the opposite direction causing the upper guide housing 140 , the upper housing 152 , the actuator nut 158 , the actuator housing 160 , the bottom housing 164 and the setting cone 174 to move upward. The withdrawal of the shoulder 181 of the setting cone 174 from the slip 180 results in the springs 182 retracting the slips 180 from contact with the segment of production tubing or casing 188 . The wireline retrieving tool 110 can then be withdrawn from the production tubing or casing. Alternatively, if the object to be retrieved is not completely free, the wireline retrieving tool 110 can be partially withdrawn up the production tubing or casing 188 and reset to perform a second or other subsequent pulling operation in the same manner as described above.
FIGS. 5A to 5C depicts a wireline setting tool 198 . The same reference characters are used in FIGS. 5A to 5C for the same components as identified in FIGS. 2A to 4C . It can be seen that the only difference between the wireline retrieving tool 110 of FIGS. 2A to 4C and the wireline setting tool 198 of FIGS. 5A to 5C is the assembly at the distal end. In particular, the wireline setting tool 198 does not contain a slip assembly. Instead, a setting housing 194 is connected at the end of the bottom housing 164 . As with the wireline retrieving tool 110 , a lower internal area seal 170 seals against a mandrel, in this case a setting mandrel 165 , of substantially the same diameter as the upper interior seal 148 which seals against the drive mandrel 150 . A setting adapter 196 is fixed to the distal end of the setting mandrel 165 . A tool to be set is fixed to the end of the setting housing 194 and the setting adapter 196 . When the wireline setting tool 198 is actuated in the manner as described with regard to the wireline retrieving tool 110 , the housings 140 , 152 , 160 , 164 and 194 move downward over the setting mandrel 165 and the force thus exerted is used to set a tool to be placed in the production tubing or casing (not shown). In FIGS. 5A to 5C , the wireline setting tool 198 is shown with the actuator nut 158 in an intermediate position such that the housings are partly but not fully extended.
The number of housings depicted in FIGS. 2A to 5C is based, at least in part, on manufacturing concerns. The invention encompasses tools having more or fewer housings. The tubular shape of the housings is preferred but not essential.
Although seals are depicted throughout the figures, seals may be unnecessary between the relatively stationary parts if a sufficiently tight fit is present.
The mechanical means of interconnecting the various components of the tool shown in the figures are exemplary only. Other known mechanical means of interconnecting the various components are contemplated by the invention.
Numerous modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described herein. | A well tool for applying a pulling or a pushing force to an object in an interior of a well bore comprising: a) a inner member comprising an first elongated member, a second elongated member and an actuation means axially interconnecting the first elongated member and the second elongated member; b) an outer elongated member longitudinally moveably engaged with the inner member; c) a first seal defined between the first elongated member and the outer elongated member; d) a second seal defined between the second elongated member and the outer elongated member; e) a first piston area defined at a first end portion of the outer elongated member between an outer diameter of the outer elongated member and a sealed outer diameter of the first elongated member; f) a second piston area defined at a second end portion of the outer elongated member between the outer diameter of the outer elongated member and a sealed outer diameter of the second elongated member; and g) a sealed chamber defined between the first seal and the second seal, the sealed chamber including a fluid at a fluid pressure; wherein operation of the actuation means axially reversibly moves the outer elongated member relative the inner member while the fluid pressure remains constant; and wherein the first piston area and the second piston area are substantially equal and external pressure acting on these two piston areas, generates two opposing forces substantially balanced during relative movement. | 4 |
This is a continuation of co-pending application Ser. No. 529,054, filed Dec. 3, 1974.
BACKGROUND OF THE INVENTION
This invention relates to structural assemblies for buildings or other architectural constructions and is particularly concerned with frame structures enclosing an area which is to be filled using one or more panes (i.e. transparent or translucent sheets) and/or panels mounted in the structure.
When creating such structural assemblies, for example as curtain walling, for a large building, especially a tall building, the task can be extremely difficult, particularly in adverse weather conditions. There is, for example, the problem of handling large panes of glass including lifting them some considerable height, and then locating and fixing them accurately often in high winds and with the construction workers themselves exposed to the weather conditions.
SUMMARY OF THE INVENTION
According to the present invention, in a frame structure for an external face of a building or other architectural construction, frame elements defining at least one planar space or cell to be filled by a pane or panel carry external sealing means adjacent a forward face of the structure from which the depth of the elements extends rearwardly and supplementary elements are located rearwardly of the external sealing means to engage the frame elements for holding the or each pane or panel against the sealing means, whereby said pane or panel can be mounted in place from the rear of the structure and is clamped in sealing engagement with the external sealing means by the supplementary elements.
With the such an arrangement, a pane or panel can be brought to an upper storey through the interior of the building so lessening the possibility of damage to it and of injury to the construction workers who are also able to fix it in place working from the exterior. It can nevertheless be possible to make this arrangement compatible with those in which panes or panels are fitted from the exterior so that a mixture of both methods can be used for different spaces or cells where this has advantages.
In a preferred feature of the invention the sealing means take the form of a covering between the frame elements and the exterior. This gives a weather seal that protects the frame elements as well as sealing the edges of the pane or panel. Thus, the covering of each frame element can comprise a pair of sealing gaskets that engage and overlie laterally opposite portions of a forward region of the frame element, and these gaskets engage each other sealingly centrally in that forward region, or alternatively a filler strip is compressibly engaged between said pair of gaskets to complete said covering in a sealing manner. Such a covering can be completely assembled before each pane or panel is inserted, so that the external means can even then provide a firm and undetachable seating for the pane or panel and, moreover, this stage of the assembly can also be performed wholly or mainly from inside the building if desired.
Preferably, means are provided to increase the pressure of clamping of the periphery of the pane or panel after it has been mounted in the structure, which allows one or more of said supplementary elements to be employed during assembly to serve as a form of retaining location to hold the pane or panel in place and only after the pane or panel has been correctly located is the clamping pressure increased to ensure sealing engagement of its periphery. This feature can also ensure a satisfactory seal irrespective of minor dimensional variations. The procedure described can be carried out effectively by arranging that the supplementary elements pivotally engage said frame elements and screw-threaded members are provided between the frame elements and the supplementary elements for adjustment of said clamping pressure by causing relative pivotting between the elements. Desirably, also, auxiliary sealing means are provided between the supplementary elements and the pane or panel, and can be secured to the supplementary elements before they are assembled in place.
The pivotal arrangement of the supplementary elements provides the possibility of having a construction in which the external sealing means are mounted on portions of the frame elements disposed forwardly of the pane or panel and that rearwardly of the pane or panel the frame elements are provided with pivotal engagement means for the supplementary elements. Thereby only the frame elements themselves need extend outwardly of the or each pane or panel and the cold bridge to the exterior (i.e. the heat conductive path through the material of the frame structure) can accordingly be kept to a minimum so reducing or avoiding condensation problems.
The appearance of the frame structure can be improved and interference with the adjustment means prevented by providing capping means, which can be simply snapped into place, covering said supplementary elements.
To allow for small dimensional variations, for the convenience of using an assembly of smaller components, and/or for accommodating differential thermal expansion, at least some of the frame elements may have longitudinaly extending engagement means for slidably receiving interconnection means joining adjacent frame elements in a manner permitting adjustment in the plane of the frame. Also as a convenient form of non-expanding fixing when using on extruded section frame element, the section of this element may comprise at least one hook-like arcuate portion for receiving a securing screw with its shank parallel to the longitudinal axis of the frame element.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be more particularly described by way of example with reference to the accompanying drawings, wherein:
FIG. 1 is an exploded perspective view of a part of a frame structure according to the invention,
FIG. 2 illustrates a complete frame structure,
FIGS. 3 and 4 are sectional views in the plane III--III and IV--IV, respectively, in FIG. 2, with the frame structure mounted in an aperture of a wall or other surrounding construction, and
FIG. 5 is a detail view of a modified form of external sealing gasket that can be employed in the construction shown in the preceding figures.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to the drawings, the frame structure comprises head and cill sections 2, 4 each extending across the width of the structure, connected at their ends by jamb mullions 6 and at intermediate positions by mullions 8. Each of these frame elements is a substantially T-form section having the head or bar of that sectional shape at the exterior face of the frame and the central leg of the sectional shape extending rearwardly therefrom.
In the mullion section, a central web 12 extends from front to rear and has, intermediate the depth of the section, a pair of spaced arcuate or hook-like portions 14, each internally subtending an angle of more than 180°, that provide receiving apertures for screws. (Closed circular bores extending longitudinally of the mullion can be provided instead but the open sectional form of the portions 14 facilitates manufacture of the section by extrusion.)
At the forward end of the web, the T-form of the section is completed by a symmetrically disposed pair of laterally projecting flanges 16. Spaced rearwards from the flanges 16 and immediately forwards of the first hook-like portion is a symmetrically disposed pair of lateral ribs 18 with forwardly directed lips 20. At the rear of the web there is a symmetrical terminal flange 22, also with forwardly directed lips 24.
The head and cill members 2, 4 and the jamb mullions 6 have the same sectional form as each other and this has many features of the mullion section. The web 26 is of the same depth as a mullion web 12 but has no intermediate arcuate portions. At its forward end a single flange 16 projects laterally to one side only and a gripper flange 28 projects to the opposite side of the web. At a position corresponding to the ribs 18 and projecting to the same side as the flange 16 there is a rib 30 which also has a forwardly directed lip 20 and, additionally, a rearwardly directed lip 32. A first auxiliary rib 34 on the same side of the web as the rib 30 and adjacent the rear of the section has a lip 36 opposed to the lip 32, and on the opposite side of the web, approximately midway between the ribs 30 and 34, there is a second auxiliary rib 38 having opposed lips 40, 42 projecting forwardly and rearwardly respectively. The section has the same form of terminal flange 22 as the mullion section.
The form of the flanges 16 of the sections can be the same as that of the corresponding frame elements described in my co-pending application Ser. No. 430,036 filed Jan. 2, 1974. The flanges serve to support and retain flexible sealing gaskets 44, one on each flange, and the pairs of flanges of the different sections are profiled to provide a forwardly open recess 46 between them with opposed re-entrant side faces 46a. The lateral edges of the flanges 16 have rearwardly directed lips 48 and the gaskets 44 are made of a resilient material and can initially be mounted on the flanges in a substantially undeformed state to embrace said lips 48. The section of each gasket 44 comprises a female region 50 that generally fits its associated flange but with some slight clearance at the forward and laterally outer regions and also at the rear region inwardly of the lips 48 where the flange is forwardly recessed. The gasket section also has an inner side margin 52 that fits one side of the recess 46.
The rear face of each gasket 44 comprises an inner lobe 54 located slightly inwardly of the rear region recess of its associated flange. An outer lobe 56 is disposed laterally outwards of the flange and in the unstrained state of the gasket section projects rearwards slightly more than the lobe 54, as may be seen in FIG. 1. Between these two lobes approximately co-incident laterally with the flange lip 46 is an auxiliarly ridge 58 shallower than either of the lobes.
There is a small gap between the two gaskets in the recess 46 of each frame element that allows the gaskets to be put in place without interference with each other. The opposed faces of the two gaskets in this region define a profiled space that into which can be foreced a zipper or locking strip 60. The material of the strip 60 is hard in relation to the material of the gaskets but is also elastically deformable by the pressure of the opposed gaskes on it, so that the strip forms a seal between and with gaskets. The maximum width of the zipper strip cross-section lies within the re-entrant side faces of the recess 46 so that the strip cannot work loose when inserted.
Panes or panels P are sealingly gripped at their edges between the gaskets 44 and rear gaskets 62 of flat strip from secured to T-section clamping bars 64 by adhesive before assembly of the frame structure. Each bar has an inneer arm 66 with a terminal lip 68 that engages under the rib 18 or 30. Screws 70 are threaded through the central web of the bar to bear on the web of the associated frame element section. The rear gaskets 62 are carried by outer arm 74 of each clamping bar and have their inner edges located by shoulder 76 of the bar. It can be seen that driving the screw 70 further into a bar will cause the bar to pivot on its lip 68 and urge the outer arm 74 forwards, thereby deforming the resilient gaskets 44, 62 to grip the peripheral margin of the pane or panel P firmly to produce a weathertight seal.
In the outer marginal elements 2, 4, 6 of the frame structure the ribs 30 operate similarly providing a fulcrum for each associated clamping bar. The gripper flanges 28 of these frame elements have forwardly opening sockets 78 with multiple internal ribs that grip a resilient auxiliary gasket 80 the body of which has a similar ribbed section and engages the socket 78 with an interference fit. Projecting outwardly from this body part of the gasket is a flexible limb 82 that bears on face F of the surrounding edge of the aperture that is to be filled by the frame, so closing the gap between the outer periphery of the frame and the edge of the aperture. As with the mullions, a zipper strip 60 is inserted in the gap between the gaskets 44, 80 to exert lateral pressure on the gaskets for sealing and for locking them in place in the same manner as the strip 60 between the juxtaposed pairs of gaskets 44 on each mullion.
On the inner faces of the outer peripheral elements of the frame structure, and on both lateral faces of each mullion, the clamping bars are concealed by capping members 84 that are resiliently clipped into place, the members having hooked end portions 86 that engage the lips 24 of the web rib flanges 22 and lips 88 of the clamping bar outer arms 74.
In the assembly of the frame structure, the head and cill members 2, 4 have screws 90 passing through them to secure the mullions, the screws tapping their own threads in the inner surfaces of the hook-like portions 14 of the mullion web section. Interconnecting, the frame elements at the corners of the frame structure are angle plates 92 consisting of an inner angle plate extending between the ribs 30 and 34 and retained by the lips 72, 36 of these ribs, and front and rear angle plates, the former being retained by the lips 24 and 42 and the latter being retained by the lip 40 and a recess 94 between the gripper arm 28 and the web. A single angle plate can be provided between the lip 24 and recess 94 but the arrangement illustrated provides a stiffer joint.
The retaining lips and recess can also be employed to receive flat connecting plates 96 spanning a frame element that is divided intermediate its length, such as may be provided to form an expansion joint at one or more points in the structure although this measure will normally be required only in relatively large frame structures. Each plate 96 is attached to the associated lengths of frame element by screws passing through holes 98, 100 in the element and plate, at least one of the holes for each screw being elongated to allow the required movements of the expansion joint.
In the use of the invention the various components of the frame structure can be cut to size and performed before they are brought to a building site. The frame elements and the clamping bars will themselves be provided from extruded metal sections drilled at required positions and cut to form abutting joints with each other, the frame elements at least being mitred for this purpose. The outer sealing gaskets 44 will each be formed as a closed loop: that is to say, the frame structure will itself be of a cellular nature (in its simplest form there being one or more cells of a rectangular form, as exemplified in FIG. 2) and an outer sealing gasket can comprise lengths of an extruded section having the cross-section illustrated with specially moulded junction pieces having a similar cross-section bonded to the ends of these lengths to join them together in the closed loop. A rectangular cell will then have said sealing gaskets formed in a rectangular loop with the four lengths providing the sides of the rectangle joined at the corners of the loop by relatively small L-pieces with which they are integrally moulded, as may be seen in FIG. 1.
The initial stage of the assembly of the structure involves the erection of the main frame elements. If the structure is not too large, this can be done at any convenient place on the site and the initial assembly then put in position in the building. Locking screws (not shown) can be provided to hold the parts of the frame together while the frame is being positioned: e.g. to secure the angle plates 92 to the jamb mullions and the head and cill members. In the initial assembly, the outer gaskets 44 and the peripheral auxiliary gaskets can also be put in place and the zipper strips 60 inserted so locking the gaskets firmly in position, but if the main frame elements are assembled before being positioned in the building the gaskets can be added either before or after said positioning.
The assembly is positioned in a conventional manner, using packing blocks (not shown) if required between the edges of the structure and its surrounding aperture in the building, and it is secured in place by screws (not shown) into said blocks and/or the adjacent structure. At this stage and with the outer sealing gaskets 44 in place, the panes or panels can be put in place from the interior of the building against the rear faces of the sealing gaskets 44 and be secured by the clamping bars 64, which already have the rear sealing gaskets 62 adhered to them. This is conveniently done by first locating loosely the clamping bar for the bottom frame element of a cell of the structure, inserting the pane or panel so that its bottom edge, resting on conventional support blocks B, is engaged by that bar and then adding the clamping bar to the top frame element of the cell to hold the pane or panel lightly in position by the top and bottom bars. The clamping bars at the opposed lateral edges of the pane or panel can next be assembled in place and the clamping screws for the bars tightened down to urge the pane or panel forwards and so grip it firmly and sealingly between the inner and outer gaskets.
When this procedure has been repeated for all the cells of the frame structure, it remains finally to apply sealing mastic 102 behind the outwardly projecting limbs 82 of the auxiliary gaskets 80 as required and to snap into place the capping members 84.
It is a feature of the structure described that the glazing or infill of the frame structure can be applied from the interior of the building so as to avoid any handling problems in raising large, elements to a height and locating them in place while exposed to winds and other difficult weather conditions. In some circumstances it may be preferred to have the panes or panels of a part of the construction applied from the exterior, but this does not preclude the use of a frame structure such as that described since this can be compatible with other forms of structure which allow this to be done, in particular that described in my co-pending application Ser. No. 430,036 filed Jan. 2, 1974.
The illustrated form of structure can be modified in many ways within the scope of the present invention. The structure can be of a single-pane nature, i.e. without mullions, or it can have internal transverse divisions provided by transoms, which may be given the same sectional form as the mullions and be connected thereto in an analogous manner to the connections between the cill and head members with the jamb mullions (the joining angle plates then conveniently being screwed to the mullions). Where required, the connections here and elsewhere in the frame structure can be arranged to allow for thermal expansion movements, as has already been exemplified by the connecting plates 96 with the slotted screw engagements employed there, although in the case of internal frame elements, such as transoms extending between adjacent mullions and/or jamb mullions a simple sliding engagement without securing screws may be sufficient.
In FIG. 5 there is shown a modified form of sealing gasket 144 that can be substituted for the gaskets 44. The manner of mounting the modified gasket and the way in which it seals against a panel or pane are essentially as already described for the gaskets 44, but no filler or zipper strip is used between an opposed pair of gaskets.
The drawing shows in full lines the form of the gasket after it has been placed on a flange 16 of a frame element but before the pane or panel has been put against it. In the region of the recess 46, the gasket extends substantially to the centre line 130 of the recess and its lateral face there is formed with a plurality of longitudinal ribs 146 having flattened or rounded tops. It will be appreciated that with two such gaskets mounted on opposite flanges 16, their ribs will be directly opposed with each rib very close to or in light contact with the facing rib.
Unlike the gasket 44, there is no clearance at the forward and laterally outer region of the frame element flange 16 between the inside face of the gasket and the front face of the flange. Therefore when the pane or panel P is pressed against the rear of the gasket in the manner already described, the resulting deformation, and in particular the displacement of the outer lobe 56 to the dotted position, causes a corresponding displacement of the front and inner region of the gasket. If there is nothing to oppose this in the recess 46, the ribs will move over the centre line, as is also shown dotted, but of course the opposing gasket will be similarly affected by the insertion of its pane or panel and instead the ribs are urged together into intimate sealing contact at the centre line. The ribbed formation enhances sealing because the smaller contact area gives an increased contact presure.
While a planar structure has been described, it is possible to employ the invention with curved or multi-planar assemblies. Also, although for simplicity a rectangular frame grid has been described, the frame and its cells may have different forms and it is by no means necessary for the cells to be similar in shape to each other. Where the frame structure extends over a number of storeys of a building, the individual cells as defined by the closed loop sealing gaskets, may themselves extend over more than one storey.
A frame structure according to the invention can of course receive infill panes and/or panels of a wide variety of forms. Opening window lights and other ventilation means may be included, for example, and illuminated panels, as well as double glazing and sandwiched or multiple layer panels. | A structural assembly comprises a cellular frame structure in the cells of which panes or panels are mounted to form a curtain wall. The frame structure carries external sealing gaskets for the peripheries of said panes and arranged so that said panes are put in place from the interior face of the structure. Internally of said panes, clamping means are disposed to urge said panes into sealing engagement with the gaskets with an adjustable force. The external sealing gaskets cover those parts of the frame structure that project externally of said panes. | 4 |
BACKGROUND OF THE INVENTION
The invention relates to an air intake manifold for an internal combustion engine, wherein the intake manifold comprises at least one flange at the engine end, at least two tube elements, as well as a manifold chamber communicating with the tube elements.
Such intake manifolds are known, for example, in use in passenger automobiles.
If it is desired to use such intake manifolds in motor vehicles which must satisfy strict noise emission requirements, it is a disadvantage that the tubes produce undesirable noise in various states of operation.
It might be possible to fully enclose an engine compartment or cover areas which produce intense noise with insulating material. This, however, is expensive to manufacture and would therefore increase the cost of the entire vehicle. Furthermore, it would increase weight, which automatically would result in an increase in fuel consumption.
SUMMARY OF THE INVENTION
It is thus the object of the invention to improve an air intake manifold of the kind described above so as to make it lightweight, inexpensive and quiet.
In accordance with the invention this object is achieved by dividing the manifold chamber of the intake manifold with a dividing element into at least two communicating compartments.
Due to the presence of the dividing element the formation of vibratory modes is impeded or suppressed.
An advantageous embodiment of the invention provides for the intake manifold to be composed of synthetic resin material. The use of synthetic resin material makes the intake manifold lighter in weight, thereby lowering fuel consumption.
Furthermore, provision can advantageously be made for the intake manifold to be manufactured by the half-shell technique. This manufacturing technique offers cost advantages with simple shapes.
In another advantageous embodiment of the invention the dividing element covers substantially 100% of the manifold chamber cross section. Since the dividing element divides the chamber substantially into two parts, the development of modes of vibration is wholly or partially suppressed.
In an advantageous embodiment of the invention, the dividing element covers 25 to 75% of the manifold chamber cross section. Even a partial cross-sectional reduction suffices to break up the propagation of vibration modes, so that this variant results in an additional weight reduction, while the air, as a vibrating mass, interacts through the cross-sectional reduction against a volume of air behind it that acts as a damper. Furthermore, it is important to see to it that the linear dimensions are small in proportion to the wavelength, which prevents scattering in the vicinity of the cross-sectional reduction. It is also advantageous to make the marginal clamping of the dividing elements resiliently mounted. Advantageously, the dividing element is composed wholly or partially of porous material.
Advantageously, the distance from the dividing element to the manifold chamber's inner wall is not evenly divisible by the wavelengths which occur in the primary operating state or a multiple thereof. This prevents the occurrence of standing waves.
In an advantageous embodiment of the invention, the distance from the dividing element to the inner wall of the manifold chamber is adjustable. By appropriate selection of the geometry, or appropriate adaptation of the geometry to the prevailing operating conditions, for example by means of displaceable intermediate walls moved by means of electrical systems or by vacuum-supported elements, the occurrence of standing waves is prevented, since they form whenever a wave after, for example, two reflections comes back to the starting point with the same phasing.
These and other features of preferred embodiments of the invention are found not only in the claims but also in the description and the drawings, the individual features can be utilized individually or severally in the form of sub-combinations in the embodiments of the invention and in other fields, and may constitute advantageous as well as independently patentable embodiments for which protection is hereby claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1a and 1b show the division of the manifold chamber by a dividing element.
FIGS. 2a to 2e show embodiments of dividing elements.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The intake manifold 1, which in the embodiment described is made by the half-shell technique, has the weld seams 11, typical of this technique, which are seen in FIG. 1a and which join the half-shells 6 and 7 together. For the connection to the actual engine block, not shown here, the intake manifold 1 has a flange 2. The tube elements 3 all open into the manifold chamber 4 which is divided in half by a dividing element 5 represented schematically in FIG. 1. The intake manifold 1 is fastened by means of the mount 9 in the motor compartment of, for example, a passenger automobile. By means of the vacuum connections 10 attached to the intake manifold 1, the pressure conditions inside the intake manifold are detected and used, for example, for control purposes. In FIG. 1a can be seen also a connection for exhaust gas recirculation 14 on the intake manifold 1.
The intake manifold 1 shown in FIG. 1b has a flange 2 on the engine end by means of which the intake manifold is fastened to the engine block of an internal combustion engine. This engine flange 2 is connected to a manifold chamber 4 by tube elements 3, which in turn are composed in this embodiment of synthetic resin half-shell elements 6 and 7. The manifold chamber communicates in turn with the air filter, which is not shown. The spatial extent of this manifold chamber 4 is limited by a dividing element 5 and bounded by a housing wall 8. This dividing element 5 acts as a barrier against the propagation of vibration modes which depend upon the operating state of the internal combustion engine. The intake manifold 1 is secured in the engine compartment by means of mount 9. The intake manifold 1, which in the embodiment described is made by the half-shell technique, has, as seen in FIG. 1b, the weld seams 11 typical of this technique. On the intake manifold 1 injection valve sockets 12 are provided into which the injection valves, not shown, are inserted, as well as fastening holes 13 by which the intake manifold is fastened to the engine block.
Alternatively, the entire intake manifold can also be made by the lost wax technique, but for this a certain complexity of geometry is necessary, such as complicated internal contours, so that if the half-shell technique were to be used, several shell molds would be necessary, and consequently the lost wax technique would have advantages with respect to the cost situation of the manufacturing process.
Different embodiments of dividing elements 5 are shown in FIGS. 2a to 2e.
In FIG. 2a the intake manifold illustrated in FIG. 1a is shown in section, whereby the dividing element 5 occupies nearly the entire cross sectional area of the manifold chamber 4. Also shown are the weld seams 11 which join the half-shell elements 6 and 7. The intake manifold is secured in the engine compartment by means of the mount 9.
In FIG. 2b the intake manifold 1 illustrated in FIG. 1a is shown in section, whereby the dividing element 5 occupies only about one-quarter of the cross-sectional area of the manifold chamber 4. Also shown are the weld seams 11 which join the half-shell elements 6 and 7. The intake manifold is secured in the engine compartment by means of the mount 9.
In FIG. 2c the intake manifold 1 illustrated in FIG. 1a is shown in section, whereby the dividing element 5 occupies only about one-half of the cross-sectional area of the manifold chamber 4. Also shown are the weld seams 11 which join the half-shell elements 6 and 7. The intake manifold is secured in the engine compartment by means of the mount 9.
In FIG. 2d the intake manifold 1 illustrated in FIG. 1a is shown in section, the dividing element 5 occupying about one-third of the cross-sectional area of the manifold chamber 4. Also shown are the weld seams 11 which join the half-shell elements 6 and 7. The intake manifold is secured in the engine compartment by means of the mount 9.
In FIG. 2e the intake manifold 1 represented in FIG. 1a is shown in section, whereby the dividing element 5 occupies about two-thirds of the cross-sectional area of the manifold chamber 4. Also shown are the weld seams 11 which join the half-shell elements 6 and 7. The intake manifold is secured in the engine compartment by means of the mount 9.
The dividing elements 5 shown in FIGS. 2b to 2e give a reduction of the noise emission of the intake manifold, even though the cross section of the manifold chamber 4 is reduced to only 25 to 75%. On the one hand this saves additional material, which corresponds to a weight reduction; on the other hand, the air behind the dividing element 5 acts like a damper on the air masses passing through the cross-sectional reduction caused by the dividing element 5. Another alternative is to be seen in the resilient mounting of dividing element 5, which leads to a further reduction of the noise emission of the intake manifold. Arranging the dividing element 5 in the manifold chamber 4 such that the distances from the housing wall 8 of the manifold chamber is not evenly divisible by the wavelength of the vibrations produced by the air flow or by an even multiple thereof, provides for a reduction of the noise emission of the intake manifold 1.
An additional alternative, which is not shown in the drawing, provides for the distance from the dividing element 5 to the housing wall 8 of the manifold chamber 4 to be adjustable. By the use either of elements which move the dividing wall 5 and are driven by electric motor or the support of dividing wall 5 by vacuum-driven elements, it becomes possible to adjust the dividing wall 5 to the ideal position with respect to the housing wall 8 of the manifold chamber depending on the respective operating state of the internal combustion engine. | An intake manifold for an internal combustion engine in which the intake manifold includes at least one flange for attachment to the engine, at least two intake tube elements, and a manifold chamber communicating with the intake tube elements, the manifold chamber being subdivided by a separator or dividing element into at least two communicating compartments. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a capping system assembling a cap to the stem.
2. Background Art
In the fabrication of optical semiconductor devices, a capping system is used when a cap is assembled to the stem (for example, refer to Japanese Patent Laid-Open No. 5-67690). In the capping system, the cap is aligned to the stem by image recognition using a camera.
FIG. 13 is an illustration showing the visual field of the camera and a searching range. When the searching range wherein an object of detection is present is wider than the visual field of the camera, the object of detection must be moved into the visual field of the camera. FIG. 14 is illustrations showing a conventional searching method. As shown, the object of detection is searched by spiral locus centered by the search starting point.
SUMMARY OF THE INVENTION
When the distribution of the detected positions is normal distribution of a concentric pattern as shown in the left side of FIG. 14 , the detected positions could be effectively searched by the spiral locus. However, when the distribution of the detected positions is not normal distribution of a concentric pattern as shown in the right side of FIG. 14 , the detected positions could not be effectively searched by the spiral locus.
Furthermore, there are cases wherein the distribution of the detected positions is different from the distribution simulated by the population (lot) of the material. If previously set initial search starting point was different from the distribution center of actually detected position, there was a problem wherein the searching time was extended.
Furthermore, when searching operation was varied depending on the position distribution of the objects of detection, a control program corresponding to respective searching operations had to be prepared. Therefore, the control program for devices was complicated.
In view of the above-described problems, a first object of the present invention is to provide a capping system which can shorten the searching time. A second object of the present invention is to provide a capping system wherein a control program can be used in common for a plurality of searching operations.
According to the present invention, a capping system includes: a moving portion moving a stem mounting an optical semiconductor element toward a horizontal direction; a fixer fixing a cap having a window under a state wherein the stem is covered with the cap; a camera taking an image of the cap and the stem from above; a detector detecting whether the optical semiconductor element is present within a visual field of the camera; and a searching action controller controlling the moving portion to move the stem to make the detector perform a searching operation for searching the optical semiconductor element. The searching action controller performs the searching operation radially and outward from a search starting point.
The present invention makes it possible to shorten the searching time.
Other and further objects, features and advantages of the invention will appear more fully from the following description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view showing a capping system according to the first embodiment of the present invention.
FIG. 2 is a sectional view showing a stem mounting an optical semiconductor element.
FIG. 3 is a block diagram showing a control circuit according to the first embodiment of the present invention.
FIG. 4 is a diagram showing the searching operation of the X-direction.
FIG. 5 is a diagram showing the searching operation of the Y-direction.
FIG. 6 is a diagram showing the searching operation of the combination of the X-direction and the Y-direction.
FIG. 7 is a graph showing the distribution of the search starting points and the detected positions.
FIG. 8 is a block diagram showing the control circuit according to the second embodiment of the present invention.
FIG. 9 is a diagram showing an example of allocation plans.
FIG. 10 is a diagram showing an example of the table.
FIG. 11 is a layout drawing wherein the searching orders of the allocation A.
FIG. 12 is a diagram showing the layout drawing wherein the searching order of the allocation B.
FIG. 13 is an illustration showing the visual field of the camera and a searching range.
FIG. 14 is illustrations showing a conventional searching method.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A capping system according to the embodiments of the present invention will be described with reference to the drawings. The same components will be denoted by the same symbols, and the repeated description thereof may be omitted.
First Embodiment
FIG. 1 is a perspective view showing a capping system according to the first embodiment of the present invention. FIG. 2 is a sectional view showing a stem mounting an optical semiconductor element. The optical semiconductor element 1 such as a laser diode is mounted on the stem 2 . The capping system is a portion for assembling a cap 4 having a window 3 (lens) to this stem 2 . The cap 4 is cylindrical, and the optical semiconductor element 1 is included therein. The optical semiconductor element 1 in the cap 4 can be viewed from above via the window 3 of the cap 4 .
An X-axis direction moving portion 5 moves the stem 2 mounting the optical semiconductor element 1 toward the horizontal X-axis, and a Y-axis direction moving portion 6 moves the stem 2 toward the horizontal Y-axis. At this time, the cap 4 is fixed under the state wherein the stem 2 is covered with the cap 4 . A fixed CCD camera 8 takes an image of the cap 4 and the stem 2 from above. A controller 9 controls the X-axis direction moving portion 5 and the Y-axis direction moving portion 6 depending on the image taken by the CCD camera 8 .
FIG. 3 is a block diagram showing a control circuit according to the first embodiment of the present invention. A detector 10 detects whether the optical semiconductor element 1 is present within the visual field of the CCD camera 8 . A searching action controller 11 controls the X-axis direction moving portion 5 and the Y-axis direction moving portion 6 to move the stem 2 to make the detector 10 perform the searching operation for searching the optical semiconductor element 1 . When the optical semiconductor element 1 enters within the visual field of the CCD camera 8 and the detector 10 detects the optical semiconductor element 1 , the searching action controller 11 ends the searching operation.
The searching action controller 11 performs searching operation radially and outward using the optimal search starting point S as the starting point. FIG. 4 is a diagram showing the searching operation of the X-direction. FIG. 5 is a diagram showing the searching operation of the Y-direction. FIG. 6 is a diagram showing the searching operation of the combination of the X-direction and the Y-direction.
A memory 12 memorizes the detected positions of the optical semiconductor element 1 on the each of a plurality of stems 2 . A searching direction priority order determination portion 13 determines the priority of the orientations for performing searching operation depending upon the distribution of the detected positions in the searching range of the two-dimensional plane (Y-Y plane). Specifically, the priority of the orientations in which the frequency of the detected positions is high is made high. The searching action controller 11 performs the searching operation along the searching orientations in descending order of priority.
FIG. 7 is a graph showing the distribution of the search starting points and the detected positions. In the case wherein the initial search starting point S (X O , Y O ) is different from the distribution center of the detected positions S′ (X O ′, Y O ′), a search starting point setting portion 14 resets the center of the distribution to the search starting point. In particular, from the first to the n batches, the initial search starting point S is made to be the origin, and the searching operation is performed (step S 1 ). Next, in the n+1 batch, the distribution center S′ of the detected positions of past n batches is obtained, and the search starting point is replaced to S′ to perform the searching operation (step S 2 ). Then, in the n+2 batch, the center of the distribution S″ of the distribution center in the detected positions of the past n+1 batches is replaced to S″, and the searching operation is performed (step S 3 ). Thereafter, steps S 2 and S 3 are repeated. Thereby, in the searching operations after n+1 batch, the search starting point is optimized.
In the first embodiment, since searching can be efficiently performed using an optimal search starting point S as the origination radially and outward, the searching time can be shortened. In addition, by determining the priority order of the orientations to perform the searching operation corresponding to the distribution of the detected positions, the time for searching can be further shortened. Furthermore, by setting the distribution center of the detected positions as the search starting point, the time for searching can be further shortened.
Second Embodiment
FIG. 8 is a block diagram showing the control circuit according to the second embodiment of the present invention. In place of the searching direction priority order determination portion 13 in the first embodiment, a layout drawing 15 and a table 16 are provided. The searching action controller 11 performs the searching operation on the basis of the layout drawing 15 and the table 16 .
FIG. 9 is a diagram showing an example of allocation plans. The layout drawing 15 is that the searching range of the two-dimensional plane centering on the search starting point is divided in grid, and tag numbers are allocated respectively. The table 16 is what searching orders are allocated to respective tag numbers. The searching action controller 11 performs searching operations to the positions corresponding to the order of the tag numbers allocated by the table 16 referring to the layout drawing 15 .
FIG. 10 is a diagram showing an example of the table. The allocation A allocates the searching order to the respective tag numbers so that the Y-axis direction is preferential. FIG. 11 is a layout drawing wherein the searching orders of the allocation A. The allocation A can shorten the searching time when the distribution of the searching locations is eccentrically located.
The allocation B allocates the searching order to respective tag numbers so that the searching operations are performed in the spiral locus making the search starting point to be the starting point. FIG. 12 is a diagram showing the layout drawing wherein the searching order of the allocation B. The allocation B can shorten the searching time when the distribution of the detected positions is the concentric normal distribution.
In the present embodiment, it is enough to prepare one control program that performs searching operations in the order of tag numbers as the control program in the searching action controller 11 . Therefore, a control program can be used in common for a plurality of searching operations. In addition, the setting of a plurality of tables can be possible. Since the order of the points to perform searching operation can be optionally determined, the freedom of the searching order can be improved.
Furthermore, in the same manner as the first embodiment, when the initial search starting point S is different from the center S′ of the distribution of the detected positions, the search starting point setting portion 14 resets the center of distribution of the detected positions. Thereby, the time for searching can be shortened.
Obviously many modifications and variations of the present invention are possible in the 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.
The entire disclosure of Japanese Patent Application No. 2012-068774, filed on Mar. 26, 2012, including specification, claims, drawings, and summary, on which the Convention priority of the present application is based, is incorporated herein by reference in its entirety. | A capping system includes: a moving portion moving a stem, on which an optical semiconductor element is mounted, horizontally; a fixer fixing a cap having a window, on the stem; a camera taking an image of the cap and the stem from above the cap and the stem; a detector detecting whether the optical semiconductor element is present within a visual field of the camera; and a searching action controller controlling the moving portion to move the stem so the detector searches the optical semiconductor element. The searching action controller causes searching radially and outwardly from a search starting point. | 8 |
The present application is a continuation of U.S. application Ser. No. 09/390,525, filed Sep. 3,1999, now issued as U.S. Pat. No. 6,340,572, which is a continuation of U.S. application Ser. No. 07/680,678, filed Apr. 4, 1991, now issued as U.S. Pat. No. 6,017,722.
BACKGROUND OF THE INVENTION
I. Field of the Invention
The present invention relates generally to the field of methods for identifying toxicants and/or isolated component substances in a sample. The types of samples which may be analyzed include either a solid sample, a liquid sample or a gaseous sample. The present invention also relates to the field of biological toxicant identification agents, as a particularly described luminescent biological reagent, for example the luminescent bacteria, are employed in the claimed isolation, identification and quantitation methods and techniques disclosed herein. The present invention also relates to the field of toxicant detecting kits, as a kit for the identification of toxicants is described employing a luminescent biological reagent.
II. Description of the Related Art
When grown in appropriate liquid culture or on semi-solid culture media, suspensions of luminescent bacteria emit a constant level of light for extended periods. Luminescent bacteria are bacteria which emit light without excitation, (i.e., they glow in the dark). The origin of the emission is biochemical, and organisms which demonstrate this characteristic are described as exhibiting the phenomenon of bioluminescence. Most known examples of luminescent bacteria are marine. Two major subclasses of the luminescent organisms are 1) free living ( Vibrio harveyi ) and 2) symbiotic ( Vibrio fischeri, Photobacterium phosphoreum, Photobacterium leiognathi ). Other major bioluminescent organisms include fire flies ( Photinus pyralis ), crustaceans ( Cyridina hilgendorfi ), dinoflagellates ( Gonyaulax polyhedra, Notiluca militaris ), fungi ( Omphalia flavida ) and the sea pansy ( Renilla reniformis ).
The luminescence of bacteria has long been known to be sensitive to a wide variety of toxic substances (e.g., heavy metals, pesticides, etc.). The exquisite sensitivity of luminescent bacteria to a variety of substances has made them a popular choice in methods for the gross detection of the presence of toxic materials. For example, the use of luminescent bacteria has been discussed for the detection of toxins on solid surfaces, such as soil 5 , and in liquid substances, such as in the analysis of waste water 3 , as well an in the detection of toxins in gaseous samples 6 .
Luminescent bacteria have also been employed in the detection of toxicants in marine environments. 2 For example, Vasseur et al. describe a Microtox luminescent bacterial assay for the detection of toxicants in water ( Photobacterium phosphoreum ) 2 .
Another variety of luminescent bacteria used in the analysis of industrial waste water is described in the Baher patent. 3 Specifically, the Klebsiella planticola bacteria has been used to detect the presence of substances toxic to particular microorganisms (used to purify industrial chemical plant waste waters) indicated through monitoring the luminescence of the Klebsiella.
Luminescent bacteria have also been used for detecting the presence of specific substances in a sample, including antibiotics, heavy metals, enzyme inhibitors, pesticides, microbial toxins, volatile hydrocarbons, disinfectants, and preservatives. 6 For example, the Siemens patent describes the use of a luciferase-gene-transformed microorganism for detecting the presence of a toxicant in a sample through a demonstrated reduction in the luminescent signal emitted by the luminescent bacteria in the presence of a toxic substance 6 .
Others have reported the ability to detect the presence of particular classes of chemical toxicants using luminescent bacteria, particularly phenolic compounds. 7 For example, in Strom et al., the relative toxicity of a variety of particularly defined phenolic compounds, including hydroquinone, is described using a luminescent bacterium 7 .
Thus, some species and components of luminescent bacteria have been adapted for use to simply detect the general presence of a toxic substance in a sample. In the presence of toxicants, detection of the toxins is provided by an observed diminution in luminescent emission and intensity in a variety of luminescent bacteria. However, the value of the “detection” techniques currently available is limited by an inability to identify, in an isolatable form, the substance which constitutes the “detected” toxicant or foreign substance.
No methods have been described wherein a generically “detected” toxicant may be identified in an isolatable form using a luminescent bacteria. The ability to actually identify an isolated substance as a potential “toxicant” in a sample would provide a powerful industrial and-research tool. Moreover, the ability to distinguish, by positive chemical analysis, the chemical structure of an isolated toxicant (using various chemical separation techniques known to those of skill in the art) would find great potential application in research, diagnostic medicine and industrial manufacturing processes.
Standard chemical visualization techniques for the localization of separated substances employ a variety of stains and staining procedures known to those skilled in the art (i.e., coomassie brilliant blue for gel electro-phoresis of proteins; 2-Naphthol or Resoranol for paper chromatography of sugars inhydrin for amino acid analysis with TLC). However, these techniques do not identify the potential toxicity of any visualized substance in the sample. No system has been proposed wherein a reagent may be used to provide a system wherein the potential toxicity of isolated substance in a sample may also be visualized and thereby identified.
Such a novel method for the simple, inexpensive and sensitive identification of a substance(s) in a sample or product which may be potentially lethal to an organism would also facilitate the further chemical elucidation of the chemical identity of the proposed toxicant through the subsequent use of various well known chemical analysis strategies available to those of skill in the art (such as mass spectrometry, nuclear resonance spectroscopy, infrared spectroscopy, x-ray crystallography, and chromatographic analysis). Thus, the complete chemical structure and identity of the potential toxicant could be determined if such a method, capable of identifying in an isolatable form the potential toxicant, were available. Such a system would be particularly valuable in the development of strategies to remove such identified toxicants from products intended for consumer use, and also in the development of procedures to render chemically identified toxicant(s) innocuous to animals and humans.
SUMMARY OF THE INVENTION
The present invention provides a rapid and accurate method for identifying a component substance (such as a toxin/toxicants) in a sample through the use of a luminescent biological agent employed together with chromatographic resolution techniques.
While any of a variety of luminescent bacteria may be used, those species found to be most particularly preferred for use in the practice of the present invention include Photobacterium phosphoreum, Vibrio fischeri, Vibrio harveyi and Photobacterium leiognathi . However, it is to be understood that the present inventive methods, reagents and kits may be practiced using any luminescent organism whose luminescence is specifically inhibited by an isolated component substance (for example, a potential toxicant) in a sample.
The present methods, reagents and kits may be used to isolate and identify a single toxicant, a number of individual toxicants, or a group of toxicants in or on a sample in the solid, liquid, or gaseous phase.
In part, the point of novelty of the present invention resides in the ability to identifiably isolate a component substance (for example, a toxicant) contained in a sample rapidly, and without the necessity of a separate biosensitivity assay of test sample. This is accomplished, for example, by applying a potentially toxicant-containing sample to a separation phase matrix, such as a chromatography paper sheet or a thin layer chromatography plate. The sample-exposed sheet is then exposed to a luminescent biological agent (i.e., the luminescent bacteria) according to the claimed method to accomplish, in one step, both the isolation of each distinct component substance of the sample and the potential toxicity of each of the distinct components in the test sample.
For example, according to the claimed invention, an unknown sample (for example a liquid unknown sample or a concentrated extract of a larger sample which potentially contains toxicants) may be spotted or streaked near one edge of a chromatography paper sheet at several points.
Most preferably, the sample “spots” or “streaks” are air dried to eliminate the carrier solvent in which the sample was dissolved. More applications of sample(s) can be overlaid onto the respective sample spots, if necessary, and dried. The end of the chromatography sheet closest to the spotted sample edge is then placed in contact with the solvent system of choice.
In the usual situation, the solvent of the solvent system will migrate through the “spotted” sample and through the length of the chromatography paper via capillary action and along the length of the chromatography sheet, thus separating the sample into its component parts onto particular locations or “segments” on the separation phase matrix (i.e., chromatography paper).
These locations or “segments” of the separation phase matrix (which provide the isolated components of the sample) are then exposed to a luminescent biological agent, and provide for the visualiation and identification of a distinct zone of luminescent inhibition” at locations or “segments” where luminescent inhibitory components of the sample are located.
Alternatively (to the above paper chromatography method), an unknown sample could be separated using TLC by spotting the sample on a thin layer chromatography plate. Thus, the sample would be spotted, and air dried analogously to that procedure followed for paper chromatography. However, the solvent in a TLC chamber is at the bottom of the chamber and therefore the solvent migration will be upward through the TLC plate separation phase matrix.
Depending on a variety of factors, including molecular polarity, the isolatable components in the sample will resolve, on the separation phase matrix, being more soluble in the solvent than having affinity for the silica gel or other separation phase matrix.
Resolution of the components in the mixture will depend on the polarity of the molecules in the sample verses the polarities of the stationary (e.g. paper, silica or alumina) and mobile (solvent) phases. The end result in the one dimensional TLC described is a linear array of components at different locations along the length of the chromatogram. The component substances of the sample thus migrate to isolatable locations or “segments” on the plate.
Vertical sections along one side or portion of the TLC plate may be sprayed with the luminescent biological agent to visualize toxicant location. Corresponding unsprayed zones of the plate may then be scraped off and eluted with an appropriate solvent or solvent mixture. In this manner, individual toxicants may be obtained for further separation, chemical identification, or quantitation using those laboratory techniques well known to those of skill in the art.
More toxicant may be obtained for specific chemical analysis of the thus “identified” locations or segments (areas of luminescent inhibition on the chromatogram) of the separation phase matrix by eluting identical segments from a second run selected separation phase matrix (TLC or chromatography paper) that has not been exposed to the luminescent biological agent. The chemical structural identity of the toxicant or isolated component substance of the sample may be elucidated according to standard laboratory techniques well known to those skilled in the art, such as mass spectroscopy (MS) 22 ; high performance liquid chromatography (HPLC) 10,11,12,28 ; infrared spectroscopy (IR) 23 ; nuclear magnetic resonance (NMR) 22,24 ; thin layer chromatography (TLC) 9,26 ; x-ray crystallography 22,23 and the like.
As used in the present application, the term “luminescent” biological agent is defined as an organism or an extract of an organism, which emits heatless light under appropriate conditions. Most luminescent systems involve the use of molecular oxygen. Luciferin (a pigment) and a specialized form of a luciferase enzyme are included in many luminous organisms and enables these organisms to emit a heatless light in the presence of oxygen. Cypridina is an example of a marine organism which contains the luciferin pigment. For example, Cypridina contains a luciferin which, when reacted with the Cypridina luciferase enzyme in the presence of oxygen, emits a heatless bioluminesence. Vibrio fischeri 16 and Vibrio harveyi 17 contain an enzyme necessary to make light, a well as two reagent compounds (a long-chained aliphatic aldehydes and a vitamin derivative, which is a yellow pigment flavin mononucleotide. In reduced form (i.e., in the presence of oxygen) the pigment glows and allows the organism to emit a heatless light. For example, Cypridina contains a luciferin which, when reacted with the Cypridina luciferase enzyme in the presence of oxygen, emits a heatless bioluminescence. Similarly, fire flies possess a luciferin pigment which in the presence of the firefly luciferase and oxygen, provides a bioluminescence suitable for use in the practice of the present invention. Photobacterium leiognathia is a bacteria which is strongly bioluminescent. All organisms and plants which possess a luciferin/luciferase system would be included among those luminescent biological agents which could be used in the practice of the claimed invention.
The present invention also provides a kit for the identification of a toxicant in a sample, which includes a luminescent biological (for example, bacterial) agent. In a particularly preferred embodiment, the kit comprises a carrier means adapted to receive at least two container means and at least one separation phase matrix in close confinement therewith; at least one separation phase matrix; a first container means comprising a luminescent biological agent; and a second container means comprising a diluent for the luminescent biological agent.
Most preferably, the luminescent biological agent is a luminescent bacteria, such as Vibrio fischeri (ATCC No. 7744), Photobacterium phosphoreum, Photobacterium leiognathi , or Vibrio harveyi (ATCC No. 33843). In a most preferred embodiment of the kit, the luminescent biological agent is in a lyophilized form. Where the luminescent biological agent is in a lyophilized or dried form, the kit will include a diluent suitable for reconstituting the particular biological agent into its “glowing” form.
By way of example, where the luminescent biological agent is a luminescent bacterial agent, and the particular luminescent bacterial agent is a marine bacteria, a suitable diluent would comprise a salt solution of at least 1% by weight NaCl. A saline solution between 1% to 4% NaCl is even more particularly preferred. Most preferably, the diluent should constitute 3% by weight NaCl.
The diluent of the kit most preferably is a buffering agent which includes an NaCl concentration of the diluent should be a concentration which maximizes the luminescent characteristics of the particular marine bacterial species employed. The salt concentration of the diluent has been observed by the Inventors to affect the intensity of the bacteria's luminescence, and thus the bacteria's suitability as a “visualizing” agent for the described method. For example, where the luminescent bacteria is Vibrio fischeri , a marine luminescent bacteria, the diluent is most preferably about 0.5 M NaCl. Other diluents for marine luminescent bacteria may comprise a saline solution between 0.6-0.66 M NaCl (1%-4% by weight NaCl).
The separation phase matrix may comprise a chromatography paper sheet, a TLC plate, a Sepharose matrix, or virtually any matrix which is capable of separating a mixed sample into discernable, at least partially isolated, components. The separation phase matrix most preferred for use in the described kit is a TLC plate.
Most preferably, where the method to be used to isolate the components of the sample is paper chromatography, the chromatography paper sheet is most preferably Whatman chromatography paper 1M or 3M. Where the method for separation is TLC, the most preferred TLC plates are Whatman adsorption plates flexible backed aluminum or polyester #4410-222 plates.
The luminescent bacterial agent is to be suspended in a saline solution diluen. Where the bacteria is stored in lyophilized form, the lyophilized bacterial agent is reconstituted in the referenced saline diluent to regain its luminescent form prior to use.
Attempts by the Inventors of directly laying a TLC plate on the luminescent bacteria provided relatively low-sensitivity (i.e., a large amount of inhibitor substance or toxicant needed to be present to demarcate the presence of any isolated substance) for detection, as the discernable “zones” of luminescent inhibition were relatively faint. Therefore, most preferably, the reconstituted bacterial agent is placed into an aspirator spray bottle and sprayed onto sample-exposed separation phase matrix, (for example, the sample-exposed chromatography paper sheet or TLC plate).
The method of directly spraying a TLC plate with a suspension of the luminescent bacteria was demonstrated to provide the best results, with clearly defined “zones of luminescent inhibition” and wherein even minor (less distinct) zones of luminescent inhibition are discernable. At this time, spray application of the luminescent biological reagent thus constitutes the best mode for practicing this aspect of the invention.
However, other methods for achieving contact of the luminescent biological agent to a test sample may be employed to identify substances and/or toxicants in a sample. For example, a sheet of film with an agarose or acrylamide layer, or other solid surface or gel containing a rehydratable material therein capable of being stored in sheet form and rehydratable prior to use, are contemplated by the Inventors as constituting equally usable methods for practicing the claimed invention.
In such an embodiment, a dehydrated form of the luminescent biological agent would be incorporated into a porous or water permeable material which was amenable to being formed into a sheet form. The sheet, so impregnated with a dehydrated form of the luminescent biological agent, would be stored in dry form until needed for use. For use, the sheet with the bacterial agent in it should be rehydrated in a suitable rehydrating agent, such deionized water or a saline solution. Where the luminescent biological agent is a marine luminescent bacteria, such as Vibrio fischeri , the rehydrating agent would most preferably be a saline solution of at least 1% NaCl. Most preferably, the saline solution should be between 1-4% NaCl. A 3% NaCl solution is most preferred.
After the sheet has been rehydrated, the now “glowing” sheet would be laid over a sample of isolated component substances/toxicants to render the luminescent biological agent in contact with the test sample component substances. The existance of zones of luminescent inhibition could then be examined to identify potential toxicants of the sample.
The claimed invention also comprises a luminescent bacterial agent which is capable of identifying in isolatable form a component or mixture of components, substances or a toxicant in a sample. The presence of isolatable component substances or toxicants in a sample is visualized through the presence of discernable zones of inhibition surrounding the applied luminescent bacterial reagent (i.e., termed “zones of luminescent inhibition”).
Any luminescent bacteria may be employed in the practice of the present invention. However, those luminescent bacterial agents preferred in the practice of the invention include Photobacterium phosphoreum, Photobacterium leiognathi, Vibrio fischeri , (ATCC Acc. 7744) and Vibrio harveyi (ATCC Acc. 33843). Among these exemplary bacteria, the Vibrio fischeri and Vibrio harveyi bacteria embody the even most preferred luminescent bacterial agents of the invention. The Vibrio fischeri (ATCC Acc. No. 7744) constitute the most particularly preferred embodiment of the claimed luminescent bacterial agent of the present invention.
As a method for identifying component substances in a sample, using a luminescent biological agent, the claimed method comprises: preparing a luminescent biological agent; obtaining a sufficient volume of the sample to provide a test sample; separating the component substances of the test sample by applying the test sample to a separation phase matrix to provide isolated component substances; and exposing the isolated component substances to a volume of the luminescent biological agent in a concentration sufficient to identify the isolated component substances of the sample. One or more zones of luminescent inhibition will become apparent on the luminescent biological agent-exposed separation phase matrix, and thus identify the isolated component substances in the sample. The concentration of luminescent biological agent sufficient to identify the isolated component substances of a sample is referred to as a “substance indicating amount”. Where the test sample is being analyzed to identify potential toxicant(s), the amount of luminescent biological agent is defined as “toxin indicating amount”. The necessary concentrations to provide this “indicating” effect is between 10 8 -10 9 bacterial cells/ml of diluent where the bacterial agent is contacted with the sample in the form of a liquid suspension.
Where paper chromatography is the technique used to separate component substances or toxicants in a test sample, chromatography paper (as the separation phase matrix) and an appropriate solvent system are used. Corresponding segments on a separate chromatogram (sample plus chromatography sheet) not exposed to luminescent bacteria may be used to obtain additional volumes of the component substances/toxicants of the sample, or where desired, to further chemically identify the isolated component substances of the sample. Additional sample or chemical analysis of the sample in purer form may be accomplished for example, by cutting out the chromatography paper segments (not exposed to luminescent bacteria) which correspond to the identified “zones of luminescent inhibition”; and eluting the isolated substances from the cut out chromatography paper segments with an appropriate solvent.
The isolated component substances or potential toxicants of the sample may then be analyzed using standard chemical and spectral means to chemically identify the isolated substances of the sample. If necessary, the eluate of the isolated components of the sample may be concentrated by techniques well known to those skilled in the art prior to chemical and spectral analysis to chemically identify the isolated substance or toxicant of the sample.
The luminescent biological agent of the claimed method may comprise a luminescent bacteria, a luminescent fungi, a luminescent fish extract, a luminescent dinoflagellate, a luminescent firefly extract, luminescent anthrogans, luminescent earthworm extract, luminecent coelenterate extract or a luminescent crustacean. (Cypridina organisms).
Most preferably, the luminescent biological agent is a luminescent bacteria, such as Vibrio fischeri (ATCC acc. 7744) Vibrio harveyi (ATCC Acc. 33843), Photobacterium phosphoreum , or Photobacterium leiognathi . The term “luminescent biological agent” as used in the present application may include an organism which has been modified to possess luminescence such as an organism genetically engineered to include the luciferase gene. According to the claimed methods, the test sample may comprise a liquid sample, a solid sample, or a gaseous sample. Most preferably, the sample is to be prepared as a liquid test sample for separation via a TLC plate separation phase matrix.
While the present methods may be used to isolate and identify virtually any substance(s) or toxicant(s) in a sample which is capable of inhibiting the luminescence of a luminescent biological agent (for example, a luminescent bacterial agent), preferred applications of the present method include the identification of isolated substances such as pesticides, herbicides, heavy metals and their salts, and plant extracts, from a sample. By way of example, pesticides which may be identified according to the present methods include DIAZANON®, LINDANE® and SEVIN®. By way of example, herbicides which may be identified according to the present methods include ROUNDUP® and WEED-B-GON®. Heavy metals which may potentially be identified according to the present methods include the identification of mercury, lead, cadmium and their respective salts.
According to the present method, the isolated substance or toxicant(s) in the sample may be chemically analyzed by any combination of laboratory techniques well known to those of skill in the art for the chemical characterization of an isolated or partially isolated substance. For example, MS, IR, NMR, HPLC, thin layer chromatography, etc are standard techniques which may be used to further chemically define an isolated substance in a sample. Any of these common laboratory techniques may be used alone or in combination to identify the chemical structure of substantially purified component substances or potential toxicants in a sample.
According to one preferred embodiment of the present method, wherein the separation technique is paper chromatography (separation phase matrix is chromatography paper), the developed chromatogram (having thereupon any isolatable component substances or toxicants of the sample) may be exposed to the luminescent bacterial agent by spraying a suspension of the luminescent bacterial agent, most preferably suspended in a saline solution, onto the developed chromatogram.
As the agent used to visualize the components/toxicants of a sample is of a biological nature, and therefore potentially sensitive (i.e., inhibited by chemicals) to components of a desired solvent to be used, failure to remove solvent could in itself cause nonspecific inhibition of luminescence. Thus, application of the luminescent bacterial suspension should be done after the complete evaporation of carrier solvent from the chromatogram. In addition, the developed chromatogram should also be allowed to dry a second time, after the separation solvent has passed through the sample “streaked” or “spotted” chromatogram, before the luminescent biological (for example, luminescent bacterial agent) is applied (for example sprayed) to the chromatogram.
Observation of a chromatogram exposed to the luminescent agent (the “sprayed” chromatogram) should be made while the chromatogram is still wet or at least moist with the suspension of luminescent biological reagent applied thereto. For example, luminescent bacteria are very sensitive to dehydration, and thus luminescence would be lost everywhere if the investigator does not examine the chromatogram within at least 1 hour of exposing the bacteria to the chromatogram. In practice, a bacteria-sprayed chromatogram remains moist and glowing from the luminescent biological agent for as long as 45 minutes to one hour, depending on the humidity of the environment.
The Inventors herein demonstrate that the inhibition of luminescence of particular species of luminescent bacteria employed according to the methods described herein, is discriminating as among potential toxicants and/or isolated component substances of a test sample. For example, the Inventors have found that the luminescence of one particular species of luminescent bacteria, Vibrio fischeri , is not inhibited by the pesticide, VOLCK oil spray. Neither does the luminescence of the Vibrio fischeri appear to be immediately inhibited by calcium ion. Moreover, all of the luminescent inhibition effects demonstrated through the use of luminescent bacteria, particularly Vibrio fischeri , are concentration dependent.
The methods of the present invention may be adapted for use in the identification of closely related components which may be present together in a test sample. For example, selective sensitivities as between different luminescent biological agents, particularly as between luminescent bacteria, may be used to tailor the disclosed method for use in a particular industry, or to test specific product lines. For example, the luminescence of the bacterial agent Vibrio fischeri is more sensitive to the pesticide DIAZANON® than to the pesticide LINDANE®. Similarly, the luminescence of this particular bacterial agent is more sensitive to the inhibitory action of SEVIN® as compared to LINDANE®. Selection of Vibrio fischeri bacteria would thus be indicated as particularly suitable for use in the described method where a sample is suspected to contain pesticides, such as in a pesticide production facility, or perhaps where foodstuffs are stored.
Thus, the particular species of luminescent bacteria may be selected on the basis of the specific use for which it is intended (i.e., for the identification of a particular class of related substances). For example, where an Investigator wishes to isolate and identify particular pesticides, he/she may select a luminescent bacteria which demonstrates a particular sensitivity to pesticides in general, over another, perhaps less sensitive, luminescent bacteria, for the analysis of a sample which may likely include pesticides. Therefore, a hierarchy of relative toxicant sensitivity, in regard to both the class of toxicant and particular luminescent bacteria, can be established.
The present invention provides a rapid (about 35 minutes) technique that can potentially identify a wide variety of environmentally and biologically harmful substances.
The Inventors have found that the methods described herein are capable of identifying herbicides and pesticides at their working strengths (i.e., DIAZANON®, LINDANE®, ROUNDUP® AND WEED-B-GON® diluted 1/150). Therefore, herbicides, pesticides and other environmental pollutants and contaminants may be identified according to the present method with the described kits as they occur in the environment in the air, in lakes, streams, ground water and in run-off from fields, for example, in relatively dilute form (for example diluted 1/1,000 from commercial stock concentration).
As used in the present disclosure, the term “toxicant” and “identified isolated component substance” of a sample is defined as a substance which is capable of inhibiting the luminescence of a luminescent biological agent, such as a luminescent bacteria, Vibrio fischeri.
Even more specifically, the term “toxicant” is broadly defined as a substance which is capable of inhibiting or potentially lethal to, a virus or a living organism, such as a plant, animal or microorganism. Even more specifically a toxicant potentially toxic to an animal such as a human may be identified using the described method. Toxicity to bacteria is recognized as an indication of toxicity of a substance to higher organisms, including humans. The Inventors hypothesize that forms of the biological agents which are represented by whole organisms, rather than extracts of whole organisms, will be both more sensitive and also be capable of identifying a broader range of substances and toxicants in a sample in smaller concentrations than with luminescent extracts from an organism.
As used in the present application, the term bioluminescence more specifically refers a living organism or from extracts of a living organism when combined under appropriate conditions. Lack of luminescence refers to the lack of light emission not necessarily related to the expiration of the organism.
The following abbreviations are used throughout the Specification:
ECD
=
Electron Capture Detection
TLC
=
Thin Layer Chromatography
NMR
=
Nuclear Magnetic Resonance Spectroscopy
M
=
Molar
HPLC
=
High Performance Liquid Chromatography
IR
=
Infra-Red Spectroscopy
MS
=
Mass Spectroscopy
D
=
Dimension
THF
=
Tetrahydrofuran
UV
=
Ultraviolet
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 —TLC plate with garlic extract sample in H 2 O. Not exposed to luminescent bacteria. TLC Plate identified those components which are ultraviolet light-absorbing. If compound absorbs the 254 nM light, then area where compound is located will not glow, and appears as a dark spot (V shape) in a garlic extract using fluorescent detection (254 nM excitation). Solvent used is 80:8:12 mixture of (H 3 CCN:H 2 O:NH 3 ). The V-shaped areas are not indicative of a bacteriotoxic agent. Results from these analysis indicate a compatible system for resolving ultraviolet absorbing and thereby identifiable components in a sample.
FIG. 2 —TLC plate with garlic extract sample exposed to luminescent bacteria, Vibrio fisheri , same solvent as FIG. 1 . Bioluminescence inhibition is evident as a dark circular region (about 10.5 cm from bottom of plate). This circular region is hypothesized to constitute allicin in the garlic extract.
FIG. 3 —TLC plate with DIAZANON® and LINDANE® by fluorescence.
FIG. 4 —TLC plate DIAZANON® and LINDANE® by bioluminescence.
FIG. 5 —TLC for DIAZANON® dilution series. Plates demonstrate a dilution series of DIAZANON®. The presence of DIAZANON® is demonstrated at dim areas defining the “zone of luminescent inhibition” of the luminescent bacteria, Vibrio fischeri , in response to the pesticide. Dilutions employed of the pesticides were full strength, 1:128; 1:256; 1:512 and 1:1024.
FIG. 6 —TLC for DIAZANON® dilution series with the luminescent bacteria, Vibrio fischeri (same dilutions as for FIG. 5 ).
FIG. 7 —TLC of DIAZANON® with either UV 254 fluorescence or bioluminescence inhibition with luminous bacteria, Vibrio fischeri in a sample.
FIG. 8 —TLC of DIAZANON®, ROUNDUP® and WEED-B-GON® identified at a dilution of 1/150 (working strength). Luminescent bacteria exposure time prior to examining the bacteria-sprayed plates was 35 minutes.
FIG. 9 —TLC plates of two pesticides, DIAZANON® and LINDANE® and two herbicides, ROUNDUP® and WEED-B-GON®, taken in room lighting. Dilution of pesticides and herbicides=1/150.
FIG. 10 —TLC plates of two pesticides, DIAZANON® and LINDANE® and two herbicides, ROUNDUP® and WEED-B-GONE® viewed by bioluminescence showing zones of luminescent inhibition.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention provides methods, kits and luminescent biological (for example, bacterial) agents which are demonstrated to be surprisingly advantageous for the identification of specific toxicants or component substances in a sample. Moreover, techniques are proposed wherein the identified component substances of a sample may subsequently be chemically characterized or additional volumes of the isolated component ingredient (i.e., toxicant) be obtained employing a variety of chemical techniques in conjunction with the teachings of the present disclosure.
The novel use of a luminescent biological agent together with a separation phase matrix provides a unique method for the rapid and simple identification of potentially toxic (isolated) substances in a sample. The Inventors foresee the application of the present invention in the laboratory as well as in industry for the detection of environmental pollutants, particularly in water resources. Additionally, use of the described methods in the development and identification of therapeutically valuable components in plants and organisms, such as in garlic, is also considered an important application of the described invention.
Luminescent Bacteria as the Luminescent Biological Agent
Where the luminescent biological agent to be used is a luminescent bacterial agent, such as the luminescent bacteria Vibrio fischeri , the bacteria should constitute a suspension of bacteria at a final concentration of about 10 8 -10 9 bacteria cells/ml in the suspension to be used, for example, where the luminescent bacterial agent is sprayed onto a chromatogram.
A preferred method whereby the luminescent bacteria are prepared for use in the presently described invention is as follows. The bacteria must first be allowed to become fully “induced” in their luminescent system, i.e., the luminescent system of the bacteria should be allowed to reach complete development prior to harvesting of the bacteria from the culture. Determination of at what point a bacteria has reached full luminescent system development is well known to those of skill in the art 30,31 .
Upon full development of the luminescent system of the bacteria, the bacteria should be harvested and then placed in a centrifuge tube. The bacteria are then to be centrifuged at a speed of 10,000×G for 30 minutes at room temperature. Thus centrifuged, the bacteria will form a pellet of cell “paste” at the bottom of the tube. About 1 gram of this cell paste (about 12 ml of cell “paste”=1 gram) of glowing bacteria is then to be diluted to a volume of 20 ml, by adding 20 ml of a diluent of choice. Where the luminescent bacteria is a marine bacteria, for example, the diluent is most preferably a buffered saline solution of between 1-4% NaCl. As diluted to 20 ml, the cell suspension constitutes a concentration of 10 10 -10 12 bacteria cells/20 ml (or 10 8 -10 9 cells/ml).
The following Examples are presented only to describe preferred embodiments and utilities of the present invention, and to satisfy best mode requirements. The examples are not meant to limit the scope of the present invention unless specifically indicated otherwise in the claims appended hereto. The following Examples are provided to demonstrate various aspects of the present invention.
Example 1—Isolation of Identifiable Luminescent Inhibitory Toxicant In Garlic Extract Using Luminescent Bacteria.
Prophetic Example 2—Proposed Chemical Identification of Toxicants in a Garlic Extract.
Example 3—Identification of Pesticides in Sample With Luminescent Bacteria.
Example 4—Dilution Series of DIAZANON® or TLC with Vibrio fischeri.
Example 5—Solvent Polarity and Fluorescent and Bioluminescent Detection of DIAZANON®.
Example 6—Identification of Pesticides and Herbicides in a Sample with Luminescent Bacteria.
Example 7—Identification of Herbicides and Pesticides.
Prophetic Example 8—Proposed Identification of Heavy Metals In a Sample with Luminescent Bacteria.
Prophetic Example 9—Proposed Chemical Identification of a Toxicant In a Sample Isolated With Bioluminescence Methods.
Example 10—Identification of Toxicant in a Gaseous Phase Sample with Luminescent Bacteria.
Prophetic Example 11—Proposed Identification of a Toxicant on a Solid Surface Sample with Luminescent Bacteria.
Prophetic Example 12—Proposed Test Kits for Identifying Toxicants in a Sample.
EXAMPLE 1
Isolation of Identifiable Luminescent Inhibitory Toxicant In Garlic Extract Using Luminescent Bacteria
The present example is presented to describe a method by which components of a substance which inhibit luminescent bacteria may be isolated. The sample analyzed in the present example is a garlic extract. For this experiment, the Inventors first prepared a garlic extract from garlic powder. The garlic powder was processed so as to form a liquid garlic extract. One (1) gram of garlic powder was blended with 5 ml. H 2 O. Other solvents such as ethanol, chloroform, or acetone may be used to blend the sample, but H 2 O was found to be the best solvent for the garlic.
A 5 ml. volume of the garlic extract was first applied (“spotted”) to TLC plates at several points equidistant from one edge of the plate. The plate was inverted in a sealed TLC solvent container with a small amount of solvent in the bottom such that spotted samples were parallel to and above the solvent interface.
As the solvent (acetonitrile:water:aqueous ammonia, 8:1.5:0.5) migrated up the TLC plate, the individual components in the garlic extract were sufficiently separated to detect separate zones of luminescent inhibition upon exposing the developed chromatogram to a suspension of luminescent bacteria, Vibrio fischeri applied in a suspension of 0.5 M NaCl (See FIGS. 1 - 2 ).
The Inventors applied the luminescent bacteria, Vibrio fischeri to the chromatogram specifically by spraying the described suspension of bacteria (contained in a buffered salt solution of 3% (0.5 M) NaCl at a pH of about 7) onto the developed chromatogram after the solvent in which the sample was contained had evaporated. Zones of luminescent inhibition were located prior to the dehydration of the bacteria on the chromatogram, i.e., at least within 1 hour after application of the bacteria.
The inhibition of bioluminescence of the bacteria caused by the presence of toxicants in isolated components of the garlic extract was then visualized. The bioluminescent inhibition effect of any toxicant in the garlic extract became apparent generally within a few minutes in the form of a clearly demarcated zone of bioluminescent inhibition (See FIG. 2 ). These zones of bioluminescent inhibition are areas on the chromatogram which were dimmer (i.e., less brightly emissive) than the more brightly emissive surrounding areas on the chromatogram (which did not include isolated components of the garlic extract which were capable of inhibiting the luminescence of the Vibrio fischeri ). The areas wherein the chromatogram demonstrated greatest amounts and intensity of blue bioluminescence from the applied Vibrio fischeri bacteria identified areas of no component substances or instead isolated components of the garlic extract which were not toxic to the bioluminescence of the bacteria, and therefore according to the described method were considered not to constitute toxicants.
As stated, the inhibition of bacterial luminescence which occurs when a toxicant is detected, becomes apparent very soon, often within a few minutes, and grows more distinct with time and reaching a pronounced peak effect in the minutes before the chromatogram dries out, i.e., the zones of decreased luminescence show more contrast relative to the surrounding luminescence with time, prior to the chromatogram drying out. When the chromatogram is dried out, of course, all the luminescence of the bacteria on the chromatogram will be extinguished with the dehydration of the bacteria.
Curiously, with the described methods, those positions on the chromatogram to which the toxicants have migrated (i.e., the “zones of inhibition”) appear to dry out faster than the remainder of the chromatogram which, for example, remains highly luminescent.
Alternatively, the identification of the different individual components of the garlic extract could have been accomplished using paper chromatography as the separation phase matrix for the sample or other such techniques well known to those of skill in the art.
FIG. 1 —TLC Plate of Garlic Extract
This is a photograph of a TLC plate viewed by fluorescence. The actual plate was 20 cm by about 4.5 cm. In the photograph the plate is seen reduced to 13.0 cm by 2.95 cm. Dimensions below refer to dimensions of the photograph not of the original plate.
Sample: Aqueous Garlic Extract. Preparation: 1.0 g of powdered garlic suspended in 5.0 ml of H 2 O. Mixed with Vortex mixer for 1 minute. Centrifuged in table top centrifuge on high (about 1-2000 rpm, 60 seconds) to obtain straw yellow supernatant: the sample. Five μl applied at origin of plate: pencil lines seen near 1.7 cm from bottom of plate. The application zone is seen as a circle (faint) of about a 6 mm diameter centered on the line.
Development: The solvent system used was acetonitrile: water: 25% ammonia (aqueous); 80:8:12. The sample was chromatographed in a closed chamber for approximately 20 minutes. The solvent front traveled about ⅘ of the distance of the plate. A faint demarkation line is seen at about 10.5 cm from the bottom of the plate showing the location of this solvent front.
Results: Major features of the chromatogram viewed by fluorescence excitation are a pronounced dark line at about 7.9 cm from the bottom of the plate several chevron or V-shaped dark areas in the 5.8-7.7 cm from the bottom region and a faint roughly circular shaped zone centered at about 8.8 cm from the bottom. The chevron shaped darkenings represent chemical components in the garlic resolved by the chromatographic process. The more or less circular zone at 8.8 cm (which can be more dramatically revealed by moving the photograph back and forth about 2 cm in the plane of the photograph) is the zone or near the zone of bioluminescence inhibition seen in photograph 2 .
FIG. 2 —TLC Plate of Garlic Extract
This is a photograph of a TLC plate (not the same one as in photograph 1 , but a plate developed in an identical fashion except for a longer time) viewed by the emission of Vibrio fischeri luminous bacteria. The actual plate was 20 cm by about 4.2 cm. In the photograph the plate dimensions are 12.9 cm by 2.8 cm.
Sample: Aqueous garlic extract: the identical sample used in chromatogram of photo 1 .
Development: same as in photo 1 except chromatogram ran longer, front reaching near the end of plate, near 12.5 cm in photograph. The origin was centered on the pencil line visible at about 2.4 to 2.5 cm from bottom of plate.
Results: A very dark, nearly circular zone is seen centered at about 10.5 cm from bottom of plate. A faint second zone is seen at about 6.7 cm from the bottom. Several darkened regions can be seen at the edges of the plate. The dark areas which appear at the edges are artifacts, and represent places on the chromatogram sheet which were not adequately sprayed with the luminous bacterial suspension. The zone at 10.5 cm represents the lumotox effect i.e., the determination of the location of the component in garlic which inhibits the luminous bacteria.
Routinely, for preliminary analysis of the chromatograms, the plates were irradiated with a lamp emitting UV (254 nm) radiation. The TLC plate used had the F 254 backing and were therefore fluorescent everywhere that no UV absorbing samples or components existed. This preliminary detection system also revealed component substances as dark spots on a light background where heterocyclic or other UV absorbing compounds were present. However, fluorescent extinction and luminescence inhibition were often not in parallel. For example, some samples presented as very dark zones, as viewed by fluorescence (for example, garlic), had little or no bioluminescence inhibition, while other zones presented very faint or non-existent fluorescence extinction but had substantial ability to inhibit (extinguish) bioluminescence (e.g., garlic, LINDANE®, ROUNDUP®).
Particular sources of TLC plates and chromatography sheets include Sargent Welch (No. S18953-10-TLC plate with F 254 fluorescent material), Analtech (uniplate taperplate silica gel G-F, No. 81013), and Eastman-Kodak (Kodak chromatogram sheets silica gel absorbent with fluorescent indicator, catalog no. 122-4294) and Whatman (absorbent plates flexible-backed aluminum polyester, catalog no. 4410-22 (contains fluorescent indicator)).
The Albert et al. article 22 provides a description of analyzing mevinolin, a fungal metabolite employing standard laboratory techniques such as mass spectroscopy, nuclear magnetic resonance and x-ray analysis. These alternative standard laboratory techniques could be utilized to analyze eluted components from an unknown sample.
Upon isolation/separation of the various components in the garlic extract sample by a chromatography method, the inventors then applied the luminescent bacteria to the developed chromatogram. Most preferably, the luminescent bacteria is applied to the developed chromatogram in the form of a suspension contained in a buffered salt solution (about 0.3 M Na + /K + phosphate buffered saline (3% NaCl by weight) pH 7.0).
PROPHETIC EXAMPLE 2
Proposed Chemical Identification of Toxicants In a Garlic Extract
The present prophetic example is provided to outline one proposed method by which the toxicant(s), as identified according to the method of the procedure outlined in Example 1 may be further characterized to identify the chemical structure of the isolated toxicant(s). This method may also be used where additional amounts of the isolated substance are desired or where the purity of the isolated substance is to be determined.
The particular “zones of luminescent inhibition” described above, which provide for the isolation of the component substances (i.e., toxicant) in the test sample, are used as reference points to isolate each component substance from an adjacent spotted sample which was run on the same or a separate TLC plate with the same sample. Unsprayed sections of the TLC plate, which correspond to zones of luminescent inhibition on the sprayed portion, may be scraped off and added to a sufficient volume of an appropriate solvent (i.e., distilled water, acetone, ethanol, ether, ethyl acetate-chloroform or other solvent mixtures) such that the isolated component substance of the sample may become dissolved in the solvent.
Subsequent removal of the solid TLC scrapings from the liquid eluate can be accomplished by various methods known in the art such as centrifugation or filtration. If necessary, the eluates containing dissolved toxicants may then be concentrated using standard techniques. These separated, (and in some cases, concentrated) isolated substances of the sample may be further resolved in other TLC solvent systems (or HPLC, paper chromatography, and the like) to verify purity or to obtain suitably pure isolated substances. These substantially pure isolated substances can then be identified using standard chemical and spectral methodologies. For example, such standard chemical and spectral methodologies include as HPLC, MS, IR, NMR, and the like.
Alternatively, two dimensional (2D) thin layer (TLC) can be run for higher resolution of the sample for more explicit identification of components therein. In the 2D method, a sample is spotted near one corner of the TLC sheet or plate, and run successively in two, usually perpendicular, directions, using different solvent systems or conditions. For example, the sample is chromatographed in the usual way (described above) on the TLC medium in the first direction using solvent system No. 1 (e.g., a basic non-polar system, ammonia:butanol:hexane in a 5:20:75 ratio). The chromatogram, containing components resolved in a linear fashion in this solvent system No. 1, is then to be removed from the chromatography chamber, dried fully to remove solvent molecules of this system No. 1 solvent, and then the thus dried chromatogram is rotated 90° to the orientation first used and chromatographed in the new orientation using a solvent system No. 2 (e.g., a polar, acetic system, such as acetic acid, acetone, ethanol in a 10:50:40 ratio). The components resolved into a linear array by system No. 1 move in the perpendicular direction with the solvent system 2 to provide even greater resolution of individual component substances in the sample.
This same basic approach can be utilized where luminescent bacteria are used to identify isolated component substances of a sample separated by paper chromatography systems, either 1D or 2D. As those in the art will appreciate, in using such systems, there are various ways to achieve separation such that toxicants can be obtained in relatively pure form. For example, another version of 2D paper chromatography may employ electrophoresis in one dimension and gravitational flow paper chromatography or isoelectric focussing in another dimension, or other two-dimension combination thereof (i.e., 1st D=paper chromatography, 2sn D=isoelectric focusing, etc.)
EXAMPLE 3
Identification of Pesticides in Sample With Luminescent Bacteria
The present example is provided to demonstrate the use of the claimed methods and reagents for the identification of a pesticide in a sample of known substances. In this example, the pesticides identified were DIAZANON®, LINDANE® and SEVIN®. The luminescent bacteria used in the present example was Vibrio fischeri (ATCC 7744).
Identification of these individual pesticides and herbicides was achieved essentially according to the same methods described in Example 1. A suspension of Vibrio fischeri in a saline diluent was sprayed, using an aspirator bottle, on the developed chromatograms. Zones of luminescent inhibition appeared surrounding those areas on the plate where the DIAZANON® had migrated. Similar, less dim zones of inhibition, where LINDANE® had migrated (See FIGS. 6 and 7). In a similarly run TLC with SEVIN®, the chromatogram also demonstrated zones of luminescent inhibition at those areas on the chromatogram where SEVIN® had migrated.
FIGS. 3 and 4
These are photographs of the same TLC plate taken by two different conditions: Fluorescence and Bioluminescence, respectively.
Samples: 5 μl samples of ({fraction (1/32)} by DIAZANON®) and (⅛ LINDANE®). The DIAZANON® sample was produced by serial dilution of the commercial diagram (25% w/v) 0,0, diethyl-0-[2-isopropyl-6-methyl-≮-pyrimidinyl] phosphorsthionate, Ortho Products. The DIAZANON® was diluted with ethanol by factors of 2 until a dilution of {fraction (1/32)} commercial strength was reached. The LINDANE® (Ortho Products) was diluted in ethanol from the commercial 20% (w/v) gamma isomer of benzene hexachloride, until a final strength of ⅛ was reached.
Development: Acetonitrile: 25% Aqueous ammonia, 75:25
Results: FIG. 3 represents the results from this study using DIAZANON® and LINDANE® on a TLC plate viewed by 254 nm excitation. A prominent dark zone for DIAZANON® is located at 8.8 cm from bottom of FIG. 3 . About 3 quite faint zones for LINDANE® at 8.2, 9.2, and 10.3 cm from bottom of FIG. 3 are demonstrated. DIAZANON® origin (application spot) at 2.5 cm from bottom of photo, LINDANE® origin at 3.0 cm.
FIG. 4 viewed by bioluminescence from vibrio fischeri . Dark zone for DIAZANON® very close to zone for fluorescence extinction (at about 8.1 cm from photobottom). Several very dark zones for LINDANE® at about 8.0, 8.8, and 10.0 from photobottom. Also seen is slight inhibition zone at origin of LINDANE® sample. The several zones for LINDANE® indicate that several isomers or different inhibition compounds are present in the LINDANE® sample.
EXAMPLE 4
Dilution Series of DIAZANON® on TLC with Vibrio fischeri
The present example is provided to demonstrate the sensitivity of the claimed invention to detect relatively low concentrations of a pesticide. An exemplary pesticide for demonstrating the sensitivity of the assay used here is DIAZANON®.
FIGS. 5 AND 6
Spot tests of DIAZANON® at several dilutions were performed at the following strengths: full strength (25% w/v DIAZANON®), 1:128; 1:256; 1:512; and 1:1024. No chromatography was done. 5 μl samples of the various DIAZANON® dilutions were applied to TLC plate material, sprayed with a suspension of Vibrio fischeri in a saline solution (3% NaCl WT/VOL.) and photographed. Marked inhibition occurred up to and including the D/256 dilution (D/252 appears by clerical mistake on sheet instead of D/256 which was used) of full strength (25% w/v) DIAZANON®. Faint inhibition is seen at dilution 1:512 and dilution 1:1024 (See FIG. 6, R).
The TLC plates with DIAZANON® demonstrate that the methods described herein are sufficiently sensitive to identify a pesticide in a sample at concentrations in which they are likely to occur in a land or water sample obtained in the environment.
EXAMPLE 5
Solvent Polarity and Fluorescent and Bioluminescent Detection of DIAZANON®
The present example is presented to demonstrate the effect of varying the solvent polarity on the detection patterns, or “zones of inhibition” of Vibrio fischeri in the presence of DIAZANON®, a pesticide.
FIGS. 7 and 8 provide photographs of TLC plates viewed by 254 nm irradiation (FIG. 7) and by bioluminescence (FIG. 8 ).
Samples: In each case, 5 μl of (DIAZANON®/8) was applied at origin on left and 5 μl of LINDANE®/8 was applied at right origin.
Development: Three solvent systems used. All composed of Hexane:THF mixtures. In FIG. 7 the left chromatogram was Hex:THF, 70:30 the middle chromatogram was Hex:THF, 80:20 the right chromatogram was Hex:THF, 90:10.
(middle chromatogram contains clerical labeling error of 80 THF:20 HEX, which should be 80 HEX:20THF)
Results: FIG. 7 shows the decrease in polarity as the proportion of THFs lowered causes the DIAZANON® and faint LINDANE® spots or zones to be progressively diminished in mobility; to have smaller R f values; to migrate shorter distances from the origin.
FIG. 8 shows only the left-hand and right-hand TLC plates seen in FIG. 9 . Dark bioluminescence zones of inhibition are seen in Photo 8 for DIAZANON® and LINDANE® samples.
EXAMPLE 6
Identification of Pesticides and Herbicides in a Sample With Luminescent Bacteria
The present example is provided to demonstrate the use of the claimed methods and reagents for the identification of pesticides and herbicides in a known test sample using a luminescent biological agent.
In this example, the herbicides ROUNDUP® and WEED-B-GON® and the pesticides DIAZANON® and LINDANE® are identified in a test sample with the luminescent bacteria, Vibrio fischeri (ATCC 7744).
EXAMPLE 7
Identification of Herbicides and Pesticides
Each sample was run on an individual TLC sheet. Photographs of the resulting 4 individual chromatograms are presented at FIG. 9 (room light) and FIG. 10 (Bioluminescence—chromatogram with luminescent bacteria).
Two solvent systems were used. The solvent systems used to identify the herbicides (ROUNDUP® and WEED-B-GONE®) was 100% ethanol. A 5 ml sample of an 8-fold dilution of these commercially available herbicides was used in the spotting of the TLC plates.
The solvent system used for the pesticides DIAZANON® and LINDANE® was Hexane:THF, 90:10. The pesticides were spotted at a concentration of 1.8. A 5 ml sample of an 8-fold dilution of these commercially available pesticides was used in the spotting of the TLC plates.
Two solvent systems were employed as no single system has yet been found to adequately resolve all compounds (i.e., the two pesticides and the two herbicides). Use of 100% ethanol causes DIAZANON® and LINDANE® to run at the front of the solvent system. Use of 90% Hexane, 10% THF causes ROUNDUP® and WEED-B-GONE® to stay at the origin. The TLC plates photographed are in the following order (left to right) (one sample per plate): DIAZANON®, LINDANE®, ROUNDUP®, and WEED-B-GONE®. In each case, the commercial strength was diluted by a factor of 8.
Results:
a. Pesticides
The DIAZANON® sheet did present an entirely distinct “zone of inhibition”, but the FIG. 10 only marginally indicates this characteristic, perhaps due to partial bacteria dehydration. The LINDANE® chromatogram presented as a distinct zone of inhibition culminating in a dark spot center about 2.9 cm from the bottom of the plate.
The ROUNDUP® chromatogram presented a clear zone of inhibition as seen at the origin, and at least one other inhibition zone centered at 4.5 cm from the bottom of the plate. The WEED-B-GONE® chromatogram presented as a large oval zone of luminescent inhibition (perhaps comprised of several components) starting at about 1.8 cm from the bottom of the TLC plate and stretching to beyond 6 cm from the bottom of the plate.
EXAMPLE 7
Identification of Herbicides and Pesticides
The following example presents the results of three separately run experiments by the Inventors. These data demonstrate the reliability of the described methods for consistently identifying a component substance in a sample. The following list represents a description of the particular herbicides and pesticides, and the percent dilutions used thereof, in the described 3 separately run TLC plates.
WEED-B-GON®
10.8% w/v dimethylamino salt of 2,4 dichlorophenoxyacetic acid 11.6% w/v dimethylamino salt of 2-(2-methyl-4 chlorophenoxy)propionic acid
DIAZANON®
25% w/v O,O,diethyl-O-[2-isopropyl-6-methyl-4-pyrmidinyl]phosphorothio(n)ate
ROUNDUP®
41% w/v isopropylamino salt of glycophosphate N-(phosphoromethyl)glycine
LINDANE® (bark and leaf mineral spray)
20% w/v gamma isomer of benzene hexachloride liquid
LIQUID SEVIN® CARBAMYL
27% w/v 1-naphthyl-N-methyl carbamate
The following table presents the results obtained for identifying DIAZANON®, LINDANE®, ROUNDUP®, and WEED-B-GON® in three different tests conducted by the Inventors. These data demonstrate that the described method provides a system which possesses the ability to detect, with varying sensitivity, a variety of herbicides or pesticides in a sample on a consistent and reliable basis, as demonstrated by the closely corresponding “spots” for each run of the same component substance between the three separately run chromatograms.
TABLE 1
Dis-
Ratio of
Herbicide/
tance
Spot
Spot
Spot
Front
Stan.
Pesticide
of Front
1
2
3
Fluor
Biolu
Dev.
Test 1
DIAZANON ®
2.38
0.63
—
—
0.26
0.26
0.02
LINDANE ®
2.38
.88
1.38
1.66
0.37
0.37
0.02
0.58
0.57
0.00
0.70
—
ROUNDUP ®
2.36
0.00
0.13
1.38
0.00
0.00
0.00
0.06
—
—
0.58
—
—
WEED-B-GON ®
2.36
0.66
1.64
1.88
0.28
0.28
0.02
0.69
0.69
0.04
0.80
—
—
Test 2
DIAZANON ®
2.75
0.68
—
—
0.26
0.25
0.01
LINDANE ®
2.19
0.83
1.23
1.55
0.38
0.35
0.03
0.56
0.57
0.00
0.70
—
—
ROUNDUP ®
2.00
0.00
0.12
1.22
0.00
0.00
0.00
0.06
—
—
0.61
—
—
WEED-B-GON ®
2.25
0.65
1.35
1.79
0.28
0.28
0.020
0.66
0.66
.01
0.80
—
—
Test 3
DIAZANON ®
2.79
0.68
—
—
0.24
0.24
0.00
LINDANE ®
2.09
0.83
1.23
1.59
0.39
0.40
0.01
0.58
0.60
0.03
0.73
—
—
ROUNDUP ®
2.13
0.00
0.21
1.29
0.00
0.00
0.00
0.10
—
—
0.60
—
—
WEED-B-GON ®
1.84
0.38
1.17
1.55
0.21
0.21
0.05
0.64
0.63
0.02
0.84
—
—
R f Values Represented in the Reported Values in the Table;
R f = relative to the front; a fractin of the total distance which the solvent front migrated.
PROPHETIC EXAMPLE 8
Proposed Identification of Heavy Metal Salts In a Sample With Luminescent Bacteria
The present prophetic example is provided to present a use of the claimed methods and reagents for the identification of a heavy metal in a sample. Specifically, the Inventors hypothesize that the described methods would be useful in the identification of the heavy metals such as mercury, lead and cadmium using the described luminescent biological reagents, such as the bacteria, Vibrio fischeri (ATTC Acc. No. 7744).
In the present example, the Inventors spotted the various metals on to a chromatography paper sheet, but did not run them through a chromatography separation process. Upon spotting of the various metals along one side of a chromatography paper sheet, the sample spots were allowed to dry. Upon drying, the spotted sheets were exposed to the luminescent bacteria Vibrio fischeri . Employing this method, the Inventors were able to visualize the presence of the heavy metal salts of mercury, lead, and cadmium.
To isolate the heavy metal spotted on the chromatography paper, the paper edge at which the sample was spotted should be exposed to a solvent system, most preferably an acidic solvent system.
Specific reference is made here to the RAININ® catalog 29 , wherein a standard technique (for the separation of heavy metals) is described using an ion chromatography metals column. Resolution of Pb ++ and Cd ++ is demonstrated in the reference RAININ® catalog.
Successive equal volumes of a heavy metal could be eluted using the HPLC procedure from the HPLC machine and spotted in an array or in a linear fashion on a sheet of (Whatman) chromatography paper. After the carrier solvent is evaporated or otherwise removed by drying, the sheet could be sprayed with a suspension of luminescent bacteria, such as Vibrio fischeri , as described. Zones of bioluminescent inhibition could be similarly visualized to identify the metal.
PROPHETIC EXAMPLE 9
Proposed Chemical Identification of a Toxicant In a Sample Isolated With Bioluminescence Methods
The present prophetic example is provided to outline a proposed method whereby the identified region provided on a chromatography sheet with the described luminescent agent, particularly a luminescent bacteria may be analyzed to ascertain the chemical identity of an isolated component substance of a sample.
A volume of sample containing sufficient concentration of toxicants would be applied to a chromatography paper, such as Whatman 1M or 3M and chromatographed using a solvent system which provides maximum separation of the sample components. Various solvent systems may be utilized and tested for separation efficiency as well understood by those skilled in the art. Small amounts of sample may be used to test for improved resolution in one dimensional (1D) chromatography solvent systems. Those solvents found most effective may then be utilized for larger scale separation on large sheets of chromatography paper for two-dimensional chromatography (2D).
Two dimensional chromatography may be necessary to resolve sample ingredients for subsequent identification of substantially pure compounds. By determining a combination of two solvent systems which effectively resolve the component toxicants, 2D chromatography can be run in duplicate.
Following the chromatography, the luminescent bacteria may be sprayed onto one of two identical sample sheets. Areas on the sheet which demonstrate a decreased luminescence would then be used to mark the corresponding areas of the unsprayed sheet. The corresponding areas on the unsprayed sheet are cut out and eluted with distilled water, appropriate solvents such as acetone or ethanol or a solvent mixture to provide individual, substantially pure toxicants for identification. This procedure can be repeated, and/or multiple 2D sheets may be run simultaneously, in order to accumulate sufficient quantities of various substantially pure toxicants.
In this manner, appropriate amounts of toxicants in a sample may be separated and then identified using standard chemical procedures. For example, small amounts of the purified component substances may be run on high pressure liquid chromatography (HPLC) and compared to known standards for identification 15 . As will be appreciated by those skilled in the art, additional standard techniques used for chemical identification may be employed such as spectral analysis: Mass spectra, infrared spectra (IR), nuclear magnetic resonance (NMR), and the like.
It will understood by those skilled in the art that multiple 2D chromatography sheets can be run simultaneously in which different sheets are sprayed with different luminescent bacteria. This would provide a more thorough analysis of toxicants which may be detectable by one luminescent bacterium, but not by another. Additionally, combinations of different luminescent bacteria in one spray solution may facilitate the thorough identification of most or all of the detectable isolated component substances in a sample. In this manner, a thorough analysis and identification of toxicants in a sample may be undertaken.
Essentially this same approach can be taken using thin layer chromatography (TLC), instead of paper chromatography as described above, for the initial separation and identification of toxic substances in a sample. Multiple TLC plates (e.g., Whatman 4856-840 with 1,000 μM silica layer) may be run simultaneously in the same solvent system-utilizing 1D or 2D runs, as described above, for paper chromatography. In such a TLC approach to toxicant identification, toxicants would be identified by spaying the plates with luminescent bacteria, marking the zones of decreased luminescence, and scraping off the corresponding areas on the unsprayed portions of plates. The scrapings are then eluted with an appropriate solvent, such as distilled water, acetone or ethanol or a solvent mixture, concentrated (if required), and identified using HPLC, MS, IR, NMR, and the like.
By following either of the above procedures, the separation and identification of toxicants in a sample can be accomplished simply and rapidly. The standardization of this method to be used for the identification of toxicants in certain types of samples will be appreciated by those skilled in the art as providing simple, rapid, and inexpensive methodologies for toxicant identification. For example, certain types of samples (i.e., industrial effluent) could be tested to determine the initial separation system, the solvent systems, the luminescent bacteria (or combinations of luminescent bacteria), the elution protocol, and any subsequent techniques for quantitation and/or identification.
Through the use of standard curves of easily quantitated known compounds, the percent recovery in a given separation system can be determined. In this manner, amounts of identified toxicants can be quantitated and extrapolated back to the original sample volume applied. For example, the use of radiolabeled compounds, of known specific activity, which are separated by paper or TL chromatography, eluted, and counted for radioactivity, would provide an indication of the percentage recovery of a given compound. By comparing various radiolabeled chemical compounds in a given identification system (paper or TLC with different solvents and the like), one could correct for recovery losses of a given identification system.
When the separated toxicants are quantitated by certain chemical and spectral methods, the quantities may then be extrapolated to determine the quantities of individual toxicants present in the original sample. Thus, this method, in many cases, would allow for toxicant quantification.
These steps could be standardized into kits tailored for the analysis of specific types of samples (i.e., a kit for a certain industrial effluent or certain biological samples, such as foodstuffs, pharmaceuticals, and the like). These kits would comprise certain solvents and luminescent bacteria which would effectively resolve specific sample types thereby greatly simplifying and reducing the cost of toxicant detection, identification, and quantitation.
Alternatively, an unknown sample may be processed by the above procedure for identification and quantitation.
PROPHETIC EXAMPLE 10
Identification of Toxicant in a Gaseous Phase Sample With Luminescent Bacteria
The present prophetic example is provided to outline a proposed method whereby an investigator may identify a toxicant present in a gaseous phase sample employing the methods with luminescent bacteria described herein.
As an initial step, the gaseous sample would be collected by techniques known to those skilled in the art. For example, a gas sample might be collected by filtration through a solid filter such that toxicants deposit onto the filter or by aspiration into a liquid such that toxicants dissolve in the liquid. In the case of a solid filter, the filter could then be eluted with distilled water or a suitable solvent, concentrated, chromatographed by paper or thin layer chromatography, and identified using certain luminescent bacteria as described in Example 6.
PROPHETIC EXAMPLE 11
Identification of a Toxicant on a Solid Surface Sample With Luminescent Bacteria
The present prophetic example is provided to outline a proposed method whereby a toxicant on a solid surface sample may be identified with the described luminescent bacteria.
As in Example 7, methods for removing a toxicant from a solid surface so that it is collected in a concentrated liquid form will vary depending on the nature of the solid surface. Techniques for such removal will be apparent to those skilled in the art. Using the procedures outlined in Example 6, one skilled in the art would be capable of identifying and quantifying toxicants which were eluted from or removed from the solid surface. Alternatively, for direct detection of toxicants, the solid surface could be sprayed with a certain luminescent bacteria, or mixture of more than one luminescent bacteria, such as Vibrio fischeri and the surface observed for zones of decreased luminescence (i.e., zones of luminescent inhibition) substantially as has already been outlined in Example 1. Of course, these isolated component substances of the sample (potential toxicants) could then be chemically analyzed according to laboratory techniques well known to those of skill in the art to identify the chemical structure of the isolated component. By way of example, such laboratory techniques for determining the chemical structure of an isolated component substance include HPLC, MS, IR, NMR, and the like.
PROPHETIC EXAMPLE 12
Proposed Test Kits for Identifying Toxicants in a Sample
The present prophetic example is provided to define those components which would comprise a proposed test kit useful for the identification of toxicants in a sample. Such a kit most preferably would comprise a carrier means adapted to receive at least two container means and at least one chromatography paper sheet in close confinement therewith. The kit should also include at least one chromatography paper sheet and a first container means comprising a luminescent bacterial agent. While any luminescent bacterial agent may be used in conjunction with the described kit, that bacterial agent most preferred is the Vibrio fischeri (ATTC Acc. No. 7744). Most preferably, the luminescent bacterial agent should be in lyophilized form in the container means. The lyophilized bacteria would then be suspended in a diluent solution. For example, where appropriate NaCl concentrations are within the lyophilized sample, deionized water may be employed as the diluent solution without any expected deleterious effects to the luminescence of the bacteria.
In a second container means, the kit should further comprise a diluent for a luminescent bacterial agent. Most preferably, the diluent should comprise a 0.5 M NaCl buffered saline solution at pH 7 where the bacteria is a marine bacteria and has not been lyophilized to include NaCl. The kit may optionally also include a separation solvent, such as acetonitrile, deionized water, or aqueous ammonia.
In other proposed forms of the presently proposed kit, the kit may further comprise an aspirator spray bottle to facilitate the easy application of suspended luminescent bacteria to a separation phase matrix such as a TLC plate or chromatography paper, chromatogram. In addition, the kit may comprise several vials of lyophilized luminescent bacteria. In other proposed forms of the presently proposed kits, the kit may further comprise instructions for the suspension and application of the luminescent bacteria to facilitate visualization of the isolated component substances of the test sample, and also in regard to the reaction time to be allowed and at what point the luminescent bacteria-exposed separation phase matrix should be read.
BIBLIOGRAPHY
The following references are specifically incorporated herein by reference in pertinent part.
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9 . Thin Layer Chromatography: A Laboratory Handbook 2nd ed, E. Stahl, Ed., Springer-Varlag, New York, N.Y., (1967).
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30 . Bioluminescence and Chemiluminescence: Basic Chemistry and Analytical Applications , Marlene A. DeLuca and William D. McElroy, eds., Academic Press (1981)
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33. J. W. Hastings and G. Weber (1963), J. Opt. Soc. Am ., 53:1410. | Methods for the isolation and identification of a toxicant in a sample are disclosed. Luminescent biological agents (i.e., bacteria) having sensitivity to a toxicant or an isolatable component in a sample are used to provide visually discernable zones of luminescent inhibition in the presence of a toxicant (or) in the presence of an isolatable sample component as separated by paper or thin layer chromatography. Kits for use in conjunction with the identification of a toxicant in a sample are also described, which include a luminescent biological reagent as the visualizing agent. Particular examples of luminescent bacterial agents useful in the practice of the present invention include Photobacterium leoganthi, Photobacterium phosphoreum, Vibrio fischeri, Vibrio harveyi a luminescent fungi, a luminescent fish extract, a luminescent dinoflagellate and fluorescent microorganisms, such as Cypridina. Potential toxicants, in a liquid sample, a solid sample, or in a gaseous sample may be identified and further chemically characterized using the described methods. The isolation of potential toxicants in a sample through the processing of a sample through a separation phase matrix such as chromatography paper or TLC plate, followed by exposure to luminescent biological agent, provides for a rapid and inexpensive method for identifying pesticides, herbicides and heavy metals in a known or unknown sample. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority to and is a divisional of U.S. patent application entitled, CABLE DETECTION APPARATUS AND METHOD, filed Mar. 31, 2003, having a Ser. No. 10/402,143, now U.S. Pat. No. 6,977,508, the disclosure of which is hereby incorporated by reference in its entirety.
FIELD OF THE INVENTION
The present invention relates to reduction of noise in cable detection systems.
BACKGROUND OF THE INVENTION
Before commencing excavation or other work where power or other cables may be buried, it is important to determine the location of the cables to ensure that they are not damaged during the work. It is also useful to be able to track the path of buried or otherwise inaccessible power cables. It is known to use detectors that detect the electromagnetic field emitted by power cables carrying alternating currents.
The electromagnetic field emitted by a power cable has a fundamental frequency equal to the frequency of the alternating current carried by the cable. However, harmonic frequencies (multiples in frequency) of this fundamental frequency are generally also emitted. The harmonics are emitted at two, three, four, etc times the fundamental frequency. The second, fourth, sixth etc harmonics are called even harmonics, and the third, fifth, seventh etc harmonics are called odd harmonics. Frequencies that are neither even, odd harmonics nor the fundamental frequency are non-harmonic frequencies.
Cables that do not directly carry currents may also be detected by power currents, as neighbouring power cables, and even overhead power lines can induce signals at power cable frequencies and harmonies thereof onto these cables. Ground return currents from appliances can also travel along non-power cables.
Electromagnetic signals emitted from power and other cables are useful in detecting power and/or other cables because the detector need not be connected to the cable to be located, and the signals are emitted by the cable without any additional reference signal needing to be added to the current flow. In other words, the cable can be in use while it is being detected, and it need not be isolated. Therefore, a passive sensor or detector may be used to detect the cable, and the power consumption of the detector is reduced. However, use of electromagnetic fields in detection can be compromised by high levels of noise being detected along with the signal from the cable to be located. In the present invention, noise relates to spurious, non-periodic noise, and periodic noise outside the frequencies emitted by the object to be located. Such noise problems decrease the accuracy of detection and location, and are therefore undesirable. There is therefore a need to reduce the effects of noise in detected signals, for example in order to more accurately detect/locate buried objects.
SUMMARY OF THE INVENTION
According to a first aspect of the invention, there is provided a cable detection or location device comprising a filter that can reduce the effects of interference on an electromagnetic field emitted from a buried, underground or otherwise inaccessible object. The filter filters the signal received at the device, and suppresses certain frequency components. Non-harmonic frequencies of the frequency of the alternating current carried by the cable to be detected/located (the fundamental frequency) are suppressed. The system therefore reduces noise that is non-periodic, and frequencies of the detected signal that do not correspond to part of the signal emitted from the cable to be detected. The signal to noise ratio can therefore be increased in a detector.
It has also been noticed by the inventors that the signal emanating from a typical three-phase power cable has a spectrum that contains most energy in the odd harmonics of the fundamental frequency of the alternating current, with little energy in the even harmonics of the fundamental frequency. This is because even harmonics are caused by part rectification of the alternating current, which is avoided by electricity providers and generators. Manufacturers of electrical appliances also manufacture them so that they do not draw a part rectified current when operating. Therefore, in an embodiment of the invention, even harmonics are suppressed by the filter as well as non-harmonic frequencies. A high proportion of noise added to an electromagnetic signal will be spread across the frequency spectrum, and so retaining only the fundamental frequency and odd harmonics thereof will filter out a high proportion of the noise. However, this will retain a high proportion of the signal, and so increase the signal to noise ratio in the invention.
In an embodiment of the invention, two filters are provided, one of which removes non-harmonic noise, and the other of which removes non-harmonic noise and even harmonics of the fundamental frequency. The fundamental frequency may be 50 Hz or 60 Hz, or another frequency, as appropriate. In an embodiment of the invention there are provided a plurality of filters that remove non-harmonic noise. In an embodiment of the invention there are provided a plurality of filters that remove non-harmonic noise and even harmonics of the fundamental frequency. In an embodiment of the invention there are a combination of two types of filter (removing non-harmonic noise, and removing non-harmonic and even harmonic noise) arranged in series to progressively filter the detected signal. In an embodiment of the invention, at least one comb filter is used in the filter of the device.
In an embodiment of the invention, as well as use of a passive detector to locate power cables, one or more active sensors may also be used. The active sensors, or EMS emitters, emit electromagnetic signals at one or more predetermined frequencies, which are received by EMS (Electromagnetic Marker System) markers, which are commonly buried in the ground. When irradiated with an electromagnetic field at certain frequencies, EMS markers resonate and re-radiate an electromagnetic field at the same frequency as the irradiation frequency. This re-radiated signal is then detected by an EMS detector. The EMS detector may be a separate detector to that used for the passive sensing, although it may be housed in the same unit as the passive sensor.
The EMS detector can then detect the EMS markers, which are commonly used to mark the location of cables, such as non-metallic cables, and to mark specific points in the ground. EMS markers that mark different types of buried object can be made to resonate at different frequencies, so that by detecting the re-radiated field at a certain frequency, the location of a specific type of marker, and therefore a specific type of buried object, can be found. The emission of such fields from the EMS emitter could interfere with the passive sensing, in effect, generating electromagnetic noise. However, by choosing emission frequencies that coincide with the high attenuation frequencies of the filter of the device, the emitted radiation for the active locate of the device does not interfere with the passive location of power cables, because the emitted signal detected by the passive system is filtered out by the filter of the device. Therefore both passive and active locate modes can detect objects at the same time.
In an embodiment, the apparatus outputs audio signals, representing the filtered signals, at a frequency corresponding to a high attenuation frequency of the apparatus, which will then not be fed back into the apparatus, so reducing interference in the system.
There has thus been outlined, rather broadly, certain embodiments of the invention in order that the detailed description thereof herein may be better understood, and in order that the present contribution to the art may be better appreciated. There are, of course, additional embodiments of the invention that will be described below 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 embodiments in addition to those described and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein, as well as the abstract, are for the purpose of description and should not be regarded as limiting.
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.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the invention will now be described, purely by way of example, with reference to the accompanying drawings, in which:
FIG. 1 shows a filter for use in a cable detection apparatus according to a first embodiment of the invention;
FIG. 2 shows a typical frequency response for the filter of FIG. 1 ;
FIGS. 3 a and 3 b show further filters for use in a cable detection apparatus according to a second embodiment of the invention;
FIG. 4 shows a typical frequency response for the filter of FIG. 3 ;
FIG. 5 shows a filter system comprising a number of filters of FIGS. 1 and 3 ;
FIG. 6 shows an alternative filter system comprising a number of filters of FIGS. 1 and 3 ;
FIG. 7 shows a typical frequency response for the filter systems of FIG. 5 and FIG. 6 ;
FIG. 8 shows a schematic diagram of a device incorporating a filter system according to any of FIGS. 3 , 5 or 6 ;
FIG. 9 shows a schematic diagram of a further device incorporating a filter system according to any of FIGS. 3 , 5 , 6 , or 8 ; and
FIG. 10 shows a schematic diagram of a further device incorporating a filter system according to any of FIGS. 1 , 3 , 5 or 6 .
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows a type 1 comb filter 100 for use in a cable detection apparatus according to a first embodiment of the invention. The filter comprises a time delay unit 110 , and an adder 130 . In the present embodiment, a signal input into the filter 100 comprises multiple frequency components. The input signal is split; half is delayed by a time internal Δt′ by the time delay unit 110 before being output to the adder 130 , while the other half is input directly into the adder 130 . The adder 130 outputs the sum of the two inputs and therefore has a peak in transmittance when the time delay is an exact multiple of the cycle length or period, of the input signal.
An optional high pass filter 140 is also included. The high pass filter removes D.C. signals. In an embodiment, the high pass filter also removes the fundamental frequency of the signal passed through the filter 100 . The filter 140 may alternatively be omitted.
A typical frequency response of the type 1 filter at point A is given in FIG. 2 . The frequency response gives peaks in transmission when the time delay (Δt′) is equal to the period of the signal and at multiples thereof. The high pass filter, if employed, removes the frequency response peaks at 0 Hz (i.e. D.C.) and at 1/Δt′Hz.
FIG. 3 a shows a schematic of a type 2 comb filter 200 a , used in a device for detection of cables according to a second embodiment of the invention, which can be used either on its own or with one or more type 1 comb filters according to embodiments of the present invention. The filter 200 a comprises a time delay unit 210 to receive an input signal, an inverter 220 connected to the time delay unit 210 , and an adder 230 a connected to the inverter 220 and also to receive the input signal.
The type 2 filter 200 a operates by firstly receiving and splitting an input signal. The type 2 filter 200 a differs from the type 1 filter 100 in that it has an inverter 220 .
In the present embodiment, the signal comprises multiple frequency components. The input signal is split to the time delay unit 210 , as well as directly to the adder 230 a . The inverter 220 receives the output from the time delay unit 210 and inverts the signal received by it (multiplies it by −1) and outputs the inverted signal to the adder 230 a . The adder 230 a outputs the sum of its two inputs. The adder 230 a therefore has peak transmittance at frequencies where the time delay of Δt causes the signal output from the time delay unit 210 to be the inverse of that input into the time delay unit 210 as, at such frequencies, the signal inverted by the inverter 220 is restored by the time delay unit 210 and is the same as the signal supplies directly to the adder 230 a.
An alternative type 2 filter 200 b shown in FIG. 3 b omits the inverter, and the adder 230 a is replaced by a subtractor 230 b . The subtractor 230 b , instead of summing the two signals received by it, subtracts the delayed signal from the time delay unit 210 from the direct signal received. This arrangement also gives a type 2 filter for use in a cable detection apparatus according to an embodiment of the invention.
An optional high pass filter 240 is employed in embodiments of the invention with type 2 filter 200 a , 200 b shown in FIGS. 3 a and 3 b . The high pass filter 240 filters out the fundamental frequency (½Δt) from the signal output from the filter 200 a , 200 b . The filter 240 may alternatively be omitted.
FIG. 4 shows a typical frequency response for the type 2 filter 200 a , 200 b at point B. In the present embodiment, the time delay unit 210 imparts a time delay (Δt). The filter 200 a , 200 b has peak attenuation where the time delay (Δt) is the same as the period of the input signal, or a multiple thereof. There are peaks in transmission at frequencies corresponding to half way between the peak attenuation frequencies.
If, for example, the type 1 and type 2 filters were arranged to have the same time delay, the type 1 filter 100 would give peak transmission at frequencies where the type 2 filter 200 a , 200 b gave peak attenuation and vice versa.
If, however, different time delays are used for the type 1 and type 2 comb filters, different frequency attenuation profiles can be obtained. A time delay (Δt′) in the type 1 filter of FIG. 1 of 20 ms will have high transmittance at a frequency of 50 Hz and all harmonics thereof, as shown in FIG. 2 . Between the peak transmission frequencies are peak attenuation frequencies. The type 1 filter can therefore remove non-harmonic noise from a signal detected by a cable detection apparatus.
The filter 200 a , 200 b is arranged to filter signals from a cable carrying alternating current at 50 Hz, corresponding to use in the United Kingdom. A time delay of 10 ms is used. A filter in a device for detecting cables carrying alternating current at 60 Hz, for example in the United States of America, the time delay (Δt) would be 8.3 ms, and all following calculation would follow from that calculated time delay.
Using such a time delay, the filter 200 a , 200 b has peaks in attenuation at all even harmonics of the fundamental frequency (50 Hz) of the alternating current in the cable to be detected. The filter 200 a , 200 b has peaks in transmission at the fundamental frequency and all odd harmonics thereof. As has been discussed above, most of the signal in typical 3-phase alternating current carrying cables is in the odd harmonic frequencies. Therefore, by removing some or all even harmonic frequencies, the noise levels from non-periodic interference, and interference at even harmonic frequencies is reduced, while transmitting the fundamental and odd harmonic frequencies of the signal. The signal to noise ratio is therefore improved. The fundamental frequency is also suppressed in the case where a high pass filter 240 is used.
FIG. 5 shows a filter system according to a third embodiment of the invention. The filter system comprises a first and second type 1 comb filter 510 and 520 , of the type discussed above, and a first and second type 2 comb filter 530 and 540 , as discussed above, cascaded, i.e. connected in series. In embodiments of the invention, a single type 1 filter 100 can be used with a single type 2 filter 200 a , 200 b . Use of the two filters together will result in reduction of even harmonics and increased removal of non-harmonic noise, compared with use of a single type 1 filter. Alternatively, multiple type 1 and/or type 2 filters can be used in combination, which will lead to an increased removal of non-harmonic and even harmonic noise.
As discussed above, the type 1 filters have a time delay (Δt′) of 20 ms. The type 2 filters have a delay (Δt) of 10 ms. The filters are thus tuned have peak transmittance at a fundamental frequency of 50 Hz. The type 1 filters reduce non-harmonic noise, and the type 2 filters then reduce the even harmonics of the fundamental frequency as well as non-harmonic noise. This corresponds to detection of cables carrying alternating current at 50 Hz, as stated above. For detection of currents at 60 Hz, the type 1 filters 510 and 520 could have a time delay Δt′ of 16.6 ms, and the type 2 filters 530 and 540 a delay Δt of 8.3 ms.
FIG. 6 shows an alternative cascade system arrangement, which also reduces the non-harmonic noise and even harmonics of the fundamental frequency. The second type 1 filter is replaced with a type 2 filter. Either cascade system will produce a frequency response similar to that shown in FIG. 7 . Other combinations of such filters are also possible in order to achieve the desired filter effect. As shown in FIG. 7 , the ratio of gain of non-harmonic, or even harmonic, frequencies output from the cascade system, to the gain of the fundamental frequency and odd harmonics is increased from the use of a single type 2 filter, and greatly improved over the input signal. The signal to noise ratio is therefore improved. FIG. 7 shows a frequency response for detection of cables in both the United Kingdom and the U.S.A., i.e. detection of cables carrying either 50 Hz or 60 Hz alternating current. If one or more of the optional high pass filters 140 , 240 are employed, the peak at the fundamental frequency may be removed and only odd harmonic frequencies are transmitted through the cascade filter system.
FIG. 8 shows a schematic diagram of a cable detection device of a further embodiment of the present invention in which a filter system as described above is used, together with an audio indication system. The device comprises an antenna 810 for receiving signals from a power cable or a cable with power currents induced on it, a low pass filter 815 , a filter system 820 , as described above, to filter the received signal, a multiplier 830 connected to an oscillator 840 for frequency shifting the filtered signal, an amplifier 850 for amplifying the frequency shifted signal before being output from a loudspeaker 860 .
The detected signal from an antenna 810 in the device is input into the low pass filter 815 , to remove frequency components above a predetermined frequency. In the present embodiment, the predetermined frequency is set to be 1 kHz. However, it will be appreciated that the value of the predetermined frequency will be determined in relation to the value of the fundamental frequency that is to be detected. If the fundamental frequency to be detected is higher than 50 Hz, the predetermined frequency can be adjusted appropriately.
The low pass signal is then input into the filter system 820 . The filter system 820 reduces non-harmonic and even harmonic content of the signal. If one of more optional high pass filters 140 , 240 are employed, the fundamental frequency may also be removed. The signal output from the filter system 820 is then input into a multiplier 830 . As well as the filtered signal, the multiplier 830 also receives an input from an oscillator 840 . The oscillator oscillates at a frequency determined to frequency shift the signal so that high attenuation frequencies of the signal are shifted to high transmittance frequencies of the signal after frequency shifting. In the present invention, the oscillator is set to input a frequency signal of 975 Hz into the multiplier. The multiplier then multiplies the filtered signal to produce an audio frequency signal. However, in addition to the signal being audio frequency, because only odd harmonics are transmitted through the filter system, the frequency shift is such that any noise from the audio stage being fed back into the detector and filter system will be shifted from an odd harmonic to an even harmonic of the fundamental frequency. Therefore, the filter system will filter out this feedback, and the audio stage does not provide interference in the detected signal.
According to a further embodiment of the invention, the filter system making use of at least one type 2 filter may be used in conjunction with an EMS marker system emitter. The same principle as in previous embodiments is used in this embodiment. Such an embodiment is shown in FIG. 9 . The system comprises a filter 910 according to any of the embodiments with a type 2 filter, an electromagnetic emitter 920 and an EMS detector 925 .
The emitter 920 is set to emit a burst frequency of radiation that is an even harmonic of the alternating current frequency in a cable 940 to be detected. All harmonics of this even harmonic burst frequency will, in turn, be even harmonics of the frequency carried by the cable 940 . Therefore, by emitting radiation bursts at an even harmonic frequency of the alternating current on the cable 940 , the emitted radiation from an active locator will be attenuated by the filter system 910 and will not interfere with detection of the cable 940 . This allows both modes of location (active and passive) to be operating at the same time, even within the same device, so that a cable 940 can be tracked, while the EMS detector 925 also scans for EMS markers 930 denoting other features in the vicinity of the cable 940 . Alternatively, an EMS marker 930 may be located, and then, while still keeping a reference of the position of the EMS marker 930 , any power cables 940 in the vicinity of the device can be detected.
FIG. 10 shows a basic cable detection apparatus according to embodiments of the invention. The apparatus comprises a filter system 1010 as described above, which receives cable detection input signals from an electromagnetic detection device 1020 . The filter system 1010 outputs filtered signals to an indicator 1020 , which indicates the detection of a cable based on the detected signal.
The present invention has been described particularly in relation to comb filters, and particular arrangements and combinations of comb filters. However, it should be noted that the invention is not limited to these particular arrangements and combinations, but that any filter system giving a result of attenuating the non-harmonic signals or even harmonics of one or more fundamental frequencies are within the scope of the invention.
The present invention can be implemented in hardware, software, firmware, and/or combinations thereof, including, without limitation, gate arrays, programmable arrays (“PGAs”), Field PGAs (“FPGAs”), application-specific integrated circuits (“ASICs”), processors, microprocessors, microcontrollers, and/or other embedded circuits, processes and/or digital signal processors, and discrete hardware logic. The present invention can be implemented with digital electronics, with analogue electronics and/or combinations of digital and analogue electronics.
The present invention has been described above purely by way of example, and modifications can be made within the spirit of the invention. The invention has been described with the aid of functional building blocks and method steps illustrating the performance of specified functions and relationships thereof. The boundaries of these functional building blocks and method steps have been arbitrarily defined herein for the convenience of the description. Alternate boundaries can be defined so long as the specified functions and relationships thereof are appropriately performed. Any such alternate boundaries are thus within the scope and spirit of the claimed invention. One skilled in the art will recognise that these functional building blocks can be implemented by discrete components, application specific integrated circuits, processors executing appropriate software and the like or any combination thereof.
The invention also consists in any individual features described or implicit herein or shown or implicit in the drawings or any combination of any such features or any generalisation of any such features or combination, which extends to equivalents thereof. Thus, the breadth and scope of the present invention should not be limited by any of the above-described exemplary embodiments. Each feature disclosed in the specification, including the claims, abstract and drawings may be replaced by alternative features serving the same, equivalent or similar purposes, unless expressly stated otherwise.
Any discussion of the prior art throughout the specification is not an admission that such prior art is widely known or forms part of the common general knowledge in the field.
Unless the context clearly requires otherwise, throughout the description and the claims, the words “comprise”, “comprising”, and the like, are to be construed in an inclusive as opposed to an exclusive or exhaustive sense; that is to say, in the sense of “including, but not limited to”. | A cable detection apparatus is disclosed having a filter, the filter transmitting components of a signal detected substantially at certain harmonics of a first frequency. The filter may also attenuate the signal at certain even harmonics thereof. A method of detecting and/or locating cables in the same manner is also disclosed. | 6 |
TECHNICAL FIELD
The present disclosure relates in general to information handling systems, and more particularly to systems and methods for current sharing between a power supply unit and a battery back-up unit in an information handling system.
BACKGROUND
As the value and use of information continues to increase, individuals and businesses seek additional ways to process and store information. One option available to users is information handling systems. An information handling system generally processes, compiles, stores, and/or communicates information or data for business, personal, or other purposes thereby allowing users to take advantage of the value of the information. Because technology and information handling needs and requirements vary between different users or applications, information handling systems may also vary regarding what information is handled, how the information is handled, how much information is processed, stored, or communicated, and how quickly and efficiently the information may be processed, stored, or communicated. The variations in information handling systems allow for information handling systems to be general or configured for a specific user or specific use such as financial transaction processing, airline reservations, enterprise data storage, or global communications. In addition, information handling systems may include a variety of hardware and software components that may be configured to process, store, and communicate information and may include one or more computer systems, data storage systems, and networking systems.
An information handling system may include one or more power supply units for providing electrical energy to components of the information handling system. Typically, a power supply unit is configured to operate from an input alternating current (AC) source of electrical energy, which the power supply unit converts to a direct current (DC) output. Thus, typically a power supply unit may include a rectifier and/or power factor correction stage to receive the input AC source and rectify the input AC waveform to charge a bulk capacitor to a desired voltage. A direct-current-to-direct-current (DC-DC) stage may convert the voltage on the bulk capacitor to a DC output voltage which may be used to power components of the information handling system.
In traditional approaches, a power supply unit may be capable of, immediately after removal of the AC source to the power supply unit, providing electrical energy at its output for a period of time using the stored charge on the bulk capacitor to provide an output direct-current voltage. Such a period of time is limited, of course, as once the alternating current input is not available, the bulk capacitor will discharge and the power supply unit will shutdown. A portion of this period of time is known as a ride-through time and represents a period of time for which the power supply unit continues to generate a direct current output while waiting for reapplication of the AC source. If the AC source is not reapplied within the ride-through time, the available stored energy on the bulk capacitor may fall below a threshold, and the power supply unit may de-assert a signal. The de-assertion of such signal signifies entry into a period known as the hold-up time in which the information handling system may use additional energy remaining stored within the bulk capacitor to facilitate a graceful handover from the power supply unit to one or more battery back-up units configured to provide electrical energy to components of an information handling system resulting from loss of external power source.
Typically, a battery back-up unit will have a lower power rating than the power supply unit. Because the battery back-up unit has a different power rating, maintaining a stable current transition between the power supply unit and the battery back-up unit presents many challenges.
SUMMARY
In accordance with the teachings of the present disclosure, the disadvantages and problems associated with existing approaches to current sharing between a power supply unit and a battery back-up unit in an information handling system may be reduced or eliminated.
In accordance with embodiments of the present disclosure, an information handling system may include an information handling resource, a power supply unit for supplying electrical energy to the information handling resource via a power bus and a battery back-up unit for supplying electrical energy to the information handling resource via the power bus in response to a power event affecting an ability of the power supply unit to deliver electrical energy to the power bus. The battery back-up unit may be configured to, in response to the power event and prior to the power supply unit ceasing to deliver electrical energy to the power bus monitor a current share bus having a current share signal driven at least in part by the power supply unit, the current share signal indicative of a first current driven by the power supply unit to the power bus, drive a second current to the power bus in accordance with the current share signal and refrain from driving the current share bus.
In accordance with these and other embodiments of the present disclosure, a battery back-up unit for supplying electrical energy to an information handling resource via a power bus in response to a power event affecting an ability of a power supply unit to deliver electrical energy to the information handling resource via the power bus may be configured to, in response to the power event and prior to the power supply unit ceasing to deliver electrical energy to the power bus monitor a current share bus having a current share signal driven at least in part by the power supply unit, the current share signal indicative of a first current driven by the power supply unit to the power bus, drive a second current to the power bus in accordance with the current share signal, and refrain from driving the current share bus.
In accordance with these and other embodiments of the present disclosure, a method may include, in a system comprising a battery back-up unit for supplying electrical energy to an information handling resource via a power bus in response to a power event affecting an ability of a power supply unit to deliver electrical energy to the information handling resource via the power bus, in response to the power event and prior to the power supply unit ceasing to deliver electrical energy to the power bus, monitoring, by the battery back-up unit, a current share bus having a current share signal driven at least in part by the power supply unit, the current share signal indicative of a first current driven by the power supply unit to the power bus, driving, by the battery back-up unit, a second current to the power bus in accordance with the current share signal; and refraining, by the battery back-up unit, from driving the current share bus.
Technical advantages of the present disclosure may be readily apparent to one skilled in the art from the figures, description and claims included herein. The objects and advantages of the embodiments will be realized and achieved at least by the elements, features, and combinations particularly pointed out in the claims.
It is to be understood that both the foregoing general description and the following detailed description are examples and explanatory and are not restrictive of the claims set forth in this disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
A more complete understanding of the present embodiments and advantages thereof may be acquired by referring to the following description taken in conjunction with the accompanying drawings, in which like reference numbers indicate like features, and wherein:
FIG. 1 illustrates a block diagram of an example information handling system, in accordance with embodiments of the present disclosure; and
FIG. 2 illustrates a timing diagram depicting various voltages and currents associated with a transition between a power supply unit and a battery back-up unit, in accordance with embodiments of the present disclosure.
DETAILED DESCRIPTION
Preferred embodiments and their advantages are best understood by reference to FIGS. 1 and 2 , wherein like numbers are used to indicate like and corresponding parts.
For the purposes of this disclosure, an information handling system may include any instrumentality or aggregate of instrumentalities operable to compute, classify, process, transmit, receive, retrieve, originate, switch, store, display, manifest, detect, record, reproduce, handle, or utilize any form of information, intelligence, or data for business, scientific, control, entertainment, or other purposes. For example, an information handling system may be a personal computer, a personal data assistant (PDA), a consumer electronic device, a network storage device, or any other suitable device and may vary in size, shape, performance, functionality, and price. The information handling system may include memory, one or more processing resources such as a central processing unit (CPU) or hardware or software control logic. Additional components of the information handling system may include one or more storage devices, one or more communications ports for communicating with external devices as well as various input and output (I/O) devices, such as a keyboard, a mouse, and a video display. The information handling system may also include one or more buses operable to transmit communication between the various hardware components.
For the purposes of this disclosure, computer-readable media may include any instrumentality or aggregation of instrumentalities that may retain data and/or instructions for a period of time. Computer-readable media may include, without limitation, storage media such as a direct access storage device (e.g., a hard disk drive or floppy disk), a sequential access storage device (e.g., a tape disk drive), compact disk, CD-ROM, DVD, random access memory (RAM), read-only memory (ROM), electrically erasable programmable read-only memory (EEPROM), and/or flash memory; as well as communications media such as wires, optical fibers, microwaves, radio waves, and other electromagnetic and/or optical carriers; and/or any combination of the foregoing.
For the purposes of this disclosure, information handling resources may broadly refer to any component system, device or apparatus of an information handling system, including without limitation processors, service processors, basic input/output systems (BIOSs), buses, memories, I/O devices and/or interfaces, storage resources, network interfaces, motherboards, power supplies, air movers (e.g., fans and blowers) and/or any other components and/or elements of an information handling system.
FIG. 1 illustrates a block diagram of an example of an information handling system 102 . As depicted, information handling system 102 may include one or more power supply units (PSUs) 110 , one or more battery back-up units (BBUs) 120 , a motherboard 101 , and one or more other information handling resources.
Motherboard 101 may include a circuit board configured to provide structural support for one or more information handling resources of information handling system 102 and/or electrically couple one or more of such information handling resources to each other and/or to other electric or electronic components external to information handling system 102 . As shown in FIG. 1 , motherboard 101 may include a processor 103 , a memory 104 , and one or more other information handling resources.
Processor 103 may comprise any system, device, or apparatus operable to interpret and/or execute program instructions and/or process data, and may include, without limitation a microprocessor, microcontroller, digital signal processor (DSP), application specific integrated circuit (ASIC), or any other digital or analog circuitry configured to interpret and/or execute program instructions and/or process data. In some embodiments, processor 103 may interpret and/or execute program instructions and/or process data stored in memory 104 and/or another component of information handling system 102 .
Memory 104 may be communicatively coupled to processor 103 and may comprise any system, device, or apparatus operable to retain program instructions or data for a period of time. Memory 104 may comprise random access memory (RAM), electrically erasable programmable read-only memory (EEPROM), a PCMCIA card, flash memory, magnetic storage, opto-magnetic storage, or any suitable selection and/or array of volatile or non-volatile memory that retains data after power to information handling system 102 is turned off. In particular embodiments, memory 104 may comprise a non-volatile memory comprising one or more non-volatile dual-inline memory modules (NVDIMMs). Generally speaking, a PSU 110 may include any system, device, or apparatus configured to supply electrical current to one or more information handling resources of information handling system 102 . As shown in FIG. 1 , a PSU 110 may include a controller 112 , a power train 114 , and a current sensor 118 . Power train 114 of PSU 110 may be coupled at its outputs to a power bus (labeled “POWER” in FIG. 1 ) configured to deliver electrical energy to motherboard 101 and other components of information handling system 102 .
Controller 112 may comprise a microprocessor, DSP, ASIC, FPGA, EEPROM, or any combination thereof, or any other device, system, or apparatus for controlling operation of PSU 110 . As such, controller 112 may comprise firmware, logic, and/or data for controlling functionality of PSU 110 . As shown in FIG. 1 , controller 112 may couple to a current share bus (labeled with voltage CS_BUS in FIG. 1 ) with which PSUs 110 and BBUs 120 may communicate in order to establish a current share for the various currents delivered to the power bus by PSUs 110 and BBU 120 .
Power train 114 may include any suitable system, device, or apparatus for converting electrical energy received by PSU 110 (e.g., a 120-volt alternating current or 240-volt alternating current voltage waveform) from an input source 116 into electrical energy usable to information handling resources of information handling system 102 (e.g., 12-volt direct current voltage source). In some embodiments, power train 114 may comprise a rectifier, a power factor correction circuit, and/or a direct-current-to-direct-current converter. In these and other embodiments, power train 114 may comprise a voltage regulator (e.g., a multi-phase voltage regulator). Although FIG. 1 depicts each PSU 110 having a separate alternating current input source 116 , in some embodiments, one or more PSUs 110 may share an alternating current input source 116 . In operation, a power train 114 may deliver an amount of electrical current to the power bus in accordance with a control signal communicated from controller 112 indicative of a desired amount of electrical current to be delivered.
Although FIG. 1 depicts each PSU 110 as having an alternating current input source 116 , in some embodiments (not shown), power train 114 may include any suitable system, device, or apparatus for converting electrical energy received by PSU 110 e.g., a 48-volt DC or 240-volt DC or 380-volt DC direct current voltage waveform) from a direct current input source into electrical energy usable to information handling resources of information handling system 102 (e.g., 12-volt direct current voltage source). In these and other embodiments, the direct current inputs to power trains 114 may be from independent direct current sources or may be from a shared direct current source.
Current sensor 118 may comprise any suitable system, device, or apparatus for sensing a current delivered by a power train 114 to the power bus and generating a signal indicative of such current. For example, in some embodiments, such current sensor 118 may include a resistor which generates a voltage indicative of the current, in accordance with Ohm's law.
Generally speaking, a BBU 120 may include any system, device, or apparatus configured to supply electrical current to one or more information handling resources of information handling system 102 . As shown in FIG. 1 , a BBU 120 may include a controller 122 , a power train 124 , a battery 126 , a current sensor 128 , a diode 130 , and a signal buffer 132 . Power train 124 of BBU 120 may be coupled at its outputs to a power bus (labeled “POWER” in FIG. 1 ) configured to deliver electrical energy to motherboard 101 and other components of information handling system 102 . In some embodiments, in the event of a fault of one or more alternating current input sources 116 , PSUs 110 coupled to such one or more alternating current input sources 116 may de-assert a signal (labeled AC_OK in FIG. 1 indicating loss by such PSUs 110 of their respective alternating current input sources 116 . In other embodiments in which power train 114 uses a direct current source, an analogous signal to AC_OK may be used to indicate the event of a fault of one or more direct current input sources. Furthermore, such signal or a derivative thereof may be communicated to controllers 122 of BBUs 120 , causing BBUs 120 to activate from a deactivated state to supply electrical current to the power bus.
Controller 122 may comprise a microprocessor, DSP, ASIC, FPGA, EEPROM, or any combination thereof, or any other device, system, or apparatus for controlling operation of BBU 120 . As such, controller 122 may comprise firmware, logic, and/or data for controlling functionality of BBU 120 . As shown in FIG. 1 , controller 122 may couple to the current share bus (labeled with voltage CS_BUS in FIG. 1 ). Controller 122 may receive as inputs the voltage CS_BUS from the current share bus and a voltage indicative of a current i IN sensed by a current sensor 128 , and based on the voltage CS_BUS and the voltage current i IN in order to generate a control signal to power train 124 to control a current output by power train 124 and to calculate an internal current sense signal i OUT and output such signal (or a voltage representing such signal) to signal buffer 132 (which is shown implemented as a voltage follower in FIG. 1 ).
Turning again to FIG. 1 , power train 124 may include any suitable system, device, or apparatus for converting electrical energy received by BBU 120 from a battery 126 or other energy storage device (e.g., a capacitor) into electrical energy usable to information handling resources of information handling system 102 (e.g., 12-volt direct current voltage source). Accordingly, in some embodiments, power train 124 may comprise a direct-current-to-direct-current converter (e.g., a boost converter or buck converter). In operation, a power train 124 may deliver an amount of electrical current to the power bus in accordance with a control signal communicated from controller 122 indicative of a desired amount of electrical current to be delivered.
Current sensor 128 may comprise any suitable system, device, or apparatus for sensing a current delivered by a power train 124 to the power bus and generating a signal indicative of such current. For example, in some embodiments, such current sensor 128 may include a resistor which generates a voltage indicative of the current, in accordance with Ohm's law.
Diode 130 may have an anode coupled to an output of controller 122 and a cathode coupled to the current share bus (labeled with a voltage CS_BUS) in FIG. 1 , and may comprise any system, device, or apparatus configured having an asymmetric conductance; such that it has a low resistance to current in one direction (e.g., from anode to cathode), and high resistance in the other direction (e.g., from cathode to anode). Although diode 130 is depicted as a single diode in FIG. 1 , in some embodiments, diode 130 may be implemented as a plurality of physical diodes in series.
In addition to motherboard 101 , processor 103 , memory 104 , management controller 106 , PSU 110 , and BBU 120 , information handling system 102 may include one or more other information handling resources. For example, in some embodiments, information handling system 102 may include a number of PSUs 110 other than two. As another example, in these and other embodiments, information handling system 102 may include a number of BBUs 110 other than two.
Operation of the virtual current sharing functionality of the present disclosure may be understood by reference to FIG. 2 . FIG. 2 illustrates a timing diagram depicting various voltages and currents associated with a transition or current delivery between PSUs 110 and BBUs 120 , in accordance with embodiments of the present disclosure.
In operation, when alternating current input sources 116 are operating without fault, such as shown in FIG. 2 prior to a time labeled t 1 , controllers 112 may communicate via the current share bus in order to control the amount of current delivered to the power bus by each PSU 110 . Numerous approaches for performing current sharing among PSUs are well known in the art, including without limitation, master-slave current sharing (e.g., in which “slave” PSUs attempt to track current delivered by a “master” PSU having the highest current of the PSUs) and average current sharing (e.g., each PSU attempts to track an average current generated by each PSU). The voltage CS_BUS may operate in a defined range (e.g., zero to eight volts) wherein the voltage CS_BUS is indicative of (e.g., proportional to) a target current to be delivered by a PSU 110 . In some embodiments, the minimum value of voltage CS_BUS may correspond to a minimum target current and the maximum value of voltage CS_BUS may correspond to a maximum target current such that a ratio of the voltage CS_BUS to its maximum value is indicative of the portion of a rated power capacity of a PSU 110 which is delivered when outputting the target current. Thus, if voltage CS_BUS has a range of 0 to 8 volts and has a voltage of 6 volts, each PSU 110 may attempt to deliver an amount of power equal to 6/8=75% of its maximum power rating.
At time t 1 , alternating current input sources 116 may experience a fault, as indicated by the sinusoidal waveform V IN decreasing to a magnitude of zero at time t 1 . At such time, PSUs 110 may enter a ride-through period T rt , as discussed in the background section, and such ride-through period T rt may end at time t 2 .
At time t 2 , PSUs 110 may de-assert signals AC_OK, indicating that alternating current input sources 116 have experienced a fault and that the ride-through period T rt has ended. Controllers 122 of BBUs 120 may receive such de-assert signal AC_OK or a derivative thereof, at which point BBUs 120 may turn on and PSUs 110 and BBUs 120 may begin virtual current sharing between the period between time t 2 and time t 3 (the “transition period”) during which current delivery transitions from PSUs 110 to BBUs 120 , as described in greater detail below.
During the transition period, the presence of diodes 130 may cause BBUs 120 to act as forced slaves on the current share bus, such that BBUs 120 control their respective currents in accordance with a current share voltage CS_BUS established by PSUs 110 . In other words, the presence of diodes 130 prevents any BBU 120 from becoming a “master” during the transition period and forces such BBUs 120 to act of slaves. For each BBU 120 , its power capacity may be mapped to the voltage range of the current share bus, such that a ratio of the voltage CS_BUS to its maximum value is indicative of the portion of a rated power capacity of a PSU 110 which is delivered when outputting a target current in accordance with the voltage CS_BUS. In these and other embodiments, a default output voltage of a BBU 120 may be lower than that of a PSU 110 . For example, a default output voltage of a BBU 120 may be 12 volts while a default output voltage of a PSU 110 may be 12.2 volts.
In accordance with the virtual current sharing described above, an output voltage V PSU of a PSU 110 , an output voltage V BAT of a BBU 120 , an output current i BBU of a BBU 120 , an output current i PSU of a PSU 110 , and the voltage CS_BUS may vary as depicted in FIG. 2 . During this period, the current i BBU at time t 2 when BBUs 120 are turned on may be at or near zero. During the transition time, BBUs 120 will monitor the current share bus, but diode 130 in each BBU 120 will prevent each BBU 120 from actively driving the current share bus. Accordingly, BBUs 120 act like forced slave units, regardless of whether a master-slave or average method is used for current sharing between PSUs 110 .
At time t 3 , PSU 110 may cease generating output current, at which point BBUs 120 alone provide energy to components of information handling system 102 . After such time t 3 , diodes 130 present in BBUs 120 may ensure master-slave type current sharing after PSUs 110 power down, such that the BBU 120 with the highest current will drive the current share bus through its respective diode 130 . In some embodiments, the control loop created by controllers 122 and the current share bus may have a low bandwidth, so as to ensure current stability when PSUs 110 are powered down.
As used herein, when two or more elements are referred to as “coupled” to one another, such term indicates that such two or more elements are in electronic communication or mechanical communication, as applicable, whether connected indirectly or directly, with or without intervening elements.
This disclosure encompasses all changes, substitutions, variations, alterations, and modifications to the example embodiments herein that a person having ordinary skill in the art would comprehend. Similarly, where appropriate, the appended claims encompass all changes, substitutions, variations, alterations, and modifications to the example embodiments herein that a person having ordinary skill in the art would comprehend. Moreover, reference in the appended claims to an apparatus or system or a component of an apparatus or system being adapted to, arranged to, capable of, configured to, enabled to, operable to, or operative to perform a particular function encompasses that apparatus, system, or component, whether or not it or that particular function is activated, turned on, or unlocked, as long as that apparatus, system, or component is so adapted, arranged, capable, configured, enabled, operable, or operative.
All examples and conditional language recited herein are intended for pedagogical objects to aid the reader in understanding the disclosure and the concepts contributed by the inventor to furthering the art, and are construed as being without limitation to such specifically recited examples and conditions. Although embodiments of the present disclosure have been described in detail, it should be understood that various changes, substitutions, and alterations could be made hereto without departing from the spirit and scope of the disclosure. | In accordance with embodiments of the present disclosure, a battery back-up unit for supplying electrical energy to an information handling resource via a power bus in response to a power event affecting an ability of a power supply unit to deliver electrical energy to the information handling resource via the power bus may be configured to, in response to the power event and prior to the power supply unit ceasing to deliver electrical energy to the power bus monitor a current share bus having a current share signal driven at least in part by the power supply unit, the current share signal indicative of a first current driven by the power supply unit to the power bus, drive a second current to the power bus in accordance with the current share signal, and refrain from driving the current share bus. | 8 |
BACKGROUND OF THE INVENTION
Schistosomiasis (also known as bilharziasis, after Theodor Bilharz who identified the parasites) is a state of infection with leaf-like flat worms belonging to one or more species of blood flukes known as Schistosomatidae. Schistosomiasis is the most important among diseases caused by worms. Some 200 million people are infected by blood flukes (trematodes) in regions of Europe, Asia, South America, and also the Caribbean area. The disease complex results from infection by three major species of digenetic trematodes, viz., Schistosoma mansoni, S. japonicum, and S. haematobium. Fundamentally, an infected fresh water snail sheds free swimming infective forms (cercariae) into the water, and man (or other animal) is infected by the penetration of the parasite through the skin, followed by maturation of the worms (male and female) in the body, pairing of male and female worms, shedding of eggs in excrement into water where development occurs and host snails are then invaded for continuation of the cycle. In the mammalian host, the schistosomes enter blood circulation and pass through the lungs to mature in the liver, then reside in mesenteric-portal or pelvic veins. Eggs are shed by the female into the lumen of the small intestine in the case of S. japonicum, the colon (S. mansoni, and, rarely, S. haematobium) or the bladder (S. haematobium, or, rarely S. mansoni). Most of the pathological effects resulting from schistosome infections derive from the spined eggs, both within the body and in being shed in the urinary or fecal stream. Specific primary clinical problems occur in the intestine and bladder, together with secondary ones in liver, spleen, and lungs, plus variable involvement of the central nervous system and retina. The worms live for years (immune response of the host has little effort on established adult schistosomes, but does work against development of new infections. Pathological changes in schistosomiasis are considerably variable with the species and strain of parasite, duration of the infection, intercurrent infections, and nutritional state of the host.
Treatment of the schistosomiases does not reverse the damage already done the host by the parasitic worms. Anti-schistosomal agents generally impair the production of eggs and hinder development and functions of the flukes, with or without actually killing them. "Cure" is said to be achieved when viable eggs are no longer found in the excrement. Such criterion does not imply absence of worms, it must be understood. Successful treatment of the schistosomiases is difficult to achieve safely, for anti-schistosomal agents are appreciably toxic to the host. Suppressive management of schistosomiasis through administration of drugs at regular intervals may also be hazardous to the patient. Treatment of the infections is increasingly difficult in the sequence: S. haematobium, S. mansoni, and S. japonicum. That is essentially the same as the general extent of severity of the consequences of those schistosomiases.
Control of schistosomiasis through interruption of the life cycle of the parasite is a more attractive course of action than treatment of the infection. Two points at which control may be exercised include eradication of the snail intermediate host and prevention by protection of the mammalian final host against the cercariae shed by the snails. Various means have been tried to eliminate snails, for example, molluscicides and biological control; however, the basic problems have not been solved and even 0.2% of a snail population being infected renders a region highly endemic to schistosomiasis. Prevention of schistosomiasis, in sensu stricto, involves protection of man or other final host against infection by cercariae of the trematodes. In this regard, it would be desirable to have perdurable topical agents which, when applied to the skin, could afford means of safely preventing schistosomiasis. Hitherto, this goal has not been achieved.
It is known that various agents, when applied topically, provide some extent of protection of a final host against infection by penetration of the cercariae of Schistosoma mansoni or S. japoniucm. On the practical assessment of the results, however, the protective effects decrease markedly if the surface is exposed to washing or exposed to running water. Therefore, such topical agents offer little advantage in use by personnel (civilian or military) who may be exposed to waters containing schistosome-bearing snails. Practical utility of a topical anti-penetrant must include: resistance to washing action of flowing water, lack of irritant characteristics to the skin, ease of application, and low cost.
SUMMARY OF THE INVENTION
Accordingly, it is an object of this invention to provide perdurable topical agents useful in the prevention of schistosomiasis.
It is another object of the invention to provide topical agents which are resistant to the washing action of flowing water.
It is another object of the invention to provide topical agents which are non-irritating when applied to the skin.
It is another object of the invention to provide topical agents which are inexpensive and easy to apply.
Yet other objects of the invention will become apparent to one of ordinary skill upon reading this disclosure.
The above objects are achieved by the method of this invention for preventing schistosomiasis in a mammal which comprises: applying to the skin of said mammal a composition which contains dehydroabietylamine or a derivative thereof in order to achieve an antipenetrant effect against cercariae of infectious schistosome parasites. Preferred agents are dehydroabietylamine, its salts, and its ethylene oxide adducts.
The present invention relates to novel means for protecting mammalian species against infection by schistosome species. It is based upon preventing access of cercarial forms of the worms through the skin by topical application of compositions containing perdurable anti-penetrant agents. Broadly, the anti-penetrant agents are dehydroabietylamine and its derivatives, which protect mammals against infective cercariae of the parasitic worm. Preferred agents are dehydroabietylamine, its salts, and its ethylene oxide adducts. These novel anti-penetrants are perdurable and more resistant to removal by washing than other compositions. Evidence indicates that they are effective in barring entry of the cercariae of the various Schistosoma species, including S. japonicum, which is well known for producing infections upon exposure to only a few cercariae.
The anti-penetrant agents used in the method of this invention offer safe, easy, and cheap means for protection of civilian populations and troops against infection by schistosomiasis, as will be apparent from the detailed description below.
DETAILED DESCRIPTION OF THE INVENTION
The compositions of the invention may be applied to the skin by any suitable means in protecting against penetration by cercariae of schistosome worms. Exemplary vehicles for achieving uniform application include: solutions (as, an alcoholic menstrum); creams (as, vanishing cream); ointment (as, white or yellow ointment); liniment (as, green soap tincture); or malagma (as, an emollient oil). The anti-penetrant may remain on the skin for hours without decrease in effectiveness and without irritation, and exposure to water will not readily remove the agent. Accordingly, persons who are protected by the method of this invention may be exposed to schistosome-infected waters, whether for civilian or military purposes, with minimal hazards of skin penetration by cercariae of the worms.
The concentration of anti-penetrant agent in the composition is not critical, and one of ordinary skill may readily determine a suitable concentration. In general, of course, lower concentrations have an advantage from the standpoint of economics and lack of irritation. A preferred range of concentration of anti-penetrant agent in the composition is from about 1% to about 20% weight/volume (w/v). A more preferred range is from about 1% to about 10% w/v, and an even more preferred range is from about 1.25% to about 5% w/v.
When salts of dehydroabietyamine are employed, again, the particular salt selected is not critical. One of ordinary skill will routinely select an appropriate salt, for example, a pharmaceutically-acceptable acid addition salt. Salts derived from organic or inorganic acids may be used, non-limiting examples being the acetate, sulfate, benzoate, napthaleneacetate, and hydrochloride salts. Preferred among the salts is the acetate salt.
The following non-limiting examples are now provided, merely to illustrate the invention:
MATERIALS
For practical reasons, only commercial grade materials were used in the work on prophylaxis of schistosomiasis. Variability from lot-to-lot appeared to be of little consequence in performance in the tests.
The technical grade dehydroabietylamine was ordinarily a viscous liquid designated Amine D R or Amine 750 R by Hercules, Inc.; however, other dehydroabietylamine samples of at least 90% amine content were also used. Compositions of the acetate salt of dehydroabietylamine were of 50% or 70% solids content derived from the technical grade amines. Ethylene oxide adducts of technical grade dehydroabietylamine were also employed as anti-penetration agents. The products contained 5 moles of ethylene oxide in an adduct with 15% of free amine (Polyrad 0515 R ), 11 moles of ethylene oxide in the adduct with either no free amine (Polyrad 1100 R ) or 10% of free amine (Polyrad 1110 R ).
METHODS
(a) Drug Preparation
Preferred vehicles used for dissolving the drugs included methanol or ethanol, and the highest concentration of drugs was usually 5% w/v.
(b) Prophylactic Trials: S. mansoni
The experimental animals were female ICR/FG mice, 9-10 weeks old (28-33 g.) which were held for 1 week prior to use. In the initial trials of drugs, 5 mice were used per dose level of drugs, together with appropriate controls. The mice were placed in a special restrainer and tails were wiped clean and dry with isopropyl alcohol before the tails were immersed in the drug solution for 5 minutes. During immersion of the tails, complete coverage with drug solution was ensured by washing with the solution while in the restrainer, and the tails were dried in a current of air during 1-2 hours. Following drug exposure, the mice were retained for 24 hours without or with washing of the tails in flowing warm tap water for 30 minutes.
At the end of the pre-exposure handling, each mouse was placed in a restrainer and the tail exposed to S. mansoni parasites (100 cercariae per mouse) for 45-90 minutes. Following exposure, the mice were kept in plastic boxes lined with heat-sterilized sawdust until the tails were dry, then transferred to stainless steel cases, 5 per cage. The animals were observed daily for 7 weeks, until killed with sodium pentobarbital-heparin. Evidence of drug toxicity was indicated in deaths occurring 12-24 hours after treatment. Survivors at (49±3) days were killed and the livers perfused to determine the total burden of adult worms, following the method of Radke et al, J. Parasitol. 47: 366-68 (1961).
(c) Prophylactic Trials: S. japonicum
Because of the characteristics of S. japonicum cercariae, it was not satisfactory to expose mice to cercarial-infected water, either by immersing the tail or by pipetting parasites onto the shaven belly.
Mice were anesthetized (cf. D. G. Erickson, J. Parasitol. 60: 553-54 (1974) and the bellies trimmed and shaven. A loop of 5 or 6 mm. diameter made from suture material, attached to an applicator, was used to transfer 20 to 30 cercariae of S. japonicum (counted individually) to the bellies of the mice. There was penetration within 5 minutes for controls (five to a group minimum). In testing of drugs, the alcoholic solutions were painted on the bellies 24 and 48 hours prior to exposure of the mice to cercariae of S. japonicum. Otherwise, the trials were done as with S. mansoni, using a 7 week holding period.
RESULTS
EXAMPLE 1. DEHYDROABIETYLAMINE
Technical dehydroabietylamine of 92-94% amine content was dissolved in ethanol to give 5% w/v solution and diluted to obtain 2.5% and 1.25% solutions.
In the anti-penetration test on the shaved bellies of mice, 99 to 100% protection was afforded against penetration by S. japonicum cercariae through prior application of the amine solutions of 2.5% and 5% concentration. No evidence of irritation resulted from dehydroabietylamine to the shaved skin of mice.
The prior application of dehydroabietylamine in ethanol to tails of mice gave excellent protection against infection by S. mansoni. A tabulation (Table 1) shows the results of multiple trials in which no penetration by cercariae occurred among treated mice.
EXAMPLE 2. DEHYDROABIETYLAMINE ACETATE
The acetate salt of dehydroabietylamine was available in the form of technical-grade compositions. One was a tan colored paste containing 70% solids and 30% water. The other was an aqueus alcoholic solution of the salt which held 50% of solids. Each water soluble amine acetate was used as obtained to prepare 5% alcoholic solutions and then diluted with ethanol for 2.5% and 1.25% solutions.
Testing for anti-penetration effects of the amine acetate preparations was done on shaved bellies or backs of mice restrained during application of S. japonicum cercariae. Little difference in protection was apparent whether the compound was applied 24 or 48 hours prior to exposure. The extent of protection was 91-100% for 5% solutions of the amine acetate preparations and 49 to 81% for 2.5% solutions.
Tables 2 and 3 show, respectively, the anti-penetrant effects of alcoholic preparations made from the 70% amine acetate paste or the 50% solution of the salt when tested using S. mansoni cercariae. Excellent protection was afforded, never falling below 94% of animals exposed.
EXAMPLE 3. ETHYLENE OXIDE ADDUCTS OF DEHYDROABIETYLAMINE
So-called oxyethylated amines were formed from technical dehydroabietylamine by interaction with ethylene oxide. The adducts had the general structure ##STR1## where n was 5 or 11. In the case of n=5, there was present 15% of dehydroabietylamine; where n=11, 10% of dehydroabietylamine was unchanged. Solutions of the material were prepared on the weight/volume basis without considering the composition of the technical-grade product. The stock solution was 5% in methanol.
The amine adducts were screened for protective effects against S. mansoni cercariae in the usual way. The data assembled in Table 4 were from use of the adduct with 5 moles of ethylene oxide, and those in Table 5, the adduct with 11 moles of ethylene oxide.
TABLE 1______________________________________Dehydroabietylamine: Antipenetrant Effectsvs. S. mansoni Cercariae in Mice Mean Worm Burden % ofTime Conc. Surv. Treated Control Control______________________________________24 Hours 5 5/5 0 33.8 0.024 Hours 2.5 5/5 0 33.8 0.048 Hours 5 5/5 0 33.8 0.048 Hours 2.5 5/5 0 33.8 0.024 Hours 5 5/5 0 14.6 0.024 Hours wash 5/5 0 11.0 0.024 Hours 2.5 5/5 0 31.4 0.024 Hours wash 5/5 0 30.6 0.024 Hours 1.25 5/5 0 31.4 0.024 Hours wash 5/5 0 30.6 0.0______________________________________
TABLE 2______________________________________Dehydroabietylamine Acetate: AntipenetrantEffects of 70% Preparation vs. S. mansoniCercariae in Mice Mean Worm Burden % ofTime Conc. Surv. Treated Control Control______________________________________24 Hours 5 5/5 0 30.0 0.024 Hours 2.5 5/5 0 30.0 0.048 Hours 5 5/5 0 30.0 0.048 Hours 2.5 5/5 0 30.0 0.048 Hours 5 5/5 0 24.4 0.048 Hours 2.5 5/5 0 24.4 0.072 Hours 5 5/5 0 24.4 0.072 Hours 2.5 5/5 0 24.4 0.024 Hours 5 5/5 0 14.6 0.024 Hours wash 5/5 0 11.0 0.024 Hours 2.5 5/5 0 31.4 0.024 Hours wash 5/5 0 30.6 0.024 Hours 1.25 5/5 0 31.4 0.024 Hours wash 5/5 0 30.6 0.0______________________________________
TABLE 3______________________________________Dehydroabietylamine Acetate: AntipenetrantEffects of 50% Preparation vs. S. mansoniCercariae in Mice Mean Worm Burden % ofTime Conc. Surv. Treated Control Control______________________________________24 Hours 5 5/5 0 43.4 0.024 Hours 2.5 4/4 0 43.4 0.048 Hours 5 5/5 0 43.4 0.048 Hours 2.5 5/5 0 43.4 0.048 Hours 5 5/5 0 24.4 0.048 Hours 2.5 5/5 0 24.4 0.072 Hours 5 5/5 0 24.4 0.072 Hours 2.5 5/5 0 24.4 0.024 Hours 5 5/5 0 24.4 0.024 Hours wash 5/5 0 37.0 0.024 Hours 2.5 5/5 0 24.4 0.024 Hours wash 5/5 1.2 37.0 3.248 Hours 5 5/5 0 24.4 0.048 Hours wash 5/5 2.2 37.0 6.048 Hours 2.5 5/5 0 24.4 0.048 Hours 5/5 1.8 37.0 4.924 Hours 2.5 5/5 0 31.4 0.024 Hours wash 5/5 1.2 30.6 3.924 Hours 1.25 5/5 0 31.4 0.024 Hours wash 5/5 0 30.6 0.0______________________________________
TABLE 4______________________________________Adduct of Dehydroabietylamine with EthyleneOxide (1:5): Antipenetrant Effects vs.S. mansoni Cercariae in Mice Mean % of Worm Burden Sup- Con- % of pres-Time Conc. Surv. Treated trol Control sion______________________________________24 hrpre-treat. 5% 5/5 0 40.8 0 100%24 hr wash 5% 5/5 0.4 48.0 0.8 99.224 hr 2.5% 5/6 0.4 34.2 1.2 98.8pre-treat.24 hr wash 2.5% 5/5 1.8 44.6 4.0 96.024 hr 1.25% 5/5 3.2 34.2 9.4 90.6pre-treat.24 hr wash 1.25% 4/4 30.8 44.6 69.1 30.9______________________________________
TABLE 5______________________________________Adduct of Dehydroabietylamine with EthyleneOxide (1:11): Antipenetrant Effects vs.S. mansoni Cercariae in Mice Mean Worm Burden % of Treat- Con- % of Suppres-Time Conc. Surv. ed trol Control sion______________________________________24 hr 5 5/5 0 33.2 0 10024 hr 2.5 5/5 0 33.2 0 10048 hr 5 5/5 15.6 33.2 47.0 5348 hr 2.5 5/5 14.4 33.2 43.4 56.624 hr 2.5 5/5 0 40.8 0 10024 hr wash 2.5 5/5 31.8 48.0 66.2 33.824 hr 5 5/5 5.0 28.4 17.6 82.424 hr wash 5 5/5 38.6 52.2 74.0 26.0______________________________________ | An improved method is provided for the prevention of schistosomiasis in her animals. The topical application of a composition containing a dehydroabietylamine or a derivative thereof provides a coating of perdurable anti-penetrant through which the infective cercariae of the parasitic worm do not pass readily. | 0 |
BACKGROUND OF THE INVENTION
As the World's human population grows and as the economic prosperity of our global population grows, the energy demand of our global population also grows. With limited availability of oil reserves, there is a growing need for the conception, development and deployment of cost-effective and large-scale renewable energy alternatives. The continued use of fossil fuels to meet current and emerging energy needs also has very negative environmental consequences, including massive emissions of carbon dioxide and other pollutants, along with exacerbation of global warming and climate change effects. These factors provide strong motivation for the invention, development and deployment of cost-effective, large-scale renewable energy alternatives.
The Sun provides enormous quantities of energy to the World every second, and that energy can be found in harvestable form as direct solar energy and as wind energy.
BRIEF SUMMARY OF THE INVENTION
The present invention provides a renewable energy harvesting system for harvesting fluid-dynamic renewable energy as contained in wind or air current energy.
The invention provides a revolving overhead windmill which includes airfoil means for interfacing with a fluid current such as a wind, and which includes energy harvesting means utilizing fluid current driven periodic motion of the airfoil means, for capturing fluid-dynamic renewable energy and converting it into usable energy in a desired form such as electricity. The invention provides devices, methods and systems for harvesting renewable energy for medium-scale, large-scale and ultra-large-scale applications, with a special focus on abundant offshore wind resources, to provide real and substantial benefits towards efficiently fulfilling energy needs while also more broadly serving humanity and our global environment. The various embodiments of the invention provide energy with zero consumption of fossil fuels and zero emissions of greenhouse gases.
The invention with its several preferred embodiments can be understood from a full consideration of the following specification including drawings, detailed description, and claims.
This invention constitutes a further advance of inventive technology related to a prior invention defined in U.S. Pat. No. 7,750,491 entitled “Fluid-Dynamic Renewable Energy Harvesting System” that was invented by the same Inventor and assigned to the same Assignee.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A shows a plan view of a revolving overhead windmill, similar to a satellite view of the invention.
FIG. 1B shows a partial side view from a location far outside of the advancing airfoil means, of one preferred embodiment of the invention, showing only the upwind airfoil means and downwind airfoil means and adjacent structure.
FIG. 1C shows a partial side view of the same embodiment as FIG. 1B , more clearly illustrating an annular volume and second annular volume.
FIG. 1D shows a partial side view of the same embodiment as FIG. 1B , more clearly illustrating a third annular volume and fourth annular volume as well as location of a center of gravity below a metacenter.
FIG. 1E shows an increased scale partial side view of the embodiment of FIG. 1B , to more clearly illustrate inventive features of the upwind airfoil means and adjacent structure.
FIG. 1F shows a further increased scale partial side view of the embodiment of FIG. 1B , to more clearly illustrate inventive features near the base of the upwind airfoil means.
FIG. 1G shows an increased scale partial side view of the embodiment of FIG. 1B from a location outside of the advancing airfoil means, of the advancing airfoil means and adjacent structure.
FIG. 2 shows an increased scale partial side view of another preferred embodiment of the invention from a location outside of the advancing airfoil means, illustrating the advancing airfoil means and adjacent structure.
FIG. 3A shows an increased scale partial side view of another preferred embodiment of the invention, illustrating inventive features of the aerostatically supported upwind airfoil means and adjacent structure.
FIG. 3B shows an increased scale partial side view of the same preferred embodiment of the invention as in FIG. 3A , from a location outside of the advancing airfoil means, illustrating the aerostatically supported advancing airfoil means and adjacent structure.
FIG. 4 shows an increased scale partial side view of another preferred embodiment of the invention from a location outside of the advancing airfoil means, illustrating the aerostatically supported advancing airfoil means and adjacent structure.
FIG. 5 shows an increased scale partial side view of another preferred embodiment of the invention, illustrating inventive features of the aerostatically supported upwind airfoil means and adjacent structure.
FIG. 6 shows an increased scale partial side view of another preferred embodiment of the invention, illustrating inventive features of the aerostatically supported upwind airfoil means and adjacent structure, sited over a layer of moving water such as a floodplain in a flood state, or tidelands with maximum high tides, or marshlands following heavy monsoon rains, or similar or analogous situations of a variable or a temporary layer of moving water.
FIG. 7A through 7N show, in block diagram form, several alternate generator means for converting mechanical “net work” to “energy in a desired form for at least one of transmission, storage, processing and use” in one preferred form as electrical energy.
FIG. 8 shows a plan view of multiple revolving overhead windmills in an array, with shared anchors in the underwater ground surface.
FIG. 9 shows a plan view of a revolving overhead windmill being towed to its installation site by a tugboat.
FIGS. 10A through 10D illustrate aspects of control system means for controlling the revolving overhead windmill.
DETAILED DESCRIPTION
Prior to commencing with the detailed description, certain expressions are defined as pertaining to their use in the following detailed description and claims.
The expression “topologically coaxial” as pertaining to two annular volumes refers to these two annular volumes having axes of revolution that are either (i) identical or (ii) separated some not excessive measure of linear or angular separation. To cite a common world example, a stack of onion rings of various sizes and geometries all ringing a common post would be considered “topologically coaxial” according to this definition.
The expression “overhead” as pertaining to the revolving overhead windmill, refers to a location that is up or at a level located somewhere in the opposite direction as the local gravity vector, from the perspective of a person or camera or viewpoint at the level of a local ground surface.
FIG. 1A shows a plan view of a revolving overhead windmill 1 above a ground surface 89 , with the plan view being similar to a satellite view of the invention.
FIG. 1A shows a revolving overhead windmill 1 comprising plural airfoil means 3 for contacting proximate flow fields of an air current or wind current or wind 5 , when said wind current exists and carries wind current energy in the form of fluid-dynamic kinetic energy. Each airfoil means 3 is installed with an effective axis of rotation 9 A around which each of said airfoil means can effectively rotate in orientation to some extent, said axis of rotation being disposed within 60 degrees of vertical during normal operation of said revolving overhead windmill 1 .
Connecting means 17 are provided, for serving as means for connecting the plural airfoil means 3 in a sequential arrangement around a circuit 21 of closed periphery topology enclosing an axis of revolution 21 A, as illustrated, wherein the axis of revolution 21 A is disposed within 60 degrees of vertical (vertical being out from the page in this plan view). The connecting means 17 include connecting members 19 that connect adjacently-located airfoil means 3 in the sequential arrangement.
While the configuration of the invention illustrated in FIG. 1A shows a total of 45 airfoil means arranged in a closed periphery topology, it should be understood that variant embodiments of the invention may feature different numbers of airfoil means and different geometric specifics and different size and different scale, without any express or implied limitation.
Note that the revolving overhead windmill 1 is revolving in a direction of revolution 1 D that is a clockwise direction as seen in this plan view or satellite view, but that in variant embodiments it may revolve in a direction of revolution that is counterclockwise or clockwise as seen from a satellite view, or selectably clockwise or counterclockwise at different times as desired. Selection of clockwise or counterclockwise revolution for arrays of revolving overhead windmills in either the Northern Hemisphere or Southern Hemisphere, may also help reduce severity or risk of cyclonic storms in these Hemispheres, such as cyclones, hurricanes, typhoons and similar storm systems with air mass rotational energy content that can be destructive.
In the plan view shown in FIG. 1A , the air current or wind 5 is flowing from left to right, but it will be understood that the invention is operable for any and all steady or varying wind directions. With the wind 5 flowing from left to right in the illustration, the airfoil means 3 closest to the left end of the system is designated as the upwind airfoil means 3 U. With the wind 5 flowing from left to right in the illustration, the airfoil means 3 closest to the right end of the system is designated as the downwind airfoil means 3 D. With the clockwise direction of revolution 1 D and the wind 5 flowing from left to right in the illustration, the airfoil means 3 closest to the top end of the system in this plan view, is designated as the retreating airfoil means 3 D. With the clockwise direction of revolution 1 D and the wind 5 flowing from left to right in the illustration, the airfoil means 3 closest to the bottom end of the system in this plan view, is designated as the advancing airfoil means 3 A.
Thus FIG. 1A illustrates revolving overhead windmill 1 , comprising: plural airfoil means 3 for contacting proximate flow fields of a wind current 5 when said wind current exists and carries wind current energy in the form of fluid-dynamic kinetic energy; an effective axis of rotation 9 A around which each of said airfoil means can effectively rotate in orientation to some extent, said axis of rotation being disposed within 60 degrees of vertical during normal operation of said revolving overhead windmill; and connecting means 17 for connecting said plural airfoil means in sequence in an annular volume 101 , said connecting means including connecting members 19 that connect adjacently-located airfoil means in said sequence.
FIG. 1B shows a partial side view from a location far outside of the advancing airfoil means 3 A (shown in FIG. 1A ), of one preferred embodiment of the revolving overhead windmill 1 of FIG. 1A , showing only the upwind airfoil means 3 U and downwind airfoil means 3 D and adjacent structure. Other parts of this preferred embodiment are hidden, so as to more clearly illustrate how key parts of the invention are related.
The airfoil means 3 are shown as wing-like windfoils with internal structure including wing spars 3 SP, and also fitted with control surfaces 9 CS that are used to appropriately orient each airfoil means 3 at an optimized angle of attack at various parts of its circuit around the axis of revolution 21 A, to maximize wind energy extraction and harvest. In this preferred embodiment the illustrated energy harvesting means 25 includes control system means 9 , for converting a portion of said fluid-dynamic kinetic energy into net work on said airfoil means over the course of a cycle of substantially periodic motion of said airfoil means revolving in said annular volume, by utilizing time-variable fluid-dynamic pressure distributions and resulting forces acting on said airfoil means 3 at said time-variable orientations to contribute to driving said substantially periodic motion when said wind current 5 exists and carries wind current energy in the form of fluid-dynamic kinetic energy. The control system means 9 includes the control surfaces 9 CS. The illustrated airfoil means 3 are also shown fitted with trailing edge flaps 9 F, to enable higher airfoil lift coefficients and further optimize wind energy harvest.
As shown, the energy harvesting means 25 further includes energy conversion means 27 for converting at least some of said net work into energy in a desired form for at least one of transmission, storage, processing and use, with said energy conversion means 27 including an annular electromagnetic generator 120 . The annular electromagnetic generator could be a permanent magnet generator (PMG) or other generator.
In this preferred embodiment, buoyant support means 4 B are provided, for utilizing a buoyancy force from fluid displacement comprising water displacement from a volume below a water surface 13 , to at least partially contribute to supporting said airfoil means 3 above the water surface 13 and above a ground surface 89 wherein the ground surface is an underwater ground surface 89 U. The water depth 13 D can be any value from fractions of an inch to many miles, but without limitation may be on the order of 750 feet nominal for one version of the preferred embodiment as illustrated. Thus the revolving overhead windmill 1 here comprises an offshore vertical axis wind turbine with variable pitch airfoil means or windfoil means or blades, that revolve in a large circuit around the axis of revolution 21 A. The revolving overhead windmill 1 is held substantially on station in a given geographic location, using position-keeping means 23 that include a position-keeping tether or cable 23 T and anchor 89 B in the underwater ground surface 89 U. Note that a variety of known anchor devices including anchors, pilings, buried posts, ground screws penetrating into the underwater ground surface 89 U, etc., that are known from the prior art, can be used within the spirit and scope of the invention herein described.
FIG. 1B also illustrates vertical load reacting means 110 for reacting vertical loads, said vertical loads comprising at least one of airfoil means weight loads and buoyant support means buoyancy loads. The vertical load reacting means 110 here include an annular truss 113 A comprising a floating annular truss 113 FA that serves as at least part of the buoyant support means 4 B. The distributed buoyancy support provided around a large circumference by the floating annular truss 113 FA enables adequate support while reducing wave-induced loads and structural failure risk of the revolving overhead windmill 1 , even for large amplitude and/or large wavelength waves such as tsunami waves in open seas or coastal regions.
FIG. 1C shows a partial side view of the same embodiment as FIG. 1B , more clearly illustrating an annular volume 101 and second annular volume 102 . Connecting means 17 serve as means for connecting said plural airfoil means 3 in sequence in the illustrated annular volume 101 .
FIG. 1C also illustrates vertical load reacting means comprising plural vertical-load-carrying structural members 111 arranged in sequence in a second annular volume 102 that is topologically coaxial with said annular volume 101 .
FIG. 1C further illustrates position-keeping means 23 for maintaining said revolving overhead windmill 1 substantially within a desired geographic envelope 13 G, which position-keeping means includes at least one of a tether or cable 23 T and an anchor 89 B fastened to the underwater ground surface 89 U.
FIG. 1D shows a partial side view of the same embodiment as FIG. 1B , more clearly illustrating a third annular volume 103 and fourth annular volume 104 as well as location of a center of gravity 4 CG below a metacenter 4 MC.
FIG. 1D shows wave load reduction means 140 comprising plural load reduction elements 141 arranged in sequence in a third annular volume 103 that is topologically coaxial with the annular volume 101 of FIG. 1C .
FIG. 1D also shows energy harvesting means including energy conversion means 27 for converting at least some of said net work into energy in a desired form for at least one of transmission, storage, processing and use; said energy conversion means 27 including an annular electromagnetic generator 120 located in a fourth annular volume 104 that is topologically coaxial with the annular volume 101 of FIG. 1C .
FIG. 1D further shows a revolving overhead windmill 1 , wherein a portion of said revolving overhead windmill 1 that is supported by the buoyancy force from buoyant support means 4 B, has a center of gravity location 4 CG that is below a metacenter 4 MC associated with said buoyancy force.
It is well known in the art of floating entities that floating entities have a metacenter associated with the entity's center of buoyancy and its movement, and that a floating entity will typically float stably when it has a center of gravity location that is below this metacenter. Sometimes there are multiple metacenters associated with different axes of rotation of a floating entity, and in this case it will float stably when it has a center of gravity location below the lowest of the plural metacenters associated with different possible axes of rotation. For cases with water and/or air displacement buoyancy, the concept of stability associated with center of gravity location below one or more equivalent metacenters can be similarly defined by extension.
FIG. 1E shows an increased scale partial side view of the embodiment of FIG. 1B , to more clearly illustrate inventive features of the upwind airfoil means and adjacent structure.
A light 136 is shown on top of the airfoil means, and could be an aviation warning strobe or wind turbine warning light, to cite a couple of examples without any implied limitation.
The airfoil means 3 is shown with three spars, comprising a main spar or central spar, forward spar and rear spar. While a three spar design is shown, it should be understood that designs with a single spar, with two spars, or with multiple spars are also possible within the spirit and scope of the invention, and based on analogous precedents in aircraft wing design and wind turbine blade design, without limitation. The space between spars is shown as gaseous content volume 4 GCV, which may be sealed or vented to the external atmosphere in alternate preferred embodiments. For reference, this space between spars is commonly used for fuel carriage in aircraft wings. The gaseous content volume 4 CGV is preferably filled with air, but in an alternate variant embodiment could be filled with a lifting gas such as hot air, hydrogen gas, or helium gas.
The illustrated airfoil means 3 is shown fitted with four trailing edge flaps 9 F, without limitation. Various types of flaps such as simple hinged flaps, split flaps, slotted flaps, multi-slotted flaps, fowler flaps, blown flaps, or variable camber trailing edge integrated flaps, can be used within the spirit and scope of the invention. The preferred airfoil means have a well-designed symmetrical airfoil section, and the trailing edge flaps enable higher lift coefficients to be obtained, without excessive drag penalties. Leading edge high-lift devices (not shown) as known from the prior art of airfoils and wings, can also optionally be fitted to the airfoil means 3 in alternate embodiments of the invention.
The illustrated control system means 9 include actuator means 10 , and serve as means for controlling time-variable orientations of said airfoil means 3 relative to said proximate flow fields of said wind current 5 when said wind current exists and carries wind current energy in the form of fluid-dynamic kinetic energy. The actuator means 10 may comprise one or more of electrical actuation and electro-mechanical actuation and electro-hydraulic actuation and hydraulic actuation and pneumatic actuation and magnetic actuation and piezoelectric actuation and thermal actuation and shape memory alloy actuation, in variant embodiments of the invention as described and claimed.
In the illustrated embodiment the actuator means 10 acts on a control surface 9 CS, that can be commanded to deflect to a desired angle so as to exert a desired control moment (in yaw) on one or both of the airfoil means 3 and the trailing edge flaps 9 F, so as to set the airfoil means at a desired angle of attack relative to the incoming airstream (accounting for the wind as well as the revolution speed of the revolving overhead windmill 1 ) and so as to set the flaps at an optimal deflection to optimize wind power extraction. Note that the control surface support structure may be mated to either the airfoil means 3 or flaps 9 F or both through mechanical means for coupling aerodynamic surfaces, known in the prior art of airfoil and wing and control surface and control system design. The mechanical means may include one or more of mechanical linkage means, spring means, damper means, gearing means, nonlinear linkage means, and travel stop means, as are known and applied in related fields of art. Note also that a control surface may have mass balance such as for avoiding aeroelastic effects such as flutter or divergence, may have aerodynamic balance, may have a horn balance (as illustrated) for reducing actuator power, may have proportional control, may have nonlinear control, and may have bang-bang control. Control laws or control algorithms for actuator control may include elements such as aerodynamic wake compensation control law that optimizes at least one of circumferential thrust, torque or power harvest while effectively compensating for downstream airfoils traversing the aerodynamic wake of upstream airfoils. Further description of control system features will be presented subsequently, in the context of FIGS. 10A through 10D .
FIG. 1E shows energy harvesting means 25 that include the control system means 9 , actuator means 10 , control surface 9 CS, support structure connecting the airfoil means 3 to the control surface 9 CS, trailing edge flaps 9 F, the airfoil means 3 including spars 3 SP, and energy conversion means 27 including an annular electromagnetic generator 120 .
FIG. 1E also shows vertical load reacting means 110 for reacting vertical loads, said vertical loads comprising at least one of airfoil means weight loads and buoyant support means buoyancy loads, said vertical load reacting means comprising plural vertical-load-carrying structural members 111 .
FIG. 1E also illustrates buoyant support means 4 B for utilizing a buoyancy force from fluid displacement comprising water displacement from a volume below a water surface 13 , to at least partially contribute to supporting said airfoil means 3 above the water surface 13 and above a ground surface 89 wherein the ground surface is an underwater ground surface 89 U; connecting means 17 for connecting said plural airfoil means, said connecting means 17 including connecting members 19 that connect adjacently-located airfoil means 3 in sequence; and wave load reduction means 140 for reducing peak wave-induced loads acting on said connecting means 17 relative to reference peak wave-induced loads that would occur if said connecting means were rigidly attached to and supported by a rigid half-submerged toroidal ring floating in the water directly beneath said connecting means 17 , said wave load reduction means comprising plural load reduction elements 141 .
FIG. 1E further illustrates means for transmitting energy 43 T, such as electrical wire, to carry energy from the energy conversion means 27 including the annular electromagnetic generator 120 . The harvested electrical energy is consequential to the time integral of electrical power generated by said annular electromagnetic generator 120 , driven by captured wind power flowing as mechanical power in the circumferentially aligned force components from said airfoil means 3 , acting on said circumferential connecting means 17 and multiplied by the circumferential or azimuthal velocity of said connecting means 17 .
FIG. 1E also illustrates a revolving overhead windmill 1 , further comprising protection means 150 for reducing risk of damage to said revolving overhead windmill 1 from an environmental threat, wherein said environmental threat comprises at least one of a lightning strike (e.g., using the illustrated lightning rod) and an electromagnetic energy threat and a hurricane and a typhoon and a cyclone and a storm and a tsunami and a seismic sea wave and a tidal wave and a tidal bore and a large sea wave and an earthquake and volcanic activity and hail and a rainstorm and a snowstorm; and wherein said protection means comprises at least one of a grounding wire 151 , an electromagnetic threat shielding layer 152 , and tether load reduction means 153 for reducing loads consequent to said environmental threat acting on said revolving overhead windmill 1 from at least one tether connecting said revolving overhead windmill Ito said underwater ground surface 89 U.
FIG. 1E also illustrates an electrical device 130 supported by structure in said airfoil means 3 , as will be described further in the context of FIG. 1F , below.
FIG. 1F shows a further increased scale partial side view of the embodiment of FIG. 1B , to more clearly illustrate inventive features near the base of the upwind airfoil means.
FIG. 1F shows an electrical device 130 supported by structure in said airfoil means 3 , which electrical device 130 comprises at least one of a battery 131 (shown) and a sensor 132 (shown) and an electrical wire 133 E (shown) and a signal wire 133 S (shown, may be electrical or optical or other type of signal wire, without limitation) and an electro-optical component 134 (shown) and a computer 135 (shown) and a light 136 (shown in FIG. 1E preceding) and a display 137 (shown) and a communication device 138 (shown) and a human interface device 139 (shown) and a photovoltaic electrical power source device 130 PV and an air turbine electrical power source device 130 AT.
FIG. 1F also shows the revolving overhead windmill 1 including plural modular structural members 50 and further including fastener means 51 for detachably connecting adjacent modular structural members to enable at least one of assembly and maintenance and inspection and service and repair and replacement, and further including an access space 52 for at least one of a human and a robot and a tool and a camera to be in said access space to at least one of facilitate and perform said at least one of assembly and maintenance and inspection and service and repair and replacement.
Variant embodiments of the invention may include access spaces 52 suitable for human access that include without limitation an access hole, a catwalk, a gangway, a ladder, a stairway, an elevator, an escalator, a control room, an instrumentation/diagnosis room, an observation room or deck, an apartment room, a restroom, a dining area, a medical area, a helipad and a shelter area. Access means for accessing parts of the revolving overhead windmill 1 for inspection, maintenance, cleaning, service, repair and other purposes, may include human access means, robot access means, humanoid robot access means, and camera or imaging access means.
For embodiments where the airfoil means 3 includes one or more of laminar flow surfaces or hybrid laminar flow surfaces or riblet surfaces or surfaces with vortex generators to inhibit airflow separation, access and/or cleaning and/or maintenance and/or service and/or replacement means may be provided.
FIG. 1F further illustrates airfoil rotating base structure 3 RBS at the base of the airfoil means 3 , with the three spars 3 SP structurally connected thereto. The rotating base structure 3 RBS, in normal operation, can freely rotate around the effective axis of rotation 9 A on a bearing interface 69 , above the annular connecting means 17 . Bearing means 69 also enable the connecting means 17 and annular electromagnetic generator rotor 120 R, part of the energy conversion means 27 , to together revolve above the air gap between rotor and stator 120 AG, over the stator part of the annular electromagnetic generator 120 . Note that annular connecting means 17 , bearing means 69 , and annular electromagnetic generator 120 can all include multiple components arranged in the annular geometry around the closed periphery topology enclosing the axis of revolution 21 A shown in FIG. 1A .
FIG. 1G shows an increased scale partial side view of the embodiment of FIG. 1B from a location outside of the advancing airfoil means, of the advancing airfoil means and adjacent structure.
FIG. 1G shows many of the same inventive features as FIG. 1E , but now illustrating more features of the annular truss 113 that comprises a floating annular truss 113 FA.
FIG. 1G also shows vertical load reacting means 110 for reacting vertical loads, said vertical loads comprising at least one of airfoil means weight loads and buoyant support means buoyancy loads, said vertical load reacting means comprising plural vertical-load-carrying structural members 111 arranged in sequence. FIG. 1G illustrates vertical-load-carrying structural members 111 including (i) a post 112 and (ii) a truss 113 and (iii) an annular truss 113 A and (iv) a floating annular truss 113 FA. The post 112 could comprise a rod, bar, beam, spar, mast or other similar structural member.
FIG. 1G also illustrates buoyant support means 4 B along with buoyancy control means 4 BC that serves as means for varying the buoyancy force by pumping water ballast between a water tank 4 WT and the body of water below said water surface 13 .
FIG. 1G also illustrates wave load reduction means 140 for reducing peak wave-induced loads acting on said connecting means 17 relative to reference peak wave-induced loads that would occur if said connecting means were rigidly attached to and supported by a rigid half-submerged toroidal ring floating in the water directly beneath said connecting means 17 , said wave load reduction means comprising plural load reduction elements 141 arranged in sequence.
The illustrated wave load reduction means 140 comprise water surface penetrating members 142 with a total cross-sectional area on the plane of said water surface 13 when there are no waves, that is less than a corresponding total cross-sectional area that would occur for said rigid half-submerged toroidal ring on the plane of said water surface 13 when there are no waves. This reduces the incremental wave induced load for a given local water surface level change, as the incremental water displacement volume is smaller and thus the incremental water displacement load will be smaller.
Note that the wave load reduction means 140 may act to reduce one or more of many different kinds of wave induced loads from many different kinds of waves with different amplitudes, wavelengths, waveforms, speeds and three-dimensional and time-varying aspects. Waves can range from modest wind-driven waves to very large wavelength and/or amplitude waves such as tsunamis, tidal waves, earthquake caused waves etc. in open water and in shallowing or coastal waters. Wave loads may also combine with water current loads such as from an ocean current, tidal current or river current, and in conjunction may cause heaving, rolling, compression, tension, bending, twisting and/or torsion loads on structural members in the revolving overhead windmill 1 .
While not illustrated, the embodiment illustrated in FIG. 1G can include features for preventing or inhibiting loss of cleanliness or damage to surfaces from biological entities such as birds, marine life forms and animals. Other examples include algae, barnacles, crustaceans, sucker-equipped fish, etc. Examples of inhibiting or prevention means know from related prior art include bird inhibiting means such as bird perch prevention strips, visual or aural or olfactory inhibiting means, biofouling inhibiting means such as special coatings or surface treatments, etc.
The preferred embodiment of FIG. 1B through 1G , in conjunction with the plan view configuration of the invention as shown in FIG. 1A , therefore illustrates:
a revolving overhead windmill 1 , comprising:
plural airfoil means 3 for contacting proximate flow fields of a wind current 5 when said wind current exists and carries wind current energy in the form of fluid-dynamic kinetic energy; an effective axis of rotation 9 A around which each of said airfoil means can effectively rotate in orientation to some extent, said axis of rotation being disposed within 60 degrees of vertical during normal operation of said revolving overhead windmill; control system means 9 including actuator means 10 , for controlling time-variable orientations of said airfoil means relative to said proximate flow fields of said wind current when said wind current exists and carries wind current energy in the form of fluid-dynamic kinetic energy; buoyant support means 4 B for utilizing a buoyancy force from fluid displacement to at least partially contribute to supporting said airfoil means 3 above a ground surface 89 ; connecting means 17 for connecting said plural airfoil means in sequence in an annular volume 101 , said connecting means including connecting members 19 that connect adjacently-located airfoil means in said sequence; vertical load reacting means 110 for reacting vertical loads, said vertical loads comprising at least one of airfoil means weight loads and buoyant support means buoyancy loads, said vertical load reacting means comprising plural vertical-load-carrying structural members 111 arranged in sequence in a second annular volume 102 that is topologically coaxial with said annular volume; and energy harvesting means 25 including said control system means 9 , for converting a portion of said fluid-dynamic kinetic energy into net work on said airfoil means over the course of a cycle of substantially periodic motion of said airfoil means revolving in said annular volume, by utilizing time-variable fluid-dynamic pressure distributions and resulting forces acting on said airfoil means 3 at said time-variable orientations to contribute to driving said substantially periodic motion when said wind current 5 exists and carries wind current energy in the form of fluid-dynamic kinetic energy; said energy harvesting means further including energy conversion means 27 for converting at least some of said net work into energy in a desired form for at least one of transmission, storage, processing and use; wherein said energy harvesting means 25 utilizes relative motion between (i) revolving structure connected to said airfoil means 3 revolving in said annular volume 101 and driving said substantially periodic motion when said wind current exists and carries wind current energy in the form of fluid-dynamic kinetic energy, and (ii) nonrevolving connected structure including said vertical-load-carrying structural members 111 arranged in sequence in said second annular volume 102 , said vertical-load-carrying structural members 111 comprising elongated structural members making plural separated penetrations through a water surface 13 , with portions of said elongated structural members below said water surface 13 displacing water to generate said buoyancy loads and to thereby serve as plural separated float members, said buoyancy loads associated with said plural separated float members further providing at least contributory support to support said energy conversion means 27 above said water surface 13 .
The preferred embodiment of FIG. 1B through 1G , in conjunction with the plan view configuration of the invention as shown in FIG. 1A , also illustrates:
a revolving overhead windmill 1 , comprising:
plural airfoil means 3 for contacting proximate flow fields of a wind current 5 when said wind current exists and carries wind current energy in the form of fluid-dynamic kinetic energy; an effective axis of rotation 9 A around which each of said airfoil means can effectively rotate in orientation to some extent, said axis of rotation being disposed within 60 degrees of vertical during normal operation of said revolving overhead windmill; control system means 9 including actuator means 10 , for controlling time-variable orientations of said airfoil means relative to said proximate flow fields of said wind current when said wind current exists and carries wind current energy in the form of fluid-dynamic kinetic energy; buoyant support means 4 B for utilizing a buoyancy force from fluid displacement comprising water displacement from a volume below a water surface 13 , to at least partially contribute to supporting said airfoil means 3 above the water surface 13 and above a ground surface 89 wherein the ground surface is an underwater ground surface 89 U; connecting means 17 for connecting said plural airfoil means in sequence in an annular volume 101 , said connecting means including connecting members 19 that connect adjacently-located airfoil means in said sequence; wave load reduction means 140 for reducing peak wave-induced loads acting on said connecting means 17 relative to reference peak wave-induced loads that would occur if said connecting means were rigidly attached to and supported by a rigid half-submerged toroidal ring floating in the water directly beneath said connecting means 17 , said wave load reduction means comprising plural load reduction elements 141 arranged in sequence in a third annular volume 103 that is topologically coaxial with said annular volume and energy harvesting means 25 including said control system means 9 , for converting a portion of said fluid-dynamic kinetic energy into net work on said airfoil means over the course of a cycle of substantially periodic motion of said airfoil means revolving in said annular volume, by utilizing time-variable fluid-dynamic pressure distributions and resulting forces acting on said airfoil means 3 at said time-variable orientations to contribute to driving said substantially periodic motion when said wind current 5 exists and carries wind current energy in the form of fluid-dynamic kinetic energy; said energy harvesting means further including energy conversion means 27 for converting at least some of said net work into energy in a desired form for at least one of transmission, storage, processing and use; wherein said energy harvesting means 25 utilizes relative motion between (i) said connecting means 17 for connecting said plural airfoil means 3 , serving as revolving structure connected to said airfoil means 3 , revolving in said annular volume 101 and driving said substantially periodic motion when said wind current exists and carries wind current energy in the form of fluid-dynamic kinetic energy, and (ii) nonrevolving connected structure including said plural load reduction elements 141 arranged in sequence in said third annular volume 103 , said load reduction elements 141 comprising elongated structural members making plural separated penetrations through said water surface 13 , with portions of said elongated structural members below said water surface 13 displacing water to serve as plural separated float members, with said plural separated float members together serving as said buoyant support means 4 B.
The preferred embodiment of FIG. 1B through 1G , in conjunction with the plan view configuration of the invention as shown in FIG. 1A , also illustrates:
a revolving overhead windmill 1 , comprising:
plural airfoil means 3 for contacting proximate flow fields of a wind current 5 when said wind current exists and carries wind current energy in the form of fluid-dynamic kinetic energy; an effective axis of rotation 9 A around which each of said airfoil means can effectively rotate in orientation to some extent, said axis of rotation being disposed within 60 degrees of vertical during normal operation of said revolving overhead windmill; control system means 9 including actuator means 10 , for controlling time-variable orientations of said airfoil means relative to said proximate flow fields of said wind current when said wind current exists and carries wind current energy in the form of fluid-dynamic kinetic energy; buoyant support means 4 B for utilizing a buoyancy force from fluid displacement to at least partially contribute to supporting said airfoil means 3 above a ground surface 89 ; connecting means 17 for connecting said plural airfoil means in sequence in an annular volume 101 , said connecting means including connecting members 19 that connect adjacently-located airfoil means in said sequence; and energy harvesting means 25 including said control system means 9 , for converting a portion of said fluid-dynamic kinetic energy into net work on said airfoil means over the course of a cycle of substantially periodic motion of said airfoil means revolving in said annular volume, by utilizing time-variable fluid-dynamic pressure distributions and resulting forces acting on said airfoil means 3 at said time-variable orientations to contribute to driving said substantially periodic motion when said wind current 5 exists and carries wind current energy in the form of fluid-dynamic kinetic energy; said energy harvesting means further including energy conversion means 27 for converting at least some of said net work into energy in a desired form for at least one of transmission, storage, processing and use; said energy conversion means 27 including an annular electromagnetic generator 120 located in a fourth annular volume 104 that is topologically coaxial with said annular volume.
The preferred embodiment of FIG. 1B through 1G , in conjunction with the plan view configuration of the invention as shown in FIG. 1A , also illustrates:
revolving overhead windmill 1 ,
wherein said control system means 9 utilizes actuator means 10 that acts on at least one of (i) said airfoil means 3 and (ii) a control surface 9 CS connected to at least one of said airfoil means 3 and a trailing edge flap 9 F, which trailing edge flap is connected to said airfoil means and (iii) a control tab 9 CT; and wherein said actuator means 10 utilizes at least one of electrical actuation and electro-mechanical actuation and electro-hydraulic actuation and hydraulic actuation and pneumatic actuation and magnetic actuation and piezoelectric actuation and thermal actuation and shape memory alloy actuation.
The preferred embodiment of FIG. 1B through 1G , in conjunction with the plan view configuration of the invention as shown in FIG. 1A , also illustrates:
a revolving overhead windmill 1 , wherein said buoyant support means 4 B utilizes at least one of (i) a buoyancy force from fluid displacement comprising displacement of water utilizing an underwater float member 4 UF, and (ii) a buoyancy force from fluid displacement comprising displacement of air utilizing a lifting gas chamber 4 LG.
The preferred embodiment of FIG. 1B through 1G , in conjunction with the plan view configuration of the invention as shown in FIG. 1A , also illustrates:
a revolving overhead windmill 1 ,
wherein said vertical-load-carrying structural members 111 include at least one of (i) a post 112 and (ii) a truss 113 and (iii) an annular truss 113 A and (iv) a floating annular truss 113 FA and (v) a pivoting structural member 114 and (vi) a cable 115 and (vii) a stretchable cord 116 and (viii) a damper 117 and (ix) a shock absorber 118 .
The preferred embodiment of FIG. 1B through 1G , in conjunction with the plan view configuration of the invention as shown in FIG. 1A , also illustrates:
a revolving overhead windmill 1 ,
wherein said energy conversion means 27 for converting at least some of said net work into energy in a desired form for at least one of transmission, storage, processing and use, comprises an annular electromagnetic generator 120 located in a fourth annular volume 104 that is topologically coaxial with said annular volume, which annular electromagnetic generator is configured to convert said net work into electrical energy.
The preferred embodiment of FIG. 1B through 1G , in conjunction with the plan view configuration of the invention as shown in FIG. 1A , also illustrates:
a revolving overhead windmill 1 ,
further comprising an electrical device 130 supported by structure in said airfoil means 3 , which electrical device 130 comprises at least one of a battery 131 and a sensor 132 and an electrical wire 133 E and a signal wire 133 S and a an electro-optical component 134 and a computer 135 and a light 136 and a display 137 and a communication device 138 and a human interface device 139 and a photovoltaic electrical power source device 130 PV and an air turbine electrical power source device 130 AT.
The preferred embodiment of FIG. 1B through 1G , in conjunction with the plan view configuration of the invention as shown in FIG. 1A , also illustrates:
a revolving overhead windmill 1 ,
wherein said revolving overhead windmill 1 includes plural modular structural members 50 and further includes fastener means 51 for detachably connecting adjacent modular structural members to enable at least one of assembly and maintenance and inspection and service and repair and replacement, and further includes an access space 52 for at least one of a human and a robot and a tool and a camera to be in said access space to at least one of facilitate and perform said at least one of assembly and maintenance and inspection and service and repair and replacement.
The preferred embodiment of FIG. 1B through 1G , in conjunction with the plan view configuration of the invention as shown in FIG. 1A , also illustrates:
a revolving overhead windmill 1 ,
wherein said wave load reduction means 140 are contained in vertical load reacting means 110 for reacting vertical loads, said vertical loads comprising at least one of airfoil means weight loads and buoyant support means buoyancy loads, said vertical load reacting means comprising plural vertical-load-carrying structural members 111 arranged in sequence in a second annular volume 102 that is topologically coaxial with said annular volume 101 .
The preferred embodiment of FIG. 1B through 1G , in conjunction with the plan view configuration of the invention as shown in FIG. 1A , also illustrates:
a revolving overhead windmill 1 ,
wherein said load reduction elements 141 include at least one of (i) a damper 117 and (ii) a shock absorber 118 and (iii) a pivoting structural member 114 P and (iv) a flexible structural member 114 F and (v) a stretchable cord 116 and (vi) a cable 115 .
The preferred embodiment of FIG. 1B through 1G , in conjunction with the plan view configuration of the invention as shown in FIG. 1A , also illustrates:
a revolving overhead windmill 1 ,
wherein said wave load reduction means 140 comprises water surface penetrating members 142 with a total cross-sectional area on the plane of said water surface 13 when there are no waves, that is less than a corresponding total cross-sectional area that would occur for said rigid half-submerged toroidal ring on the plane of said water surface 13 when there are no waves.
The preferred embodiment of FIG. 1B through 1G , in conjunction with the plan view configuration of the invention as shown in FIG. 1A , also illustrates:
a revolving overhead windmill 1 ,
wherein said water surface penetrating members 142 collectively include at least one of (i) a post 112 and (ii) a truss 113 and (iii) an annular truss 113 A and (iv) a floating annular truss 113 FA.
The preferred embodiment of FIG. 1B through 1G , in conjunction with the plan view configuration of the invention as shown in FIG. 1A , also illustrates:
a revolving overhead windmill 1 ,
wherein said buoyant support means 4 B includes utilizes a buoyancy force from fluid displacement comprising displacement of water utilizing an underwater float member 4 UF, and further comprising buoyancy control means 4 BC for varying said buoyancy force by pumping water ballast between a water tank 4 WT and the body of water below said water surface 13 .
The preferred embodiment of FIG. 1B through 1G , in conjunction with the plan view configuration of the invention as shown in FIG. 1A , also illustrates:
revolving overhead windmill 1 ,
further comprising protection means 150 for reducing risk of damage to said revolving overhead windmill 1 from an environmental threat, wherein said environmental threat comprises at least one of a lightning strike and an electromagnetic energy threat and a hurricane and a typhoon and a cyclone and a storm and a tsunami and a seismic sea wave and a tidal wave and a tidal bore and a large sea wave and an earthquake and volcanic activity and hail and a rainstorm and a snowstorm; and wherein said protection means comprises at least one of a grounding wire 151 , an electromagnetic threat shielding layer 152 , means for limiting revolutions per minute of said plural airfoil means 3 over said cycle of substantially periodic motion, means for commanding said plural airfoil means 3 to a feathered condition, motion limiting means for protecting bearing members that normally enable said cycle of substantially periodic motion, means for elevating said plural airfoil means to an increased elevation above said water surface 13 , and tether load reduction means 153 for reducing loads consequent to said environmental threat acting on said revolving overhead windmill 1 from at least one tether connecting said revolving overhead windmill 1 to said underwater ground surface 89 U.
The preferred embodiment of FIG. 1B through 1G , in conjunction with the plan view configuration of the invention as shown in FIG. 1A , also illustrates:
a revolving overhead windmill 1 ,
further comprising position-keeping means 23 for maintaining said revolving overhead windmill 1 substantially within a desired geographic envelope 13 G, which position-keeping means includes at least one of a tether or cable 23 T and an anchor 89 B fastened to the underwater ground surface 89 U.
The preferred embodiment of FIG. 1B through 1G , in conjunction with the plan view configuration of the invention as shown in FIG. 1A , also illustrates:
a revolving overhead windmill 1 ,
wherein a portion of said revolving overhead windmill 1 that is supported by said buoyancy force, has a center of gravity location 4 CG that is below a metacenter 4 MC associated with said buoyancy force.
FIG. 2 shows an increased scale partial side view of another preferred embodiment of the invention from a location outside of the advancing airfoil means, illustrating the advancing airfoil means and adjacent structure.
The preferred embodiment of FIG. 2 illustrates control system means 9 that utilizes actuator means 10 that acts on a control tab 9 CT that controls a control surface 9 CS that in turn acts on the airfoil means 3 . No trailing edge flaps are provided in this illustrated embodiment. The actuator means 10 can utilize at least one of electrical actuation and electro-mechanical actuation and electro-hydraulic actuation and hydraulic actuation and pneumatic actuation and magnetic actuation and piezoelectric actuation and thermal actuation and shape memory alloy actuation.
The preferred embodiment of FIG. 2 also illustrates vertical load reacting means 110 for reacting vertical loads, said vertical loads comprising at least one of airfoil means weight loads and buoyant support means buoyancy loads, said vertical load reacting means comprising plural vertical-load-carrying structural members 111 , wherein said vertical-load-carrying structural members 111 include a post 112 and a damper 117 and a shock absorber 118 .
The preferred embodiment of FIG. 2 also illustrates revolving overhead windmill 1 , wherein the wave load reduction means 140 comprises water surface penetrating members 142 with a total cross-sectional area on the plane of said water surface 13 when there are no waves, that is less than a corresponding total cross-sectional area that would occur for said rigid half-submerged toroidal ring on the plane of said water surface 13 when there are no waves.
Thus FIG. 2 in conjunction with the layout of the revolving overhead windmill 1 shown in FIG. 1A and the understanding of the annular volumes 101 , 102 , 103 and 104 as shown in FIGS. 1C and 1D , together show:
a revolving overhead windmill 1 , comprising:
plural airfoil means 3 for contacting proximate flow fields of a wind current 5 when said wind current exists and carries wind current energy in the form of fluid-dynamic kinetic energy; an effective axis of rotation 9 A around which each of said airfoil means can effectively rotate in orientation to some extent, said axis of rotation being disposed within 60 degrees of vertical during normal operation of said revolving overhead windmill; control system means 9 including actuator means 10 , for controlling time-variable orientations of said airfoil means relative to said proximate flow fields of said wind current when said wind current exists and carries wind current energy in the form of fluid-dynamic kinetic energy; buoyant support means 4 B for utilizing a buoyancy force from fluid displacement to at least partially contribute to supporting said airfoil means 3 above a ground surface 89 ; connecting means 17 for connecting said plural airfoil means in sequence in an annular volume 101 , said connecting means including connecting members 19 that connect adjacently-located airfoil means in said sequence; vertical load reacting means 110 for reacting vertical loads, said vertical loads comprising at least one of airfoil means weight loads and buoyant support means buoyancy loads, said vertical load reacting means comprising plural vertical-load-carrying structural members 111 arranged in sequence in a second annular volume 102 that is topologically coaxial with said annular volume; and energy harvesting means 25 including said control system means 9 , for converting a portion of said fluid-dynamic kinetic energy into net work on said airfoil means over the course of a cycle of substantially periodic motion of said airfoil means revolving in said annular volume, by utilizing time-variable fluid-dynamic pressure distributions and resulting forces acting on said airfoil means 3 at said time-variable orientations to contribute to driving said substantially periodic motion when said wind current 5 exists and carries wind current energy in the form of fluid-dynamic kinetic energy; said energy harvesting means further including energy conversion means 27 for converting at least some of said net work into energy in a desired form for at least one of transmission, storage, processing and use.
Thus FIG. 2 in conjunction with the layout of the revolving overhead windmill 1 shown in FIG. 1A and the understanding of the annular volumes 101 , 102 , 103 and 104 as shown in FIGS. 1C and 1D , together show:
a revolving overhead windmill 1 , comprising:
plural airfoil means 3 for contacting proximate flow fields of a wind current 5 when said wind current exists and carries wind current energy in the form of fluid-dynamic kinetic energy; an effective axis of rotation 9 A around which each of said airfoil means can effectively rotate in orientation to some extent, said axis of rotation being disposed within 60 degrees of vertical during normal operation of said revolving overhead windmill; control system means 9 including actuator means 10 , for controlling time-variable orientations of said airfoil means relative to said proximate flow fields of said wind current when said wind current exists and carries wind current energy in the form of fluid-dynamic kinetic energy; buoyant support means 4 B for utilizing a buoyancy force from fluid displacement comprising water displacement from a volume below a water surface 13 , to at least partially contribute to supporting said airfoil means 3 above the water surface 13 and above a ground surface 89 wherein the ground surface is an underwater ground surface 89 U; connecting means 17 for connecting said plural airfoil means in sequence in an annular volume 101 , said connecting means including connecting members 19 that connect adjacently-located airfoil means in said sequence; wave load reduction means 140 for reducing peak wave-induced loads acting on said connecting means 17 relative to reference peak wave-induced loads that would occur if said connecting means were rigidly attached to and supported by a rigid half-submerged toroidal ring floating in the water directly beneath said connecting means 17 , said wave load reduction means comprising plural load reduction elements 141 arranged in sequence in a third annular volume 103 that is topologically coaxial with said annular volume and energy harvesting means 25 including said control system means 9 , for converting a portion of said fluid-dynamic kinetic energy into net work on said airfoil means over the course of a cycle of substantially periodic motion of said airfoil means revolving in said annular volume, by utilizing time-variable fluid-dynamic pressure distributions and resulting forces acting on said airfoil means 3 at said time-variable orientations to contribute to driving said substantially periodic motion when said wind current 5 exists and carries wind current energy in the form of fluid-dynamic kinetic energy; said energy harvesting means further including energy conversion means 27 for converting at least some of said net work into energy in a desired form for at least one of transmission, storage, processing and use.
Thus FIG. 2 in conjunction with the layout of the revolving overhead windmill 1 shown in FIG. 1A and the understanding of the annular volumes 101 , 102 , 103 and 104 as shown in FIGS. 1C and 1D , together show:
a revolving overhead windmill 1 , comprising:
plural airfoil means 3 for contacting proximate flow fields of a wind current 5 when said wind current exists and carries wind current energy in the form of fluid-dynamic kinetic energy; an effective axis of rotation 9 A around which each of said airfoil means can effectively rotate in orientation to some extent, said axis of rotation being disposed within 60 degrees of vertical during normal operation of said revolving overhead windmill; control system means 9 including actuator means 10 , for controlling time-variable orientations of said airfoil means relative to said proximate flow fields of said wind current when said wind current exists and carries wind current energy in the form of fluid-dynamic kinetic energy; buoyant support means 4 B for utilizing a buoyancy force from fluid displacement to at least partially contribute to supporting said airfoil means 3 above a ground surface 89 ; connecting means 17 for connecting said plural airfoil means in sequence in an annular volume 101 , said connecting means including connecting members 19 that connect adjacently-located airfoil means in said sequence; and energy harvesting means 25 including said control system means 9 , for converting a portion of said fluid-dynamic kinetic energy into net work on said airfoil means over the course of a cycle of substantially periodic motion of said airfoil means revolving in said annular volume, by utilizing time-variable fluid-dynamic pressure distributions and resulting forces acting on said airfoil means 3 at said time-variable orientations to contribute to driving said substantially periodic motion when said wind current 5 exists and carries wind current energy in the form of fluid-dynamic kinetic energy; said energy harvesting means further including energy conversion means 27 for converting at least some of said net work into energy in a desired form for at least one of transmission, storage, processing and use; said energy conversion means 27 including an annular electromagnetic generator 120 located in a fourth annular volume 104 that is topologically coaxial with said annular volume.
Thus FIG. 2 in conjunction with the layout of the revolving overhead windmill 1 shown in FIG. 1A and the understanding of the annular volumes 101 , 102 , 103 and 104 as shown in FIGS. 1C and 1D , together show:
a revolving overhead windmill 1 ,
wherein said vertical-load-carrying structural members 111 include at least one of (i) a post 112 and (ii) a truss 113 and (iii) an annular truss 113 A and (iv) a floating annular truss 113 FA and (v) a pivoting structural member 114 and (vi) a cable 115 and (vii) a stretchable cord 116 and (viii) a damper 117 and (ix) a shock absorber 118 .
FIG. 3A shows an increased scale partial side view of another preferred embodiment of the invention, illustrating inventive features of the aerostatically supported upwind airfoil means 3 U and adjacent structure.
In FIG. 3A , the gaseous content volumes 4 GCV are used to serve as lifting gas chambers 4 LG, and serve as buoyant support means 4 B. The embodiment of FIG. 3A also illustrates the use of load reduction elements 141 that include a pivoting structural member 114 P.
FIG. 3B shows an increased scale partial side view of the same preferred embodiment of the invention as in FIG. 3A , from a location outside of the advancing airfoil means, illustrating the aerostatically supported advancing airfoil means and adjacent structure. This view of the embodiment also illustrates the use of load reduction elements 141 that include a flexible structural member 114 F, built into the connecting means 17 to enable the revolving overhead windmill 1 to better withstand storm-related load conditions by allowing some degree of engineered flexure. This view also shows a near-planar floating annular truss 113 FA, with the lighter-than-air subsystem above held in place with some allowed movement, by the pivoting structural members 114 P that can pivot as needed to react aerostatic loads and wind-driven thrust loads on the airfoil means 3 .
FIG. 4 shows an increased scale partial side view of another preferred embodiment of the invention from a location outside of the advancing airfoil means, illustrating the aerostatically supported advancing airfoil means and adjacent structure.
The embodiment of FIG. 4 also illustrates the use of load reduction elements that include cables 115 that can pivot as needed to react aerostatic loads and wind-driven thrust loads on the lighter-than-air airfoil means 3 . More specifically, the embodiment of FIG. 4 illustrates a revolving overhead windmill 1 , comprising: plural airfoil means 3 for contacting proximate flow fields of a wind current 5 when said wind current exists and carries wind current energy in the form of fluid-dynamic kinetic energy; an effective axis of rotation 9 A around which each of said airfoil means can effectively rotate in orientation to some extent, said axis of rotation being disposed within 60 degrees of vertical during normal operation of said revolving overhead windmill; control system means 9 including actuator means 10 , for controlling time-variable orientations of said airfoil means relative to said proximate flow fields of said wind current when said wind current exists and carries wind current energy in the form of fluid-dynamic kinetic energy; buoyant support means for utilizing a buoyancy force from fluid displacement to at least partially contribute to supporting said airfoil means 3 above a ground surface 89 , wherein said buoyant support means utilizes a buoyancy force from fluid displacement comprising displacement of air utilizing a lifting gas chamber 4 LG; connecting means 17 for connecting said plural airfoil means in sequence in an annular volume, said connecting means 17 including connecting members 19 that connect adjacently-located airfoil means in said sequence; and energy harvesting means 25 including said control system means 9 , for converting a portion of said fluid-dynamic kinetic energy into net work on said airfoil means over the course of a cycle of substantially periodic motion of said airfoil means 3 revolving in said annular volume, by utilizing time-variable fluid-dynamic pressure distributions and resulting forces acting on said airfoil means 3 at said time-variable orientations to contribute to driving said substantially periodic motion when said wind current 5 exists and carries wind current energy in the form of fluid-dynamic kinetic energy; said energy harvesting means further including energy conversion means 27 for converting at least some of said net work into energy in a desired form for at least one of transmission, storage, processing and use; said energy conversion means 27 including an annular electromagnetic generator 120 located in a fourth annular volume that is topologically coaxial with said annular volume; wherein said energy harvesting means 25 including said annular electromagnetic generator 120 , is connected to plural vertical-load-carrying structural members 111 arranged in sequence in a second annular volume that is topologically coaxial with said annular volume, said plural vertical-load-carrying structural members 111 comprising plural separated elongated structural members spaced around said second annular volume; wherein each said elongated structural member comprises at least one of a cable 115 (illustrated here), a stretchable cord, a pivoting structural member, a post and a guy wire; and wherein each said elongated structural member has a length less than half the height of said airfoil means 3 and is capable of carrying some tension loading in a circumferential direction associated with circumferential forces between (i) revolving upper structure (here including connecting means 17 above the air gap 120 AG) of said revolving overhead windmill 1 and (ii) nonrevolving lower structure (here including tether 23 T and floating annular truss 113 FA) of said revolving overhead windmill 1 .
FIG. 5 shows an increased scale partial side view of another preferred embodiment of the invention, illustrating inventive features of the aerostatically supported upwind airfoil means and adjacent structure.
The revolving overhead windmill 1 is supported by aerostatic buoyancy forces in a manner analogous to aerostatically supported dirigibles, airships or balloons. The revolving overhead windmill 1 includes a plurality of airfoil means (or “windfoil” means) 3 that are filled in considerable part with lifting gas 3 LG such as at least one of helium, hydrogen, other lifting gas and hot air; and connecting means 17 comprising a substantially toroidal ring structure that is an airfoil assembly support ring 35 AR, that is also preferably inflated with lifting gas 3 LG. If hydrogen is used as some or all of the lifting gas, it can optionally be re-supplied from electrolysis of water using energy from energy conversion means 27 to produce hydrogen, which can be fed by a pipe (not shown so as not to clutter the Figure) to the inflated elements to replace leakage losses of the lifting gas (any additional hydrogen produced could optionally be sent by pipe or barge or ship to end user entities on shore). Lightweight structure for the airfoil means 3 and the support ring 35 AR may both use advanced strong and light materials such as advanced composites, advanced fabrics and advanced metallic elements, and construction architectures such as those used in rigid, semirigid or nonrigid airships, for example.
FIG. 5 also illustrates inflatable elements that include variable volume control using ballonets 3 BAL as known from the prior art of dirigibles, to vary aerostatic lift acting on the airfoil means 3 .
FIG. 5 also shows the main or center spar 3 SP serving as a mast 3 M, with the bottom of the mast 3 M allowed to pivot in azimuth or yaw using bearings 69 at the locations illustrated.
The embodiment of FIG. 5 also illustrates the use of load reduction elements that include a stretchable cord 116 that can pivot as needed to react aerostatic loads and wind-driven thrust loads on the lighter-than-air airfoil means 3 and assembly support ring 35 AR.
The distributed aero buoyancy around the perimeter of a large annulus, reduces water displacement of floating annular truss 113 FA, which in turn also enables reduced wave induced vertical loads for given wave height and wavelength.
The preferred embodiment of FIG. 5 , in conjunction with the plan view configuration of the invention as shown in FIG. 1A , also illustrates:
a revolving overhead windmill of claim 1 , wherein said buoyant support means 4 B utilizes at least one of (i) a buoyancy force from fluid displacement comprising displacement of water utilizing an underwater float member 4 UF, and (ii) a buoyancy force from fluid displacement comprising displacement of air utilizing a lifting gas chamber 4 LG.
FIG. 6 shows an increased scale partial side view of another preferred embodiment of the invention, illustrating inventive features of the aerostatically supported upwind airfoil means and adjacent structure, sited over a layer of moving water 13 M, such as (without limitation) a floodplain in a flood state, or tidelands with maximum high tides, or marshlands following heavy monsoon rains, or an arroyo or wash following heavy precipitation, or similar or analogous situations of a variable or a temporary layer of moving water.
In this embodiment, vertical load reacting means 110 for reacting vertical loads comprising at least one of airfoil means weight loads and buoyant support means buoyancy loads, include plural vertical-load-carrying structural members 111 , which in turn include posts 112 braced by guy wires 112 G. Position keeping means 23 here comprise installation of the posts 112 in the ground surface 89 .
FIG. 7A through 7N show, in block diagram form, several alternate generator means for converting mechanical net work 128 to “energy in a desired form for at least one of transmission, storage, processing and use” in one preferred form as electrical energy 129 .
The preferred embodiment of FIG. 7A through 7N , in conjunction with the plan view configuration of the invention as shown in FIG. 1A , also illustrates:
a revolving overhead windmill 1 ,
wherein said energy conversion means 27 includes at least one of (i) an annular electromagnetic generator 120 located in a fourth annular volume 104 that is topologically coaxial with said annular volume 101 , and (ii) an electrical generator using an electromagnet 121 and (iii) an induction generator 122 and (iv) a doubly fed induction generator 122 D and (v) a field excited synchronous generator 123 and (vi) a gear-driven generator 124 and (vii) a direct-drive generator 125 and (viii) an AC generator 126 and (ix) a multiphase AC generator 126 M and (x) a DC generator 127 .
The preferred embodiment of FIG. 7A through 7N , in conjunction with the plan view configuration of the invention as shown in FIG. 1A , also illustrates:
a revolving overhead windmill 1 ,
wherein said annular electromagnetic generator 120 comprises at least one of (i) a permanent magnet generator 120 P and (ii) a permanent magnet synchronous generator 120 S and (iii) a pancake permanent magnet generator 120 PP and (iv) a direct drive permanent magnet generator with an ironless stator core 120 IL and (v) a permanent magnet generator with at least one of rigid wheels and rigid rollers and rigid ball bearings that serve as means 120 RW for maintaining a small and substantially constant air gap between stator and rotor members.
FIG. 8 shows a plan view of multiple revolving overhead windmills 1 in an array, with shared anchors 89 B in the underwater ground surface 89 U.
FIG. 9 shows a plan view of a revolving overhead windmill 1 being towed to its installation site by a tugboat 95 TB in a tow direction 95 D using a tow cable 95 C.
FIGS. 10A through 10D illustrate aspects of control system means for controlling the revolving overhead windmill.
FIG. 10A illustrates a representative control system block diagram for a revolving overhead windmill, wherein control system means 9 including actuator means, for controlling time-variable orientations of fluid-foil means, comprises (i) sensor means 71 for sensing a flow direction 5 FD comprising at least one of an air flow direction (of an air current such as a wind) and a water flow direction (of a water current such as an ocean current or tidal current or river current) and optionally for sensing other measurables, (ii) computational processor means 73 with at least one computational algorithm 73 A for generating a control command 79 as a function of said flow direction 5 FD, (iii) at least one powered actuator means 77 for executing the control command 79 , and (iv) at least one signal transmission means 75 for transmitting a signal containing said control command 79 from said computational processor means 73 to said powered actuator means 77 . [c11] The powered actuator means 73 can either directly control the orientation of fluid-foil means (that can include one or both of airfoil means 3 A and water foil means 3 WF), e.g. with a rotary or linear actuator or actuators, and/or indirectly control orientation of fluid-foil means using a control tab or other means for controlling including means for controlling at least one of a control surface 9 CS, tab 3 TAB, flap 3 F, blown flap 3 BF, slat 3 SL, and morphing shape aerodynamic member 3 MSA [not shown in this Figure but shown earlier]. FIG. 10A also illustrates an optional operator interface 81 sending operator command(s) 83 to computational processor means 73 and receiving at least one of data and annunciation(s) 85 to an operator. An operator may actively control operation of the fluid-dynamic renewable harvesting system, or in alternate embodiments monitor its automatic operation and only intervene or override for non-normal, failure or emergency situations.
FIG. 10B illustrates several optional sub-elements which may reside in each of the blocks of the control system shown in FIG. 10A . The elements in the sensor means 71 could include a local wind speed sensor, local water speed sensor, air or wind flow direction sensor, water flow direction sensor(s) at one or more depths, gust sensor, pressure sensor, acceleration sensor, rate gyro, force sensor, displacement sensor, temperature sensor, camera sensor, fluid-foil condition sensor, icing condition sensor, failure detection sensor and/or other sensor(s). The computational processor means 73 could include a computer, a microprocessor, hardware, software algorithms, redundancy and redundancy management, sensor signal selection and failure detection, excess wind stow or slow control, tipover prevention control, anti-ice/de-ice control, start and stop control and/or electrical power system control. The powered actuator means 77 could include a rotary actuator, a linear actuator, other actuator, a shape memory alloy actuator, a control surface actuator, a control tab actuator, a trailing edge deflectable surface actuator, a leading edge actuator, a fluid-foil orientation actuator, an inflation control actuator, an actuator power supply and/or actuator processor. The optional operator interface 81 could include one or more of an operator display, an operator annunciator, and/or an operator control.
FIG. 10C illustrates for a revolving overhead windmill, a computational algorithm 73 A that comprises orientation command generation means 73 OC for generating time-variable orientation commands 79 OC for each of plural airfoil means 3 as a function of at least one of said flow direction 5 FD and time-varying location 3 TVL of at least one of said plural airfoil means 3 , which time-variable orientation commands if properly executed by the at least one powered actuator means 77 , would result in time-variable orientations of said plural airfoil means 3 that tend to substantially maximize the net work on the airfoil means 3 over the course of a cycle of substantially periodic motion of the fluid-foil means, through time-variable fluid-dynamic pressure distributions that tend to substantially maximize resulting forces acting on the airfoil means 3 to drive said substantially periodic motion when a fluid current comprising an air current and/or water current exists and carries energy in the form of fluid-dynamic kinetic energy. The fluid-foil means includes airfoil means.
FIG. 10C illustrates for a revolving overhead windmill, the additional feature comprising at least one of first command generation means 73 OCA for commanding orientations of airfoil or wind foil means to beneficially harvest wind or air current energy, and optionally second command generation means 73 OCB for commanding orientations of hydrofoil or water foil means to beneficially harvest water current energy.
FIG. 10D illustrates for a wind or air current, a representative fluid-foil orientation command 79 OC schedule (for airfoil or wind foil means) as a function of the azimuthal angle 19 AA along the rotational direction of motion 19 RD, starting with 0 at incoming air flow direction, as described earlier in the context of FIG. 3A . In this representative preferred schedule, note that the fluid-foil is commanded to a maximum lift coefficient (C L ) orientation for the crosswind legs of its motion, while it can be commanded to a beneficial drag torque orientation on the peak downwind leg of motion near 90 deg azimuthal angle, and to a minimum drag feathered orientation on the peak upwind leg of motion near 270 deg azimuthal angle. Variant algorithms for fluid-foil orientation commands as a function of various sensor inputs and to achieve multiple objectives, are possible within the spirit and scope of the invention as claimed. For excessively high wind speed or storm conditions where the airfoils may be at risk of excess loads or of tipping over, the orientation commands can be diminished or reduced as shown in the dot-dashed lines for reduced magnitude orientation commands 79 RED. The reduced magnitude orientation commands can optionally vary in magnitude as a function of azimuthal angle and other parameters such as wind speed or algorithmically calculated tipping risk.
FIG. 10D thus illustrates for a fluid-dynamic renewable energy harvesting system, the additional feature comprising a airfoil command modification means 79 A in said first command generation means 73 OCA, for modifying said airfoil orientation commands to avoid potential harm when said airfoil means 3 A are at risk of harm from at least one of wind loads and tipping.
Note that the type of orientation command vs. azimuthal angle schedules shown in FIG. 10D will yield considerably greater energy extracted than a simple sinusoidal or similar fixed schedule orientation control. Note also that individual local flow speed and direction sensors for air and/or water flow may provide additional input to optimize each fluid foil orientation for wind foils and/or water foils at each instant, including considerations of downwash, wake, and local flow variations both natural and induced by other fluid foils.
FIGS. 10A through 10D collectively disclose for a revolving overhead windmill, control system means 9 that includes first sensor means 71 A for at least one of measuring and estimating wind direction plus first command generation means 73 OCA for generating airfoil orientation commands intended to control said time-variable orientations of airfoil means 3 A that are members of said airfoil means 3 plus first actuation means 77 A for executing said airfoil orientation commands.
In one particular variant embodiment the airfoil orientation commands comprise a discrete set of airfoil orientation commands including (i) zero angle of attack relative to said wind direction 5 AD, (ii) angle of attack corresponding to maximum airfoil lift coefficient acting towards the right hand side from a perspective oriented against the wind direction 5 AD, and (iii) angle of attack corresponding to maximum airfoil lift coefficient acting towards the left hand side from a perspective oriented against the wind direction 5 AD.
While certain preferred embodiments of the invention have been described in detail above with reference to the accompanying Figures, it should be understood that further variations and combinations and alternate embodiments are possible within the spirit and scope of the invention as claimed and described herein. | The revolving overhead windmill includes airfoils that harvest wind energy using a configuration, in the class of vertical axis wind turbines, wherein the airfoils are modestly elevated above a water or ground surface through the use of buoyancy forces and elongated structural members. The airfoil angle of attack is controlled in a periodic manner as each airfoil revolves around a closed circuit of revolution, in order to optimize system energy harvest as measured by metrics such as megawatts of electric power generation under rated wind conditions. Typical large-scale applications in high wind, offshore locations can substantively contribute to utility-scale renewable energy production and also contribute towards climate change mitigation targets. | 8 |
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