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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to novel data gathering and sampling in connection with in-situ soil testing and analysis. More particularly, the invention concerns a method and apparatus for providing analysis and evaluation of Becker Penetration Test Data more accurately and timely to be used immediately to modify drilling programs while in progress.
2. Discussion of the Prior Art
In the past, it has been common practice to extract soil samples and make laboratory measurements of data concerning the characteristics of a soil bed on the recovered samples. While some arrangements have exhibited at least a degree of utility in the gathering of data in connection with soil mechanics analysis, room for significant improvement remains.
There are many cases in engineering practice where it is necessary to determine the engineering characteristics of gravelly and course-grained soils. Desirably, this would be done in-situ, since the properties of cohesionless soils are known to be influenced significantly by sample disturbance. However, standard methods of in-situ exploration developed for sands, such as the Standard Penetration Test (PST), the Cone Penetration Test (CPT), the self-boring pressuremeter, etc. give erroneous results in gravels because the soil particles are large compared to the dimensions of the test equipment. Furthermore, determining soil properties by laboratory testing is hampered by the fact that it is virtually impossible to take undisturbed samples of gravelly soils, except by in-situ freezing techniques, and these are enormously expensive.
In consequence, the engineering properties of gravels are more customarily determined by constructing test pits to extract samples for grain size distribution tests and for determining the in-situ density or relative density of the gravelly soil. Representative samples are then prepared in the laboratory to the same density as that of the field deposits and used to determine engineering properties such as strength, deformation, and compressibility characteristics. Alternately, the engineering properties of the deposit are assessed on the basis of judgment, based on a knowledge of the grain distribution and the density of the deposit. Only occasionally has in-situ testing been attempted or used for engineering property determinations of gravelly soils.
In many cases the above procedures have provided useful data for design studies. However, care must be exercised to insure that all relevant factors influencing the interpretation of the test data obtained from the reconstituted samples are considered in the final evaluation of properties. This involves consideration of changes in density, if it is necessary to change the gradation by scalping or adopting a parallel gradation curve for preparation of laboratory test specimens, and in some cases, consideration of other effects such as "aging", which is likely to change the properties of any cohesionless soil over a long period of time.
In recent years, it has been found necessary to explore other properties of gravelly deposits, in addition to the conventional determinations of strength, deformation and compressibility characteristics. These include the response of gravelly deposits to cyclic loading, which may be induced by earthquake shaking or water action. It is only recently that the need for such studies and determination has been recognized. Some years ago it was the conventional wisdom of the goetechnical engineering profession, for example, that gravelly soils were not susceptible to large increases in pore water pressure, leading possibly to liquifaction, under the effects of earthquake shaking. It was generally believed that gravelly soils, because of their high permeability, would be able to dissipate pore pressures virtually as fast as they could be generated by earthquake shaking, and thus were not vulnerable to liquefaction during earthquakes. Clearly, this depends on the nature of the soil (sandy gravels for example, may not be significantly more pervious than sands); pore pressure dissipation also depends on the boundary drainage conditions since a gravel is not freedraining if it is underlain and overlain by relatively impervious layers of other soils.
The concept that gravels were not vulnerable to liquifaction was also fostered by the better field performance of foundations on gravel, as compared with sands, in earthquakes such as the Alaska earthquake of 1964, and by laboratory tests, conducted under cyclic loading conditions, which showed that significantly higher stresses were required, even under undrained cyclic loading conditions, to induce high pore water pressures in gravelly soils than in sands. It has since been recognized that the higher laboratory strengths were due mainly to the effects of membrane compliance, and that when laboratory test results are corrected for this effect, the cyclic loading resistance of gravels is not very different from that for sands.
Finally, and more importantly, there have been a number of cases in recent years where liquifaction of gravelly deposits has been observed to occur, with associated effects, during earthquakes. These events have prompted a review of earlier earthquake performance of gravelly soils and several cases of earthquake-induced liquifaction in gravelly soils are now recognized to have occurred.
In a number of these cases, the generation of soil "blows" at the ground surface showed that particles up to one inch size had been carried upward by flowing water, or that sand was washed out of sandy gravel deposits to form sand boils at the surface.
Recognition of these effects has led to a renewed interest in the liquifaction characteristics of gravelly soils and in methods of field exploration which can lead to meaningful determinations of their in-situ characteristics. Since the nature of gravelly soils is likely to involve many of the same problems in geotechnical investigations as sands, i.e., significant variability within relatively short distances and significant changes in properties due to sample disturbance, it has seemed desirable to explore the possibility of exploring the properties of gravelly soils using procedures which have proved successful for sandy soils; that is by the use of some type of penetration test which can be performed rapidly, at a number of locations in a deposit, to provide a representative index of overall characteristics. Clearly such a test would need to be much larger in scale than the relatively small-scale SPT or CPT tests used widely for investigating the liquefaction resistance and other properties of sands. In fact, a large scale version of either of these tests would seem to provide a useful basis for investigating the characteristics of gravelly soils. An added advantage of such an approach is that a large-scale version of, say, the SPT test should be just as applicable in sands as the conventional SPT test and thus it should be possible to correlate the results of the test results with the extensive body of field performance data, such as liquifaction resistance and compressibility, through the development of correlations between the different test procedures. This would provide a direct basis for evaluating the field behavior of gravelly soils.
Fortunately, such a large-scale type of penetration test already exists in the form of the Becker Penetration Test, developed in Canada in the later 1950's and now widely used for exploring the characteristics of deposits containing gravel and cobble-size particles.
Present methods and apparatus for measuring the ability of a soil bed to support a structure are limited in several ways. First, there are no known methods or apparatus that measure the dynamic loading characteristics of a soil bed as a function of time. Moreover, present methods and apparatus utilize short displacement, cyclic, linear penetration techniques that penetrate a soil bed at a constant rate and do not measure the dynamic loading characteristics of the soil.
One prior art device is shown in U.S. Pat. No. 5,339,679 to Ingram et al discloses a self-contained apparatus for determining the static and dynamic loading characteristics of a soil bed. In operation, a drill string presses the apparatus into a soil bed at an uncontrolled rate resulting in a variable penetration rate. The apparatus has a self-contained data acquisition system that measures and records, as a function of time, the force exerted on the sampling apparatus and the depth of penetration as the drill string presses the sampling apparatus into the soil bed. Data is provided that enables the user to determine the static soil characteristics (e.g., shear strength and stress-strain characteristics) and the dynamic loading characteristics of the soil bed.
U.S. Pat. No. 4,542,639 to Cawley et al discloses apparatus and method for testing structures by impact. The structure is struck by an impacter associated with a force transducer, the output of which is related to the force which the transducer experiences on impact and encompasses a frequency range including the lowest frequencies (typically approaching zero frequency) which that force contains to any substantial degree. A test spectrum of the force including that full range of frequencies is produced by a Fourier transformer in a form suitable for automatic comparison, and is than compared with a reference spectrum typical of impact with a reference structure, and a signal is produced indicating fit or lack of fit between the test and reference spectra.
U.S. Pat. No. 5,048,320 to Mitsuhashi et al and U.S. Pat. No. 5,195,364 to Dehe et al disclose methods and apparatus for testing the hardness of objects or structures using non-destructive impact to an object to be inspected.
The problems enumerated in the foregoing are not exhaustive but rather are among many which tend to impair the effectiveness of previously known testing devices and data gathering systems.
SUMMARY OF THE INVENTION
The present invention addresses the problems described above by providing a method and apparatus for providing analysis and evaluation of Becker Penetration Test Data more accurately and timely to be used to modify drilling programs while in progress. The data logger monitors the bounce chamber pressure by use of a pressure transducer connected in line with, and adjacent to, the monitoring gauge. Locating the pressure transducer adjacent to the monitoring gauge ensures that the recorded pressure is the same as the visually monitored pressure and that any effect of hose length is the same for both automated and manual monitoring. Since the bounce chamber pressure is cyclical, and the primary interest is the peak pressure for each hammer blow, the data logger repeatedly measures the transducer pressure, selects the peak pressure for each hammerblow, and stores the peak pressure along with the date and time of each blow in the data logger memory.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view of the bounce chamber energy monitor of the invention.
FIG. 2 is a schematic diagram of a Becker Hammer Drill sampling operation while FIGS. 2A and 2B show details of FIG. 2.
FIG. 3 is a schematic diagram of a typical output energy rating instrument showing the location of the bounce chamber energy monitor of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The Becker Hammer Drill, shown in FIG. 2, was developed by Becker Drills during the late 1950's as a method for rapidly penetrating deposits of gravels and cobbles. The method consists of driving a double-walled casing into the ground with a double-acting diesel pile hammer. During driving, air is forced down the annulus of the casing system to the drive bit as shown in FIGS. 2A and 2B. Soil particles entering the bit (FIG. 2B) are then transported up the inner casing (FIG. 2B) to the surface (FIG. 2A) by the air flow and they are then collected in a cyclone as illustrated in FIG. 2.
The diesel hammer used on Becker drill rigs is rated at a maximum energy of 8100 foot-pounds per blow. This type of pile hammer is closed off at the top and part of its energy during driving is developed by the compression of air in the top of the hammer cylinder during the travel of the ram during each cycle. By measuring the pressure of this trapped air pressure (bounce chamber pressure), in bounce chamber 23, an estimate of the driving energy can be obtained for each blow. Correlations between potential hammer energy and bounce chamber pressure have been developed by the manufacturer.
The hammer frame is mounted on rollers or wear blocks which move along guides on the drill rig mast. Delivering 92 blows per minute, it is not unusual for the hammer to achieve penetration rates of about 100 feet per hour. On completion of each sounding, the casing is gripped with tapered slips and raised by hydraulic grips. It usually requires about 60 minutes to withdraw 100 feet of casing from the ground.
The double walled casing is composed of two heavy pipes arranged concentrically (FIG. 2B). The inner pipe floats inside the outer pipe, separation being provided by neoprene cushions, and only the outer pipe absorbs the direct impact of the hammer. The casing is provided in 8 to 10 foot lengths, and segments are connected with threaded joints in the outer pipe. An "O" ring seal is used on one end of each inner pipe segment to avoid leaks between the outer and inner pipes.
The Becker Penetration Test consists basically of counting the number of hammer blows required to drive the casing one foot into the ground. By counting blows for each foot of penetration, a more or less continuous record of penetration resistance can be obtained for an entire soil profile. This test was originally called the "Becker Denseness Test" and was developed in Canada by using a plugged 8-tooth crowd-out bit with 5.5-inch O.D. casing. The plugged bit was employed because it was found that open-bit soundings in saturated sands often gave erratic results. Over the years, however, Becker penetration testing has employed both open and plugged bits together with both 5.5-inch and 6.6-inch O.D. casing sizes.
On a number of investigations, the Becker Penetration Test has often been used for the purpose of obtaining equivalent Standard Penetration Test (SPT) blowcounts and using correlations between SPT resistance and field behavior to predict performance. During the last 13 years, several correlations between Becker blowcounts and (SPT) blowcounts have been developed. The great variability of Becker-SPT correlations is due in large measure to the fact that the different studies often employed different Becker and SPT procedures and equipment, as well as different methods of data interpretation.
The studies do indicate that the penetration resistance measured by the Becker Drill procedure has the potential for development as an index of soil penetrability and that if tests were performed under suitably standardized conditions, a useful correlation between SPT and the Becker Test blowcounts could be developed.
Use of the automated Becker Hammer Bounce Chamber Pressure Monitor of the invention, designated by the numeral 10, to monitor bounce chamber pressure for the Becker Penetration Test was initially performed to improve the quality of data obtained during a typical test, and to enable test data to be evaluated at the test site enabling the test program to be altered if required. Prior to use of the automated monitor 10, an observer was required to count the number of hammer blows for each one foot interval of casing penetration, and observe the monitoring gauge to record the average peak pressure for all of the hammer blows in that interval. Monotony, high blowcounts, or variances in pressure within each interval often resulted in errors in recording the data. Furthermore, the recorded data required additional handling to enable input into the computer programs for analysis. Use of the monitor 10 eliminated these problems by recording bounce chamber 23 pressure for each hammer blow, and computing an average bounce chamber 23 pressure and standard deviation for each one foot interval. Recorded data is immediately available for analysis and is in a format suitable for input into computer programs for further analysis.
The monitor 10 consists of a pressure transducer 11, quick connect manifold 12, data logger 13, storage devices 15 and 16 weatherproof control module 17, indicator lamp 18, keyboard 19, and telephone modem 20. The components of the monitor 10 are housed in a weatherproof storage case 21 and powered by a battery 14. The Becker Hammer bounce chamber 23 is connected to the monitor 10 through socket 25, plug 26, through hose 24 to "Tee" 12 with quick connect couplings. Pressure transducer 11 is connected from the "Tee" 12 through weatherproof connectors 22 to the data logger 13.
In a preferred embodiment, the pressure transducer 11 had a range of 0-50 psi, with an output of 4-20 mA. Transducer 11 was a model 27-142-1050 manufactured by Keller PSI, Hampton, Va. 23666. Data logger 13 was a model CR10, storage modules 15, 16 were models SM192 and SM716, keyboard display 19 was a model CR10KD, telephone modem 20, was a model DC112. Additional components (not shown) are power supply, model BPALK; optically isolated RS-232 interface, model SC32A; 9 pin peripheral to RS-232 interface, model SC 532; data logger 13 support software, model PC 208; and cables model SC12. All of these units were supplied by Campbell Scientific, Inc., Logan, Utah. Control pod 17 was fabricated from a Woodhead Pushbutton Station, Model 4023, manufactured by Daniel Woodhead, Co., Aurora, Colo. Enclosure 21 was a model 827, manufactured by Underwater Kinetics, San Marco, Calif. The connectors were supplied by Newark Electronics of Denver, Colo., or Warren Fluid Power, of Denver, Colo.
The monitor 10 is controlled by a program containing a series of instructions which control the schedule, pressure transducer 11 measurement, control module signal monitoring, computation of data, and data storage operations of the data logger 13. The program is described in Appendix I to the specification. The data logger 13 monitors the bounce chamber 23 pressure by use of a pressure transducer 11, connected in line with, and adjacent to the monitoring gauge 27. Locating the pressure transducer 11 adjacent to the monitoring gauge 27 ensures that the recorded pressure is the same as the visually monitored pressure and that any effect of hose 24 length is the same for both automated and manual monitoring. Since the bounce chamber 23 pressure is cyclical and we are interested in the peak pressure for each hammer blow, the data logger 13 repeatedly measures the transducer 11 pressure, selects the peak pressure for each hammer blow. and stores the peak pressure along with the date and time of each blow in the data logger 13 memory 15 and 16.
The operator is required to depress a switch on the keyboard 19 or control module 17 to signal the data logger 13 for each one foot of casing penetration. This signal causes the data logger 13 to compute the blowcount, and the average and standard deviation of the pressure peaks for the previous foot of penetration. This penetration, as well as the date, time, and depth of penetration is stored in the data logger 13 memory. The operator is also required to depress a switch on the keyboard 19, or control module 17 to signal the data logger 13 to indicate the completion of a drill hole.
The data logger 13 monitors the pressure transducer 11 signal sixty four times per second. At a Becker Hammer rate of ninety two blows per minute, the pressure is measured about forty two times per blow, and thus the accuracy of the measured pressure is expected to be less than the estimated 0.5 psi accuracy of visual observations. The data logger 13 is a battery powered, programmable controller in a small, rugged, sealed module which enables scheduled measurement of the pressure transducer 11, monitoring and recording of user input control signals via the control module 17 and keyboard 19, mathematical computations based upon the measurements and control signals, and storage of recorded and computed data.
The pressure transducer 11 has a range of 0-50 PSI, with an output of 4-20 MA. The quick connect manifold has quick connect fittings for instant installation of the pressure transducer 11 in the manual bounce chamber pressure gauge supply hose 24.
The storage devices 15, and 16 are small, sealed modules which expand the random access memory of the data logger 13 and retain that memory with internal battery power 14 separate from the data logger 13.
The weatherproof control module 17 contains waterproof control switches with large pushbuttons to enable user control of the data logger 13 functions. An indicator lamp 18 is provided on the wiring panel of the data logger 13 to indicate the on/off status of the data logger 13.
The keyboard 19 is a series of pushbutton switches and a display screen to enable user control of the data logger 13 and user monitoring of the status of the data logger 13 and collected data. The telephone modem 20 is a device enabling transfer of data and programming and control of the data logger 13 via telephone by using a personal computer.
The weatherproof storage case 21 is a suitcase-type box, which houses all of the monitor's components, and is fitted with external connectors for the pressure transducer 11 and weatherproof control module 17 to enable use in rainy or inclement weather.
SYSTEM OPERATION
The data logger 13 is controlled by user controlled flags which can be set and cleared by using the keyboard 19, control module 17, or an external personal computer. User controlled flags enable the user to start or stop operation of the data logger 13. When operating, the data logger 13 monitors the pressure transducer 11 signal 64 times per second, converts the signal to pressure (PSI), compares each reading to the previous reading, and retains the highest reading. When the pressure decreases below 5 psi following a reading greater than 5 psi, the retained highest reading is considered to be the peak pressure for the cycle or pulse and is stored with an identification code indicating that the data pertains to a peak pressure data point, the julian day, hour, minute, and seconds. The completed cycle increments a counter called blow/foot, and zeros out the previous peak pressure reading. Operation continues indefinitely until stopped by the user.
A second user controlled flag signals the data logger 13 to indicate completion of a one foot interval of penetration by the Becker Hammer Drill. This signal causes the data logger 13 to increment a counter called a foot counter, and to compute the average and standard deviation of all peak pressure readings since the last time the flag was turned on by the user. The computed data is stored with an identification code indicating that the data pertains to completion of a one foot interval of penetration, along with the julian day, hour, minute, seconds, and battery voltage, and the blows/foot counter is zeroed out. Then the flag is automatically reset.
A third user controlled flag signals the data logger 13 to indicate completion of the drill hole. This signal causes the data logger 13 to zero the foot counter and the blows/foot counter, and to store an identification code indicating that the data pertains to the completion of a drill hole, the julian day, hour, minute, and seconds. Then the flag is automatically reset.
All stored data is retained in the data logger in two separate areas until it overwrites itself, or until the power is interrupted. The data is separated as follows: One area includes only the data recorded for each foot of penetration, and consists of the identification code, the julian day, hour, minute and seconds, standard deviation of the pressure peaks in psi, average pressure of the pressure peaks in psi, number of blows per foot for the completed foot of penetration interval, and foot counter value indicating depth of penetration. The second area includes an identification code, the julian day, hour, minute, and seconds, and peak pressure for every completed pressure cycle, foot counter value indicating depth of penetration, and battery voltage. The identification code is unique depending upon the type of data, whether pressure data for each completed pressure cycle, foot counter increment or completion of drill hole signal.
All data from one area is transferred automatically to the first storage device and from the other area to the second storage device. Data in the storage devices are retained by internal battery power even when the devices are removed from the data logger 13 enabling transport of the devices while the data logger 13 continues to operate. Data in the storage devices can be examined or transferred to a personal computer for import into spreadsheet programs for analysis.
It will be appreciated that the method and apparatus for determining the dynamic characteristics of a soil bed by penetrating a soil bed at a variable penetration rate and measuring the force and displacement of the of the sampling device as a function of time of the present invention, provide certain significant advantages. The principal utility of the invention would be in-situ soil testing and analysis. The general field of application in geotechnical engineering, in-situ testing. The invention would be used by both federal and public agencies and private entities utilizing the Becker Hammer Drill to determine penetration resistance of soils.
Obviously, many modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described. | A system and method for providing analysis and evaluation of penetration test data for modifying Becker Hammer drill programs while in progress by measuring the bounce chamber pressure of a diesel hammer. The system comprises a pressure transducer connected to the bounce chamber for sensing the bounce chamber pressure, a data logger for monitoring the pressure transducer, storage means, a control module and a keyboard having a display screen to enable user control of the data logger, a telephone modem, and a series of instructions for controlling the schedule, pressure transducer measurement, control module signal monitoring, computation of data, and data storage operations of the data logger. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This is a division of application Ser. No. 310,011, filed Oct. 13, 1981.
BACKGROUND OF THE INVENTION
This invention relates to solid state microwave amplifiers and more particularly to divider/combiner circuits for obtaining higher power output than can be obtained from one solid state amplifier by appropriately combining the output power from more than one amplifier. More particularly, the circumferential divider/combiner circuit of the invention combines the output power of a moderate number of high frequency bipolar and/or field effect transistors to provide high power amplification in the 8-20 GHz frequency band. In this frequency range, power amplification techniques are almost totally dominated by thermionic-cathode microwave tubes with some limited applications for one-port negative resistance semiconductor devices. The need for higher-power solid state microwave amplifiers exists in order to provide amplifiers of smaller size, lighter weight, increased reliability and lower cost than are presently available.
In the prior art, the semiconductor devices which are available for amplification in the 10 GHz frequency range are limited in the output power that they can provide. Thus, although they have a broad bandwidth and have the advantage of not utilizing thermionic cathodes, their lack of ability to produce high power is a substantial limitation to their application. These active semiconductor devices have been incorporated into prior art circuits to increase their output power by paralleling a number of devices. However, it has been found that paralelling of individual semiconductor devices has disadvantages in reduction of efficiency and the effect of paralleling upon the impedance at the input and the output of the paralleled devices which limits the number of such devices which may be paralleled.
When using more than one amplifier because the required output exceeds the capability of a single device, such as a high frequency transistor, several amplifiers can be connected in parallel. There are disadvantages and dangers in the simple parallel connection. An input VSWR of 1.22, for example, represents a reflection power loss of only 1%. But if two devices both having a VSWR of 1.22 are connected in parallel, the power split between them depends on the impedance ratio which in this case could be as high as 1.5 if the phases of the two reflections were 180° apart. Similar arguments can be made about output impedances. Not only is the power divided unequally, but if one unit fails because of unequal power split or for other reasons, the resulting high VSWR can adversely affect the remaining units.
A problem arises in prior art divider/combiner circuits that utilize integral damping resistors to provide isolation between paralleled solid state amplifiers. These integral damping resistors introduce instability and also reduce efficiency in the operating mode. Although, in the prior art divider/combiner circuits the isolation resistors are connected so that currents should not flow in the operating mode, the distributed reactances within the circuit do produce current flow in the isolation resistors in the operating mode; and, hence, the stability and efficiency of the divider/combiner circuit is reduced.
Although solid state power amplifiers using combined negative resistance diodes are becoming available for use in the 8-20 GHz frequency range, they have inherent problems with noise performance, limited dynamic range, and poor stability which limits their utility. Transistors are presently being developed which operate in this frequency range and have demonstrated 5 watts output with 5 db gain at 8 GHz and 1/2 watt output with 5 db gain at 20 GHz. Numerous applications are envisioned for solid state microwave amplifiers delivering 10-50 watts output power. Assuming 90 percent combining efficiency can be achieved, a reasonable number of existing transistors do provide the desired output power when combined as in this invention.
SUMMARY OF THE INVENTION
The aforementioned problems are overcome and other advantages are provided by this invention of a circumferential divider/combiner circuit in which the field patterns and electrode geometry are such that no fields of the operating mode reach the isolation resistors. The isolation resistors are effectively out of the circuit unless there is a mismatch at one or more of the amplifier ports at which occasion the resistors are coupled by the resulting fields and thereby prevent the buildup of high Q resonance which could damage the active elements. The isolation resistors are tapered in order to reduce reflection of the energy of the mismatch produced mode by providing a matched load.
The divider/combiner amplifier circuit combines the output power of more than one solid state amplifying device spaced around the circumference of a cylinder. The cylinder has an input port which through a sectored coaxial line divides the incoming energy which is to be amplified into parallel channels, amplifies each channel with a conventional transistor of either the FET or bipolar type, and after amplification combines through a sectored coaxial line the output powers from each transistor which is provided at the output port. The circumferentially spaced channels are formed of longitudinally slotted concentric inner and outer electrically conducting cylinders. Each channel acts as a microwave waveguide which is connected to the input and output of each amplifying device and confines the microwave energy of the operating mode to the longitudinal channel formed by said waveguide. The inner and outer conductors of the waveguide extend radially and also longitudinally along the cylinder and each conductor is circumferentially spaced from its neighboring wall by a space to also form a waveguide in the radial direction which is below cut-off to the operating mode. In the event of a failure of one or more amplifying elements the radial waveguide allows a failure mode to propagate inwardly and outwardly radially to microwave absorbing material (isolating resistors) where it is absorbed to prevent reflection back into the longitudinal channel and thus effectively isolates the failure to provide a gradual deterioration of the amplifier circuit performance with element failure. The structure also provides the sectored coaxial line impedance matching circuits at the ends of the channels to couple the input power from the input port to the inputs of the channels and to couple the power from the outputs of the channels to the output port.
It is an object of this invention to provide a multiple device structure which can be used to obtain higher output power than for single devices, to provide graceful degradation of system operation with failure of the devices, and to extend the system life by operating each device conservatively. It is a more specific object of this invention to combine the power output of transistors to obtain a higher output power as an alternative to power amplifier tubes typically in the frequency range mentioned above. It is a further object of the invention to provide a structure of small size and weight, and with low production costs. It is a further object of the invention to provide a structure which can be operated with existing high frequency transistors of limited power output. It is a further object of the invention that the structure be a low loss circuit capable of operating in the frequency band of 8-20 GHz with at least 20% bandwidth and having high isolation between the input and output ports.
These and other objects will be apparent from the following description of the invention when considered in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The aforementioned objects and features of the invention are explained in the following description taken in conjunction with the accompanying drawings:
FIG. 1 is a perspective view partially in a cross-section of the structure of the invention showing the multiple channels;
FIG. 2 is a graphical cross-sectional view of the invention with an exploded view portion;
FIG. 3 shows the transistor and transistor mount for each channel of the structure of the invention.
FIG. 4 shows a partial cross-sectional view at section 4--4 of FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The circumferential divider/combiner circuit 10 of this invention is a new power combining scheme for transistor amplifiers which overcomes the problems associated with insertion loss, bandwidth, and isolation properties that are inherent in other types of power combiner approaches. A key feature of the circumferential divider/combiner approach is the geometrical configuration of the coaxial transformers 241, 242 which are formed by copper steps 240 to keep line losses low and for wide bandwidth. This circumferential design along with the external damping resistors 14 also ensures that there are no overload problems or stability problems of this multi-amplifier network that do not already exist for an individual amplifier.
In addition to solving the electrical problems, the power combining approach of this invention provides a superior configuration for cooling transistor amplifiers. For divider/combiner circuits, the power limits are usually set by the ability to control device temperature.
A ten-channel version of the circumferential divider/combiner circuit 10 is shown in the figures. This circuit 10 may be considered as a split 4-step coaxial transformer 241 in the divider circuit followed by a split 4-step coaxial transformer 242 in the combiner circuit. Inner 26 and outer 24 coaxial cylindrical conductors are split into ten sections to provide proper mode and isolation characteristics. The central regions 243, 244 which are divided into ten 50 ohm parallel plane transmission lines 12 are spaced, and 50 ohm amplifiers 17 are inserted in the spaced region. As shown schematically in FIG. 2, the amplifiers 17 are mounted on the outer conductor of the transmission line 33 face inward, providing a superior configuration for cooling. The length of this copper heat sink (transmission line 33) accommodates the matching networks 34, 43 and transistor amplifiers 17. The heat sink 33 on which the transistor amplifier 17 is mounted can be removed by screws 20, 21 and different power amplifiers may be mounted for replacement of defective amplifiers as desired, In addition to transistor amplifiers, transistor devices and impact diodes may be mounted on the heat sink 33 and connected to the circumferential divider/combiner circuit 10.
The high power handling capabilities of the circumferential divider/combiner circuit 10 should also be noted, along with the electrical features of wide bandwidth, low loss, and high isolation. There are no individual isolation resistors; isolation is achieved by means of inner 32 and outer 14 coaxial loads which can handle very high powers. These loads are effectively out of the circuit unless there is a mismatch at one or more of the transistor ports.
Although a ten-channel version of the circumferential divider/combiner was built and tested, a large number of channels (N) may readily be incorporated. The input coax is split up into N sections. There is continuity of center and outer conductors. If each amplifier operates at an impedance level equal to the coax impedance, the parallel combination represents an impedance mismatch of N to 1. Thus, there is the necessity for the wideband stepped or tapered matching section.
Since the entire structure is symmetrical about the axis 27, it is convenient to use (instead of individual amplifier connections as terminals) a set of symmetry terminals, each mode consisting of a symmetric distribution of voltages around the ring. In such a system the scattering matrix of the circumferential divider is obtained by a matrix transformation which indicates that any symmetric wave pattern excited on the divider (except the desired one) should be absorbed by non-reflecting damping resistors (transmission is impossible by symmetry). If such matched terminations are achieved, the divider performance will be ideal.
The matched terminations provided by resistors 14, 32 imply some sort of stepping or tapering of the resistors. The termination configuration looks like FIG. 2 with resistors inside 32 or outside 14 or both. If resistors are on one side of channels 12 only, the other side can be connected together without the slots 13, 28 to form a "ground" plane. The "ground" plane version of the invention is not shown in the figures since that embodiment is apparent from the preferred embodiment which is considered to provide better performance.
Referring now to FIGS. 1-4 there is shown an amplifier assembly 10 which, in accordance with the invention, comprises a cylindrical structure 11 which contains a plurality of channels 12 for the amplification of the microwave energy. The channels 12 are separated by air gap slots 13 which confine the electromagnetic energy in each channel 12. The outer portion of the channels 12 and the slots 13 are enclosed with a hollow cylinder of microwave energy absorbing material 14, typically a carbon-loaded epoxy. The input terminal 15 of the amplifier assembly 10 is at one end of the cylinder 11 while the output terminal 16 is at the other end of assembly 10. Also shown in FIG. 1 are the amplifier subassemblies 17 with terminals 18 and 19 through which power is provided to the amplifier element of the amplifier subassembly 17. The amplifier subassemblies 17 are fastened into their respective channels 12 by pressure contact produced by screws 20, 21. Conventional electrical connectors (not shown) connected to a power source provide the appropriate power to terminals 18, 19 of the transistor 46 of amplifier subassembly 17. The cylindrical absorber 14 is assembled from two semi-cylinders 14', 14" abutting along line 142 and having holes 141 sufficiently large to clear the leads 18 and 19 when being placed over the amplifier assemblies 17 and cylinder 11. Typically, there may be ten amplifier assemblies 17 uniformly distributed around the circumference of the cylinder 11.
Referring now to FIG. 2 there is shown an isometric view of the amplifier circuit 10, partially in cross-section and partially in exploded view. The microwave input connector 15 is attached to a cylindrical block 22' which is attached to the cylindrical structure 24' by screws 23. Cylindrical structure 24' has radial slots 13 which extend longitudinally in the direction of axis 27. The slots 13 in the cylindrical structure 24' begin a short distance 29 from the interface 221 of the cylinders 22, 24 and isolate the channels 12. The cylinder 24' is electrically connected through cylindrical block 22' to the outer conductor of the connector 15. The inner conductor 25 of connector 15 extends longitudinally inwardly toward the center of the amplifier assembly 10 where it makes electrical contact with a stepped cylindrical electrical conductor 26' coaxial with the axis 27 of the amplifier assembly 10. The interior stepped conductor 26' has slots 28 which correspond to and are radially aligned with the slots 13 of the stepped outer conductor 24. The portions of the inner and outer stepped conductors 24', 26' between their respective slots 13, 28 comprise a stepped coaxial waveguide for the confinement in space 36' of the electromagnetic energy which enters at connector 15. The locations 29, 31 of the beginning of the slots 13, 28, respectively, determine where in the stepped coaxial line 36' the input microwave energy starts being divided into separate channels 12. Slots 28 of the interior stepped cylindrical conductor 26 begin at a location 31 closer to the longitudinal center of the assembly 10 than do the slots 13 and extend radially toward the centered axis 27 of the assembly 10. Beginning slots 28 and 13 at different axial locations provides a gradual transition from the unslotted coaxial line 25 near the interface 221' to the channels 12 and thereby reduces impedance mismatch in this transition region. The radii and longitudinal lengths of the steps of the stepped conductors 24, 26 are chosen to provide a broad band impedance match between the impedance of the coaxial line 25 at the input and output terminals 15, 16 of the input and output lines 37, 38 connected to the emitter and base, respectively, of the transistor amplifier element 46. The base of transistor 46 being connected to conductor 33.
Located in the interior of the stepped conductors 26', 26" and extending longitudinally between the conductors 26', 26" is a matching stepped cylindrical microwave absorber 32, typically carbon-loaded epoxy, which absorbs microwave energy which leaks through the slots 28 of the stepped inner conductor 26.
The outer stepped conductors 24 are attached to the end blocks 22 by means of fastener screws 23. The input end 24' and the output end 24" of outer stepped conductors 24 are connected to input and output connectors 15, 16, respectively, as illustrated in the amplifier assembly 10 shown in FIG. 2. The amplifier subassemblies 17 are fastened by screws 20, 21 to the inner and outer stepped conductors 26, 24, respectively, the assembly forming the channels 12.
Amplifier subassembly 17 is seen in FIGS. 2, 3 to comprise an outer conductor 33 which is in electrical contact with stepped conductor 24. Subassembly 17 also has inner conductors 34', 34" to which the input and output terminals, respectively, of transistor 46 are in electrical contact. Conductors 33, 34 are of the same width as the channel 12 conductors 24, 26, respectively. Because of the symmetry of the amplifier assembly 10 the combiner portion of the assembly 10 connected to output terminal 16 is substantially identical to the divider portion of assembly 10 which is connected to the input terminal 15.
The bottom portion of FIG. 2 shows the completed amplifier assembly 10 in cross-sectional view, the incoming electrical signal at electrical connector 15 passes into the impedance-matching stepped coaxial waveguide region 36' where the signal is divided between channels 12 formed by the slots 13, 28 between conductors 24', 26', respectively. The signal in each channel 12 is transmitted along the channel space 361 between channels 12 and the ceramic 43' bonded to the inner and outer conductors 34, 33. A cross-sectional view at section lines 4--4 of the divider/combiner 10 is shown in FIG. 4 where the electric field lines 50 of the operating mode (TEM) are shown as concentrated in the space 361 between radially separated inner and outer conductors 24, 26 of each channel 12. The radial spaces 13, 28 between conductors 24, 26, respectively, form the waveguides below cutoff which isolate the operating mode field from the absorbers 14, 32, respectively. At least 30 db isolation is desired and the width and radial extent of the spaces 13, 28 are chosen to provide at least that amount of isolation by the reactive attenuation of the cut-off waveguide. The conductors 24 also serve the purpose of thermal conductors of heat produced by the transistor 46 to the end masses 22', 22" where the heat is dissipated. The modes, produced when a transistor fails, propagate through the spaces 13, 28 and are dissipated in absorbers 14, 32, respectively. The microwave energy enters enters the input terminal of a commercially available high-frequency FET transistor 46 which comprises a microstrip line 37 formed on a metallic 35. The microwave energy is amplified in transistor 46 whose output is provided on microstrip line 38 where it is propagated into the ceramic separator 43" from which the amplified signal passes through the channel spaces 36" of the stepped coaxial line conductors 24", 26" to the coaxial region in the vicinity of boundary 221" where the output signal from each of the transistors is combined before exiting at the output connector 16.
A plan view of the amplifier subassembly 17 is shown in FIG. 3 which illustrates in more detail its construction for confinement of the high frequency energy to the regions desired and for minimizing impedance mismatch. Conductor 33 of subassembly 17 has a constant width and forms a continuation of the outermost portion of a channel 12. The inner conductor 34 which is of constant width near its end 340 tapers inwardly to the center line 41 of the subassembly 17. Typically, the tapered section 341 tapers from 0.3 inches to a width of 0.1 inches which is still substantially wider than the input microstrip line 37 of the transistor 46. Conductor 34 also is tapered radially at region 342, its thickness decreasing at the end nearest transistor 46 as shown in FIG. 2 in order to reduce the length of its attached conductive spring 40 which bridges the gap between conductors 34 and 37 and makes spring contact with the conductor 37. The space between the tapered region 341 and the outer conductor 33 has a tapered ceramic material 43 which is symmetric about the center line 41. The width of the ceramic material 43 is narrow in the region 44 where the taper 341 of conductor 34 begins, and the width linearly increases in the axial direction to the end 45 of conductor 34 where the ceramic 43 width is substantially equal to the width of microstrip conductor 37. The combination of the tapered conductor 341 and the inversely tapered ceramic 43 causes the energy which has been distributed over the entire region 46 between conductors 33 and 34 to become concentrated in the ceramic 43 between these same conductors at the end 45 of conductor 341 while minimizing any impedance discontinuity. The higher dielectric constant of the ceramic 43 relative to the surrounding air results in the concentration of the energy within the ceramic. The width of the ceramic 43 in the region 44 is narrow in order to introduce the ceramic between the conductors 33 and 34 with a minimum of impedance mismatch. Typically the width dimension of the ceramic 43 in the region 44 is only 0.01 inches whereas its width at the other end 45 of the tapered section 341 is increased to 0.05 inches which is substantially the width of the microstrip conductors 37, 38 which make electrical connection with the input and output terminals, respectively, of the transistor 46. The base of transistor 46 is electrically and thermally connected to the ground plane provided by conductor 33. The emitter and collector of transistor 46 are connected to the power terminals 18 and 19 to which external connection is made to power supplies. The transistor mounting base 35 is a thermally conducting ceramic on which the conductors 37 and 38 are formed to provide in combination with the ground plane 33 a microstrip transmission line. The transistor is typically a commercially available high frequency FET transistor. A bipolar transistor is also suitable. The conductors 33 and 34 of the subassembly 17 are in electrical contact with stepped channel conductors 24, 26, respectively, by pressure contact provided by screws 20, 21 in holes 48. The slot 343 in conductor 34 leaves a portion 344 of conductor 34 which is relatively flexible without affecting the electrical preparations so that the screw 20 may be tightened without breaking the subassembly 17.
A stepped cylindrical body 32 fills the space within the stepped electrical conductor 26 and the region bounded by the subassemblies 17. The cylinder 32, typically a carbon-loaded epoxy or a lossy ceramic such as titanate, acts as a microwave absorber which absorbs any energy which escapes the channels 12 through the slots 28 of conductor 26 or which extend from the transistor subassembly 17. Also, microwave absorbing semi-cylinders 14' and 14", also typically of the same material as absorber 32, completely surround the exterior of subassemblies 17 and stepped cylinders 24', 24" and act as microwave absorbers to energy which escapes or fringes the slots 13 between the channels 12. The resistivity of the microwave absorbers 14, 32 may be tapered to prevent lower resistivity in the immediate vicinity of the slots 13, 28 in order to minimize reflection of the microwave energy of the undesired modes whose energy passes through the slots 13, 28. The resistivity may also be tapered in the direction of axis 27 in accordance with the field pattern in the axial direction of the undesired mode.
In summary, it is seen that the input energy is first divided into a plurality of separate channels in a slotted stepped transmission line 361 into an RF impedance transition region 39 where the RF energy is concentrated into a small region for introduction on microstrip lines 37, 38 and out of the transistor 46. The power output from the individual transistors is combined through similar microwave lines to be provided at the output connector 16.
The circumferential divider/combiner device 10 is designed to avoid the reflection difficulties produced by a failed transistor 46 by effectively isolating one unit from another. The scattering matrix for the circumferential N-way divider or combiner is: ##STR1## where terminal pair 1 is the external terminal and the other N terminal pairs connect to the individual units. If all terminals are terminated in matched units, the power splits equally. Any reflected power resulting from mismatch of a unit does not reach any other unit directly, but only via rereflection of (1/Nth) of the reflected power off the source mismatch. To achieve the zeros in the scattering matrix, which represent complete decoupling among the elements, all other modes on the circumferential divider/combiner circuit except the operating mode, see a match looking away from the amplifier units. For this purpose, the isolation elements are tapered. These isolation elements consist of cylindrical damping resistors at absorbers 14, 32 which are isolated from the operating mode.
The circumferential divider/combiner device 10 has the geometry shown in FIG. 4. It has rotational symmetry. When all units are identical, the voltage on all segments is identical by symmetry.
A unique difference between the amplifier device of this invention and prior art is that applicants' device has a means of isolating the stabilizing damping loads 14, 32 so that device will operate at higher efficiency than devices constructed using prior art where dissipative elements were provided by a plurality of isolation resistors connected between adjacent sectors where parasitic capacitances caused dissipation in the isolation resistors even in the operating mode.
Measured data for the ten-channel circumferential divider/combiner circuit 10 showed that the bandwidth was 70% and the combiner 241/divider 242 loss was 0.2 dB. This means that the more significant quantity, the equivalent loss for one combiner alone, is about 0.1 dB. The measurements showed that the inner and outer external damping resistors did not introduce any loss in the desired mode. Additional data on the ten-channel circumferential divider/combiner 10 showed a low VSWR over 11/2 octaves passband from 4.0 to 12.0 GHZ.
Having described a preferred embodiment of this invention, it will now be apparent to one of skill in the art that other embodiments incorporating this invention may be used. It is felt, therefore, that this invention should not be restricted to the disclosed embodiment but rather should be limited only by the spirit and scope of the appended claims. | A divider/combiner amplifier circuit divides input power through a sectored coaxial line to a plurality of longitudinal parallel channels spaced around the circumference of a cylinder; the power in each channel is amplified by a semiconductor device; and the amplified power is combined in another sectored coaxial line. A microwave waveguide connected to the input and output of each amplifying device confines the microwave energy of the operating mode to the longitudinal channel formed by said waveguide. Each waveguide extends longitudinally along the cylinder and each is circumferentially spaced from its neighboring waveguide by a space which forms a cut-off waveguide to the operating mode. In the event of a failure of one or more amplifying elements, the space allows the failure mode to propagate radially to microwave absorbing material where it is absorbed to prevent reflection back into the longitudinal waveguide and thus effectively isolates the failure to provide a gradual deterioration of the amplifier circuit performance with element failure. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to an instrument for a vehicle and more particularly to an instrument for a vehicle in which a front cover is attached to a front face of an instrument case for protecting inside of the instrument.
2. Description of the Prior Art
As an instrument for a vehicle, an instrument mounted on a dashboard 1 has been used in which a display face thereof is directed to a driver as shown in FIG. 13. This type of meter 2 is not provided with a hood in consideration of the space for the meter, and a front cover 3 made of glass or the like is usually attached to the meter 2 to protect inside of the meter.
In the meter described above, when external light falls on the driver in the daytime, the light reflects on the driver and enters the meter 2. Approximately 4% to 6% of the light reflect on a front face and a rear face of the driver and enters the eyes of the driver, which causes the recognizability of the meter 2 to be decreased since the driver's image reflects on the front face 3 thereof. To eliminate this problem, a surface of the front cover 3 may be formed to have an irregular face, so that a diffused reflection causes the rate of the light which enters the driver's eyes to be decreased.
Meanwhile, when the meter is mounted in the vicinity of a lower portion of the windshield 4, illumination For a dial 2a and the like at night cause light for the illumination to reflect on the windshield 4 and to reach the driver's eyes, as illustrated in FIG. 14, resulting in poor recognizability of viewfield of the driver. To avoid this problem, it is well known that many louvers 3' with dark color are horizontally arranged in a glass or a plastic material to form the front cover 3. With the front cover 3, light from the meter 2 directing upward is interrupted to maintain favorable viewfield.
SUMMARY OF THE INVENTION
With the front cover 3 having the irregular face for eliminating the driver's image described above, however, light from the face of the dial of the meter 2 is also scattered, resulting in poor recognizability of the dial face. Further, in case that the front cover 3 with the louvers are used for protecting reflection on the windshield at night, the dial face 2a becomes dark in daytime, which reduces the recognizability of the dial face 2a.
The present invention has been made to eliminate the drawbacks described above and it is therefore the object of the present invention to provide an instrument for a vehicle in which reflection on the front face of the instrument in the daytime is decreased and reflection on the windshield at night is eliminated.
The instrument for a vehicle according to the present invention comprises: a meter; a case for accommodating said meter; and a prism disposed at a front portion of said case for regulating amount of light which is emitted from said prism upward by bending light emitted from said meter downward, said prism also acting as a front cover of said case.
Further, another object of the present invention is to provide an instrument for a vehicle described above in which upper and lower portions of the prism are formed as flat plates.
It is a further object of the present invention is to provide an instrument for a vehicle in which a surface of the prism is inclined with an upper portion thereof being nearer a driver.
It is a further object of the present invention to provide an instrument for a vehicle in which front and rear faces of the prism are spherical with centers on side of a driver and thickness of the prism is increased as descending from an upper portion to a lower portion thereof.
It is a further object of the present invention to provide an instrument for a vehicle which is mounted on a flat plate and in which a surface of the flat plate opposing said front cover of the case is made of material with a good light absorbance.
It is a further object of the present invention to provide an instrument for a vehicle in which the meter comprises a dial, a pointer disposed on the dial, and a movement for driving the pointer, and a hole is formed at a central portion of the prism from a rear face to a front face thereof to accommodate the movement.
It is a further object of the present invention to provide an instrument for a vehicle in which a bottom face of said prism is painted dark or reflection protecting films are applied to front and rear faces of the prism.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be more apparent from the following description with reference to the accompanying drawings wherein:
FIG. 1 shows an instrument for a vehicle according to an embodiment of the present invention which is mounted on a dashboard;
FIG. 2 is a perspective view of a prism according to the embodiment;
FIG. 3 is a drawing for explaining the condition in which light emitted from a dial is bent downward;
FIG. 4 is a drawing for explaining the condition in which external light which enters the prism reaches the driver through repeated reflection;
FIG. 5 is a drawing showing an optical path of light which are emitted from the dial reaches the driver's eyes after reflected on side windshield;
FIG. 6 is a side view of an instrument for a vehicle according to the second embodiment of the present invention;
FIG. 7 is a side view of the prism of the FIG. 6 in which a portion thereof is modified;
FIG. 8 is a drawing showing a front cover which is formed as a multistage prism;
FIG. 9 is a drawing for explaining the relation among the height, apex angle, and thickness of the bottom face of the prism according to the first embodiment;
FIG. 10 is a side view of an instrument for a vehicle according to the third embodiment of the present invention;
FIG. 11 is a drawing showing the prism of the instrument for a vehicle of FIG. 10 of which shape slightly modified;
FIG. 12 is a side view of an instrument for a vehicle according to the fourth embodiment of the present invention;
FIG. 13 is a drawing showing a conventional instrument for a vehicle mounted on a dashboard;
FIG. 14 is a drawing for explaining the condition in which light emitted from a meter reflected on a windshield; and
FIG. 15 is a perspective view of a conventional front cover with louvers.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Now, an embodiment of the present invention will be explained with reference to drawings.
FIG. 1 shows an instrument of a vehicle according to the first embodiment of the present invention mounted on a dashboard 1 which is located below a windshield 4 in front of a driver's seat. The instrument is provided with an instrument case 2b having a cross section of the letter U, in which a dial 2a is inserted. On a front face of the dial 2a is disposed a pointer 2e, which is fixed to a pointer shaft extending through a hole of the dial 2a. Further, the pointer shaft extends from a movement 2c mounted on a circuit board 2d which is ranged behind the dial 2a. When a signal enters the movement 2C, the pointer shaft rotates to cause the pointer 2e to indicate characters or the like on the dial 2a according to the signal.
Further, into an opening of the instrument case 2b is inserted a front cover 13, which is made of a prism with a triangular cross section. The prism 13 is disposed in such a manner that an apex thereof directs upward and is inclined such that a rear face 13a thereof approaches the dial 2a of the meter 2 from the apex having an apex angle of θ toward a lower portion of the dial 2a. A front face 13b of the prism 13 is arranged substantially in parallel to the face of the dial
As illustrated in FIG. 2, the bottom face 13c of the prism, which is opposed to the apex of the prism 13, both sides 13e, and upper face 13f of the prism 13, that is, other faces except for the rear face 13a and the front face 13b of the prism are painted dark. Further, the rear face 13a and the front face 13b are provided with reflection protecting films not shown which are used for cameras, glasses, or the like. The reflection protecting films may be formed directly on the prism 13 through evaporation. However, the same effect is obtained when sticky reflection protecting sheets may be applied to the faces.
As described above, the arrangement of the front cover 13 in front of the dial 2a of the meter 2 causes the light A, which is emitted from the dial 2 and reflected on the windshield 4 located above the dial 2a to reach the driver's eyes, to be bent as shown in FIG. 3. As a result, even though the dial 2a is illuminated at night, the light for the illumination is not reflected on the windshield 4 so that the light does not reach the driver's eyes, which prevents the condition in which a display image is reflected on the windshield to interrupt driver's viewfield. Further, the use of the prism prevents the light from being reduced in daytime, which is generated when the louvers are used. Therefore, the quality of the image does not become poor, that is, the image does not become dark in daytime.
Further, even when light reflected from the driver who is in front of the meter 2 enters the prism 13, the reflection protecting films fixed to the front face 13b and the rear face 13a of the prism 13 prevent the light from being reflected, which prevents the driver's image being recognized on the prism 13. Providing an irregular face to the reflection protecting film through matte treatment or the like causes the recognizability of the dial 2a to be decreased but the effect of the reflection protecting to be increased.
As shown in FIG. 4, when external light with large vertical angle such as sun light falls on the prism 13, light passing through the surface 13b is reflected on the bottom face 13c and is further reflected on the rear face 13a to pass the surface 13b. The light reaches the windshield 4 and is reflected there to reach the eyes E of driver, which also becomes an eyesore for the driver. However, the light falling on the prism 13 is absorbed there due to dark painting applied to the bottom face 13c of the prism 13, which prevents the light described above optical path from being generated. At the same time, the optical path B of the light, which is emitted from the dial 2a and is reflection the bottom face 13c of the prism 13 to pass the surface 13b of the prism 13 and to reach the driver's eyes after reflected on the windshield 4, is not actually generated since the light is absorbed on the bottom face painted dark.
A part of light C emitted from the dial 2a, which reaches the eyes of the driver after reflected on a side windshield 5 as illustrated in the FIG. 5, is bent as illustrated with the line C' through the prism 13, which prevents the dial 2a and the like from being recognized on the side windshield. Meanwhile, another optical path D of light is considered which is emitted from the dial 2a and is reflected on the side face 13e to pass the surface 13b and reach the side windshield 5, and is further reflected there to reach the eyes E of the driver. However, the optical path D is not actually generated since the optical path D is absorbed on the side face 13e of the prism 18 which is painted dark.
Since it might be sufficient to paint only the bottom face 13c of the prism 13 with dark color, applying dark color to the side face 13e or the upper face 13f is selectively performed according to the condition.
Next, the second embodiment of the present invention will be explained. Like reference symbols designate like or corresponding parts and the explanation thereof will be omitted.
The instrument for a vehicle according to the second embodiment of the present invention is different from that in shape of the prism the first embodiment as illustrated in FIG. 6. That is, the prism 18 of the first embodiment has a triangular cross section, but, a prism 33 of the second embodiment has an upper portion 33A of a flat plate, a triangular central portion 33B, and a lower portion 33C of a flat plate. The range of the three portions are determined as described below.
The smallest angle formed by a normal line of a surface 33b of the prism 33 and light which is emitted from the dial 2a and passes through the prism 33 to causes an image to be reflected on the windshield 4 is represented θ1. That is, the light does not reach the driver's eyes at angle smaller than θ1. Then, we consider a optical path which is in contact with an upper end portion of the instrument case 2b and has the angle θ1 which is formed with the normal line of the surface of the prism 33, and a point where the optical path crosses a rear face 33a of the prism 33 is described as a point F. A portion from the upper end of the prism 33 to the point F is formed flat as an upper portion 33A. Further, we consider another optical path of light which is emitted with the angle θ1 from the lowest portion G of the portion of the dial 2a emitting light and a point where the optical path crosses the rear face 33a of the prism is indicated as a point H. Then, an area from the lower portion of the prism 33 to the point H is formed to be a flat plate. Further, a central portion formed between the points F and H is designed to have a trapezoidal cross section. Treatment to end faces of the prism such as applying dark paint is carried out in the same manner as the first embodiment.
Forming the prism as described above not only provides almost the same effects as obtained in the first embodiment but also allows the weight of the prism to be decreased, permitting the meter itself to be reduced in weight and thickness. In the prism described above, the dial 2a might be seen from the driver's side as discontinuous at the points F and H. Therefore, as illustrated in FIG. 7, portions where the upper portion 33A of the rear face of the prism 33 and the central portion 33B are connected to each other or the central portion 33B and the lower portion 33C are connected to each other may preferably be formed to have spherical face. The portions with the spherical face have a function as a lens. Therefore, it is preferable that the radius of the face is designed as large as possible or printed portion of the dial 2a is overlapped the spherical portion.
In the above embodiments, the overall area of the front cover is formed as the wedge prism 13 or only the central portion of the front cover is formed to have a triangular cross section with upper and lower portions thereof being formed as flat plates. The front cover may be formed as multistage prism 23 as described in FIG. 8. In such a case, rear faces 23c each and other end faces are painted dark to interrupt or absorb light.
Next, an instrument for a vehicle according to the third embodiment of the present invention will be explained.
Under the condition that the surface 13b of the prism and the surface of the dial 2a are arranged so as to be in parallel to each other as described in the first embodiment, the apex angle θ of the prism is designed to be about 14° when light having more than 45° of angle between a normal line of the surface 13b and the light does not emit from the prism, as exemplarily described in FIG. 9. That is, when the height of the dial 2a is 120 mm, the thickness of the rear face 13c of the prism is determined to be about 30 mm, resulting in considerably thick prism. As a result, not only the weight of the instrument will increase but also wide space for the instrument will be necessary.
Therefore, in this embodiment, as illustrated in FIG. 10, the surface of a prism 13' is inclined with upper portion thereof being nearer the driver. If the surface of the prism 13' is disposed so as to be inclined with β=20° with respect to the dial 2a, the apex angle of the prism θ is designed to be 5 when light with more than 45° of an angle with the normal line of the dial 2a. Then, in case that the height of the dial is 120 mm as described above, the thickness of the rear face of the prism 13c' is calculated to be about 11 mm, resulting in considerably thin and light prism.
Further, in the structure described above, the driver observes the face B of the dashboard 1 through area reflection of the surface 13b' and the rear face 13a' of the prism. Therefore, when the face B is formed of good absorbance, it is unnecessary to provide reflection protecting treatment to the front and rear faces 13b', 13a' of the prism 13'. Optical paths of light from the dial 2a which are reflected on the front and rear faces 13b' 13a' should be considered since the optical paths will form double images as illustrated with a line L. To eliminate this problem, it is sufficient to apply a reflection protecting treatment to either the front face or the rear face of the prism 13'. As a result, production cost of the instrument for a vehicle can be reduced since no reflection protecting treatment is required to the prism 13' or only one face may be treated.
Further, as shown in FIG. 11, a front face 13b" and a rear face 13a" of a prism 13 may be formed as spherical faces with a center thereof being on the driver's side and the thickness of the prism 13" is increased as descending from an upper portion to a lower portion thereof. In such a case, it is advantageous that the range of the face B of the dashboard where the driver observes, in other words, distance D from the prism 13" can be shortened in comparison to that of FIG. 10. In the above embodiments, the instrument for a vehicle is applied to an analog meter, but, the instrument may be applied to a digital meter as a matter of course.
Next, an instrument for a vehicle according to the fourth embodiments of the present invention will be explained.
An instrument for a vehicle according to this embodiment is not the same as those according to the previous embodiment. As illustrated in FIG. 12, on a central portion of a prism 13 at a front portion of the instrument is provided a hole from a rear face 13a to a front face 13b. Further, for a pointer 2e of the movement 2c is used a stepping motor or the like, which has a long and narrow shape, and a case 2cc for accommodating the movement 2c is engaged with the hole 13d. That is, the movement 2c is positioned in front of the dial 2a in a way different from the previous embodiment. Power is supplied to the movement 2c with wires from a circuit board 2d disposed behind the dial 2a through the central portion of the dial 2a.
Inner wall of the hole 13d of the prism 13 is painted dark to prevent light emitted from the dial 2a from reflecting on the hole 13d toward the windshield 4.
With the instrument for a vehicle according to the fourth embodiment having the above structure, the same effects as the previous embodiment will be obtained. In addition, the depth of the meter can be decreased through the change in position of the movement 2c to limit the space for the instrument. Since the movement 2c is positioned in front of the dial 2a, paint is preferably be applied to the front face 13b to prevent the movement 2c from being recognized.
As described above, in the instrument for a vehicle according to the present invention, the front cover of the instrument is formed of the prism for bending the emitted light downward, which prevents the reflection at night without decreased luminance of the display in daytime. Further, in the instrument for a vehicle with the hole at the central portion of the prism, the thickness of the meter is deceased besides the above effect. Application of the dark paint to the rear and side faces and the like prevents the reflection on the windshield. Further, the reflection protecting films on the prism prevents images from being formed on the front face of the prism, resulting in improved recognizability. | This invention relates to an instrument for a vehicle in which a front cover is attached to a front face of an instrument case for protecting inside of the instrument. An instrument for a vehicle according to the present invention comprising: a meter; a case for accommodating the meter; and a prism disposed at a front portion of the case for regulating amount of light which is emitted from the prism upward by bending light emitted from the meter downward, the prism also acting as a front cover of the case. | 1 |
This invention relates generally to the determination of the physical position of coordinate determination on a surface by employing a cursor embodying a coil with relation to a grid of parallel conductors and more specifically to determining the position of the cursor in a continuous linear fashion.
BACKGROUND OF THE INVENTION
Apparatus for translating the position of a writing instrument into electrical signals for transmission to a remote location such that the position, and corresponding movements, of the writing instrument may be recreated, are well known in the art. Thus, drawings, manuscripts, or the like, may be reproduced at remote locations. Among the more sophisticated prior art devices, are those in which movements of the writing instrument in the X and Y coordinates are sensed by electromagnetic means, or the like, and each sensed dimension is translated into a signal capable of transmission. X and Y coordinate positional information derived in the traditional manner may provide inputs to data processing apparatus such as computers, remote data terminals and special systems for processing coordinate data.
Some objections to some of the known art apparatus are limited resolving power, detrimental environmental effects, sensitivity to adjustment and instability and lack of accuracy to the degree which would be desirable. A number of other problems exist in these known systems including the need for a high density of grid wires for comparable performance and more complex circuits. As an example, most of these systems are both amplitude sensitive and phase sensitive, which places strict limitations on the inputs to the system. Another problem is that the spacing of the grid lines is extremely critical and very little variation is allowable. Accordingly, manufacture of the grid tablet is relatively expensive. A further problem relates to the critically of a coil diameter and the necessity of the position of the sensor being substantially parallel to the grid. Yet another problem with the known sensors is the fact that the cursor cannot be removed and replaced during a single operation, but must be initiated from the start if it is so removed.
Accordingly, it is an object of this invention to provide apparatus whereby the position of the cursor can be determined in a continuous linear fashion by using accurate electrical interpolation techniques to determine position between grids.
It is a further object of this invention to provide apparatus wherein the rate of counting is variable, thus providing any resolution desired.
Another object of this invention is to provide an apparatus wherein the accuracy of the output is not wholly dependent upon the scan rate.
Yet another object of the invention is to provide an apparatus which is substantially insensitive to amplitude and phase variation.
A still further object of this invention is to provide an apparatus wherein the diameter of the cursor coil is not critical.
A still further object of this invention is to provide an apparatus wherein some tilt of the cursor coil is permissible.
Another object of this invention is to provide an apparatus for obtaining absolute coordinate determination while permitting removal and replacement of the cursor from the grid tablet without re-initializing.
Still further objects of this invention are to:
provide a system without routine preventative maintenance requirement;
provide a small number of wires per inch;
provide a stable system without adjustments;
provide a system relatively more immune to temperature, humidity, noise, dielectric variations, magnetization and electrical noise;
provide a system with interchangeable subassemblies;
provide a system with lower parts count and assembly labor.
provide a system relatively immune to source (hard copy) material and thickness (except ferrous metals); and
provide means to energize the grid wires by sharing the multiplexing wires at different positions in the tablet to minimize the feed wires required.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other objects of the invention will become apparent from the following description taken in conjunction with the drawings wherein
FIGS. 1 and 2 are diagrams which clarify the mathematics used to derive a representation of the complex cursor signal;
FIG. 3 is a graph of the functions H(x,t) and f(t) derived in the cursor signal analysis;
FIG. 4 is a block diagram of the basic components of the present invention;
FIG. 5 is a schematic diagram of a preferred embodiment of the present invention;
FIG. 6 is a schematic diagram of the constant current grid drive multiplexer and grid tablet;
FIG. 7 is an exploded sectional view of the grid broad; and
FIG. 8 are graphical representations of the signal outputs at various points in the system of FIG. 5.
DESCRIPTION OF PREFERRED EMBODIMENT
The basic principles of the invention can be broadly described in the context of a coordinate digitizing system in which a positioning cursor is moved over a surface with parallel wires for each axis with the axes being perpendicular to each other. The wires may be hand or machine layed, printed or etched on fiberglass printed circuit board, glass or other suitable stable substrate.
The main feature of this invention is that an electromagnetic field or wave front is generated by sequentially scanning or stepping down the grid in incremental steps, is made to appear to be traveling down the grid in incremental steps and is made to appear to be travelling down the grid at a uniformly controlled rate as it passes the cursor coil. Because this wave can be made to appear to be traveling at a highly uniform rate down the grid, a simple time measurement can be made to determine the position of the cursor over that grid.
This invention uses several well known principles to accomplish this task. They are (1) that when a coil is placed near a conductor conducting an AC signal, the closer the coil is to the conductor, the greater the energy transfer; (2) that when a conductor is excited first on one side of a coil in a given phase and then on the other side, the respective signals picked up by the coil will be 180° C. out of phase.
A less obvious principle involves detecting or interpolating a reference level signal of "STOP" signal, which is linearly related to time, from the cursor coil signal envelope when a timed or controlled wave, generated by successively activating grid lines, is made to pass from one end to the other end of a grid network and, therefore, from one side to the other side of the cursor coil. In this invention, this is accomplished in a unique and linear fashion by detecting the null (see FIG. 8B) in the envelope of the cursor signal each time the grid is scanned. Many conventional methods could be utilized to detect the null in the cursor envelope signal. The current embodiment employs a filter which responds uniquely to the complex cursor waveform to predict or interpolate the cursor coil electrical center with a resolution, accuracy and stability not obtainable with other techniques using comparable wire spacing and component parts count, and without adjustments.
To determine the electrical makeup of this filter, the complex cursor waveform was defined mathematically as follows:
Referring to FIG. 1, the pickup coil (cursor) is taken at a height h 1 above the successively excited parallel grid wires. As is described later, there is a steel shield C a distance d below these wires. The resulting magnetic field is the same as that produced by a wire B at a distance h 1 below the coil and another wire D with opposite current at a distance h 2 =h 1 +2d from the pickup coil.
The flux passing through the coil was calculated by considering an arbitrary point A on the pickup plane (tablet surface). Again, referring to FIG. 1, the distance to the wire along the horizontal plane is denoted by x. The distance between wire B and arbitrary point A is r 1 . Therefore, the normal component of flux contributed by wire B is given by: ##EQU1## Because of the shield, the total component is
x/(x.sup.2 +h.sub.1.sup.2)-x/(x.sup.2 +h.sub.2.sup.2)=U (eq 2)
To determine the total flux linking the coil, the integral of U over the area of the circle bounding the coil is computed. As seen in FIG. 2, X 0 denotes the horizontal distance of the center of the coil E to the grid wire B. A scale factor is taken so that the radius of the coil is 1.
In the plane of the coil, y denotes the axis parallel to the grid wires. Integrating once in the x direction, the total flux U is ##EQU2## where
x.sup.2 +y.sup.2 =1
Substituting y=cos θ and x=sin θ, dy=-sin θdθ
The total flux U is given by ##EQU3##
Having defined the complex cursor waveform, a filter function f(t), which is practical and accurate, was chosen to operate on U(x) such that the resultant zeros produce a highly accurate and linear output as a function of time and distance.
The output of the system is defined as
H(x,t)=.sub.o.sup.n U(x-k)f(t-k) (eq 5)
The zeros of H were calculated, using a computer, with various sample functions for f(t). Extremely accurate and linear results were achieved using
f(t)=e.sup.-0.5T sin.sup.4 (0.5t),t>0 (eq 6)
f(t)=0 t≦0 (eq 7)
Using many sample points, and using a least squares linear fit to evaluate the deviation, a theoretical system error of 0.0014" was achieved.
FIG. 3 shows plots of H(1,t), H(3,t), and f(t).
As can be seen in FIG. 3, the amplitudes of the maximums of H(x,t) are different but the zeros of H(x,t) are exactly two divisions apart on the time axis in the example.
Sample and filter detector 23, shown in FIG. 4, was synthesized from the mathematical filter function f(t)=e -0 .5t sin 4 (0.5t).
The electrical implementation of f(t) is extremely simple from a component count and assembly point of view and utilizes only inexpensive, commercially available devices.
Detection of the cursor coil position by the above means provides a level of performance not obtainable through instantaneous or peak amplitude, or phase measuring techniques using the same number of grid wires and components. As shown by the above equations, the detection scheme is mathematically predictable and shows that an exceptionally high level of performance is obtainable. The filter characteristics are therefore unique and are critically related to the generated cursor coil signal.
Other variations of stimulating the grid wires should be utilized to obtain similar results providing that the predicting or interpolating filtering circuit is altered to provide an output which accurately and linearly relates the distance of the electrical center of phase reversal point of the cursor from a reference to time.
This circuit then operates on the complex cursor signal, which is induced in the cursor coil from the sequential actuation of grid lines by passing current through them, to afford a means of measuring cursor position relative to an arbitrary reference point by relating distance to time in an accurate linear fashion. The current system enables a precision clock to counters when the electromagnetic wavefront passes the arbitrary reference point and inhibits the precision clock when the detection circuitry discussed above detects a phase reversal in the complex cursor signal. The contents of the counter then contain a count which is precisely related to cursor position. An X-Y scanning system is used to thoroughly define the cursor position, that is, the horizontal position of the cursor is initially determined by scanning the X axis and then the vertical position is determined similarly by scanning the Y axis. Adding to the efficiency of the system is the fact that X axis and Y axis detection and counting circuitry can be common, thereby further reducing assembly and parts costs.
The invention will be explained by first describing the schematic illustrations of a preferred embodiment thereof with a subsequent description of the operating characteristics and signal outputs within the system.
Referring to the block diagram of FIG. 4, a precision crystal oscillator and divider 11 provides the basic system clock and subdivisions thereof required by the digitizing system. Connections are made to grid drive multiplexer 13 and system control circuits 15. Grid drive multiplexer 13 utilizes subdivisions of the basic system clock and inputs from system control 13 to sequentially energize the X and then the Y grid lines of the grid tablet 19. Grid drive multiplexer 13 is unique in that it minimizes the number of interconnections between grid tablet 19 and controller digitizing system 10, and eliminates the need for active components in grid tablet 9 which is very advantageous from a maintenance and assembly point of view. Grid drive multiplexer 13 thus establishes the electromagnetic field which induces an electrical signal in the cursor 21. The cursor inputs this signal to sample and filter detector 23, where it is processed to provide an input to system control 15 which relates the cursor position to time in a precise, linear fashion. System control 15 oversees system operation and provides gated clock inputs to the X+Y counter 17 where these gated clock pulses are accumulated in counters to precisely represent the physical position of the cursor on the grid tablet.
FIG. 5 is a schematic diagram of a preferred embodiment of the present invention. The input to the system in provided by a crystal oscillator 11 having a fixed frequency. The output of the oscillator is coupled to a frequency divider and scaler 35 whose division parameters determine both the rate of scan and the system resolution.
A first output from divider 35 is supplied to the scan control counter 59. Scan control counter 59 also receives inputs from the start/stop/control counter 53. Under control from these inputs, the scan control counter 59 provides inputs to the constant current grid drive multiplexer 13 to enable current to one grid line at a time in the proper order (sequentially left to right-X axis, followed sequentially bottom to top-Y axis).
A further output from the divider is coupled to the constant current grid drive multiplexer 13. This input enables a constant current source in the constant current grid drive multiplexer 13 which passes a controlled, fixed current to the selected grid wire.
Constant current grid drive multiplexer 13 provides outputs to grid tablet 19 to generate the moving electromagnetic field which is sensed by cursor 21 as the complex cursor waveform which was previously discussed. Constant current grid drive multiplexer 13 is critical to this invention in that it eliminates the need for active switching elements in grid tablet 19 by minimizing the number of interconnections required to control a large number of grid lines. This circuitry is shown in more detail in FIG. 6. As can be seen, the circuit is divided into sink and source elements. A sink element provides a ground to one group of grid lines while the source element provides a constant current signal to one grid line at a time. Other grid lines are connected to the activated source line but no current flows in these grid lines since the sink elements at the other end of those grid lines are inactive.
Cursor 21 inputs the complex cursor waveform to filter 31, which is one stage of the synthesized circuit which represents the mathematical model required for optimum interpolation of the cursor signal, as discussed previously. The output of filter 31 is coupled to a sample and hold circuit 33. The output of filter 31 is sampled under control of another output from the divider and scaler circuit 35, thus synchronizing the sample to the grid scan. The sampled signals are held capacitively and input to filter 37 which completes the synthesized circuit representing the previously discussed mathematical model required to linearly relate cursor position to time.
The output of filter 37 is coupled to two level detectors, lock detect 39 and stop detect 41. The output of filter 37 is a voltage envelope approximating one sinusoidal cycle, as will be discussed later in conjunction with FIG. 8. Lock detector 39 detects an arbitrary voltage level on this envelope which indicates that the cursor is coupled electrically to the grid tablet sufficiently to provide accurate results. The output of lock detector 39 clocks F/F 43 to remove the inhibit signal from gate 45.
The disclosed embodiment of this invention detects a transition across 0 volts to activate stop detector 41. Therefore, the first transition across OV of the output of filter 37, following the removal of the inhibit output of F/F 43 will pass through gate 45 as a STOP signal to clock F/F 47 thereby removing the count window enable from count gates 49 and 51.
Count gates 49 and 51 also have inputs from divider and scaler 35. These inputs are a high frequency clock (count clock) which are passed through count gate 49 or 51 to become the X COUNT or Y COUNT signals. The frequency of count clock relative to the grid scan rate determines the resolution of the system.
Count gates 49 and 51 also receive inputs (X Axis and Y Axis) from the start/stop/control counter 53. These signals indicate which axis is being scanned and, along with the count window signal (discussed below) enable the count clock through the proper count gate 49 or 51 to the X counter 55 or the Y counter 57.
Start/stop/control counter 53 receives an input from divider and scaler 35 which is a clock signal with a frequency of two times the basic grid scan rate. Counter 53 generates a START signal which sets F/F 47 to enable the COUNT WINDOW signal h and clears F/F 43. This signal, START, indicates the arbitrary reference point discussed previously from which time is measured to the STOP signal to give an accurate representation of cursor position. The time from START to STOP is represented by the duration of the COUNT WINDOW signal.
Start/stop/control counter 53 also has an output to scan control counter 59 which synchronizes the grid scan to the remainder of the system circuitry.
Other outputs from start/stop/control counter 53 are the "counter clear" and "register load" signals. The counter clear signal clears X counter 55 and Y counter 57 following the completion of an X and Y scan and just prior to the start of a new X and Y scan. The register load signal loads the contents of X counter 55 and Y counter 57 into X and Y output registers 61 and 63 following a complete X and Y scan but prior to the counter clear signal.
X counter 55 and Y counter 57 receive the X count and Y count signals, respectively, as inputs. The contents of these counters, at the time the register load signal occurs, represents the position of the cursor on the grid tablet relative to an arbitrary reference point. X counter 55 and Y counter 57 have outputs to X output register 61 and Y output register respectively. These outputs are stored in the registers when the register load signal from counter 53 goes active. The outputs of these registers are available to external interface equipment such as computers, terminals, etc., for further processing or storage.
It should be noted that X counter 55 and Y counter 57 can be combined into a single counter, to further optimize the circuitry, with the outputs multiplexed to an external device. Also, the system could have the X count and Y count signals as outputs to eliminate the need for counters and registers in this invention. In this case, the external interface equipment would provide the counting circuitry required to determine cursor position.
FIG. 7 is a cross-sectional view of a preferred digitizing table. As can be seen, the construction is very simple, consisting of only four parts, thus minimizing both material and labor costs. Reliability of the digitizing table is excellent since there are no active electronic components in the table.
The digitizing table is enclosed by a protective top cover 71 which has a smooth top surface made of durable, abrasion resistant material. The present embodiment of this invention utilizes a printed circuit board 73, with conductors forming an XY grid array (shown schematically in FIG. 6) with parallel X conductors on the top surface of the board and parallel Y conductors on the bottom surface of the board, to generate the moving electromagnetic field discussed previously. The printed circuit board also routes individual grid lines to the anodes of diodes 75, or to source bus 81 as shown in FIG. 6. Source bus 81 and the cathodes of diodes 75 are then routed to a card edge connector (not shown) for connection via a cable to the constant current grid drive multiplexer electronics. Other techniques for manufacturing the XY grid network would work equally well. Among these are hand or machine strung insulated wires bonded to virtually any nonferrous substrate, etch and fill, and deposition. A nonconductive spacer 77 (FIG. 7) serves two purposes. It insulates the Y grid conductors on grid board 73 from shield 79 and it establishes the distance d between the shield and the grid wires as shown in FIG. 1 and discussed previously in conjunction with the derivation of the mathematical model of the electromagnetic field generated by the grid array. A cutout on one edge 76 of spacer 77 is cut so as to provide space for sink diodes 75. Shield 79 serves as a protective bottom cover for the digitizing tables. More importantly, it is an integral component in the generation of the electromagnetic field. As can be seen in equations 2, 3 and 4, the shield serves as a non-linear attenuator to the generated electromagnetic field. It virtually cancels the field generated by wires not in close proximity to the cursor pickup coil. This is beneficial in that it minimizes unwanted edge effects caused by the discontinuity of the XY grid network at the edges of the table and by the fields generated by the routing conductors from the edge connector. Also, it modifies the generated field such that the complex cursor signal is more readily linearized (distance to time) between the discrete grid lines. The shield additionally minimizes the effect of unwanted externally generated electronic noise. Finally, it adds rigidity to the structure. The current embodiment of this invention utilizes cold rolled steel as a shielding material.
The digitizing table has been made translucent for back lighting application. This is accomplished by utilizing a clear or translucent material for protective top cover 71 and spacer 77. Good results are achieved using standard PC board material for the printed circuit board 73. However, best light transmission results from an XY grid network of conductors bonded to a clear glass or plastic substrate. A perforated shield may be utilized to allow for light transmission while still retaining the beneficial effects of the solid shield discussed previously.
A transparent tablet, for rear projection applications, has been realized by manufacturing a precisely registered 2 layer XY grid network with grid currents flowing in opposite directions in each plane as suggested by the mathematical model. This technique eliminates the need for a shield, but is more costly to manufacture and is more susceptible to externally generated electrical noise.
FIGS. 8(a) through (i) show outputs of the system at various points as identified in FIG. 5.
The input to the scan control counter 59 from divider and scaler 35 is the scan clock and is shown in FIG. 8(a). It is a constant clock which drives scan control counter 59 to enable current to one grid line at a time in the proper sequence through the constant current grid drive multiplexer 13.
FIG. 8(b) is the complex cursor waveform after it has been filtered and amplified by filter 31. As can be seen, when cursor wave form is present, there is one cycle in the cursor waveform for each cycle of the clock 8(a). Also, a 180° phase reversal is shown. This occurs as the moving electromagnetic field passes the exact electrical center of the cursor coil.
FIG. 8(c) is a step function which represents the output of sample and hold circuit 33. This signal is input to filter 37. The output of filter 37 is shown in FIG. 8(d). This signal corresponds to the function H (x,t), discussed previously and shown in FIG. 3, the zero crossing of which linearly relates cursor position to time.
The output of lock detector 39 is shown in 8(e). This circuit is a level detector which monitors the negative transition of the output of filter 37. When signal 8(e) is not present, it indicates that the cursor coil is not sufficiently electrically coupled to the grid tablet to provide accurate results.
FIG. 8(f) is the output of stop detector 41. The first positive transition of this signal following the lock detect signal, 8(e) clocks F/F 47 to remove the count window signal, FIG. 8(h). This positive transition indicates the zero of the function H (x,t) shown in FIG. 3. F/F 43 is set by the start pulse, FIG. 8(g) which indicates the arbitrary reference point from which time is measured to the stop signal to represent cursor position. The count window signal FIG. 8(h) is a signal which is true for the duration of this period, from start pulse to stop pulse. It is used to gate the high frequency count clock through count gates 49 and 51. FIG. 8(i) is the gated count signal at the output of either count gate 49 or 51. It should be noted that the frequency of the count clock relative to the scan clock, FIG. 8(a) determines the system resolution. By varying this ratio, virtually any scale or resolution is possible.
It is to be understood that the above description and drawings are illustrative only since equivalent components could be substituted in many instances without departing from the invention. Accordingly, the invention is to be limited only by the scope of the following claims. | An X-Y coordinate position locating or measuring digitizing device in which a cursor (inductor), moveable within an electromagnetic field generated by successively activated grid wires, develops a voltage from the field, and, in conjunction with conditioning circuits, yields the electrical intelligence required to indicate its position with a high degree of precision. Currents are successively passed through parallel grid lines for a given axis at discretely separate distances, the resultant successively generated field inducing a time variant voltage at the cursor coil output with amplitude and phase dependent upon the position of the cursor in relation to the actuated grid line. Conditioning circuitry to which the cursor coil output is coupled uniquely detects the phase reversal in the cursor coil output signal, interprets this reversal point in a manner which very accurately and linearly relates cursor position to time, and generates a "STOP" pulse indicating that the above phase reversal has been sensed. An enable signal initiated at an arbitrary reference point and terminated by the "STOP" pulse is then used to permit a precision clock to relate the distance of the cursor from this arbitrary point to the time needed to reach the cursor center from that reference point. Cursor position then becomes a function of precisely generated pulses accumulated in a counter. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to Great Britain Patent Application No. 0522751.7 filed Nov. 8, 2005, the disclosures of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] This invention relates to improvements in apparatus for providing haptic information to a person. It in particular has application in providing haptic warnings or signals to a driver of a vehicle, although it may find other application.
[0003] It is known that drowsiness of a driver or other inattention is a major cause of accidents. It is unfortunately most common on high speed, multiple lane highways used by drivers travelling long distances. A moment's inattention may be enough for the driver to allow the car to drift out of a lane and off the highway or into another vehicle.
[0004] Various attempts have been made to help maintain the drivers attention and in particular to help the driver stay awake. Lane guidance systems have been developed which enable a car to identify where it is on a highway and when a vehicle is leaving or about to drift out of a lane. These typically rely on information from a camera fitted to the front of the vehicle to identify lane markings.
[0005] It is also known to provide various warnings to a driver that the vehicle is about to drift out of a lane based on the information provided from the lane guidance (or other control) system. In its simplest form, this may comprise an audible alarm. Such alarms are effective but are not suitable for people with impaired hearing.
[0006] One alternative is to provide a haptic signal or warning to a driver as part of a driver assistance system (DAS). Haptic devices are devices that generate and control haptic sensations through information flow. It has been proposed to use haptic signals in addition to or instead of audible and visible signals. In one arrangement, it is proposed to vibrate the vehicle steering wheel to simulate the motion of a vehicle passing over a rumble strip at the edge of a road. In another, it has been proposed to provide actuators in the base of the driver's seat and to vibrate the seat by energising the sensors. Such devices are known as lane change assistants and are fitted to a number of models of road going vehicles. In each case, solutions that are built into a seat or steering system are costly, as they need to be high power and have to be engineered into the design of the vehicle at an early stage making them inflexible in versatility of application.
BRIEF SUMMARY OF THE INVENTION
[0007] According to a first aspect, the invention provides an apparatus for generating haptic signals which is adapted to be fitted to a seatbelt of a vehicle and which is adapted to vibrate when a signal is received from a control unit such that the vibration can be felt by a driver of the vehicle wearing the seatbelt.
[0008] Providing a device which is adapted to be fitted to a seatbelt and which vibrates to provide haptic signals to a driver has been found to provide a simple, elegant, solution to the problem of passing information to a driver of a vehicle.
[0009] By fitted to a seatbelt we may mean a device that is fixed on to the outside of a seatbelt or a device that is fitted within a portion of a seatbelt or a combination of the two. Fitting to the outside is preferred as it ensures the device will not become embedded in the wearer as the belt tightens in the event of an accident.
[0010] The device may therefore comprise an integral part of the seatbelt itself. The vibration of the device, or at least a part of it, may cause the seatbelt to vibrate. Indeed, the device itself may not vibrate but may simply cause the seatbelt to which it is fitted to vibrate and this is to be considered to be within the scope of at least one aspect of the invention.
[0011] The device may comprise a transducer which is adapted to convert electrical energy of a control signal into mechanical energy such that it can vibrate when driven by a suitable control signal, a housing which surrounds the transducer, a transfer means (i.e. transfer device) which is secured to the item worn by the person which transfers energy from the transducer into the item, and biasing means (i.e. biasing device) which is adapted to bias the transducer into contact with the transfer means.
[0012] The transfer means provides an efficient way of passing energy from the transducer into the seatbelt and hence to the driver.
[0013] The transfer means may comprise a rigid element or a flexible element, which is secured to the seatbelt. It may be riveted in position by a rivet passing through the seatbelt, or preferably is glued in position. It is preferably bonded to the outside of the seatbelt, e.g. the side facing away from the wearer of the belt.
[0014] Most preferably, the transfer means comprises a magnet or a material that is attracted to magnets such as a magneto-steel material.
[0015] The transducer may comprise a motor, preferably a multi-phase rotating eccentric disk motor. It may comprise a solenoid. The commonality between these two choices is that they both are capable of providing a high degree of vibrational energy from a small package size.
[0016] The biasing means most preferably comprises a magnet to be used in combination with a transfer means that is magnetic or ferromagnetic. The transducer may then be positioned at least partially in between the biasing means and the transfer means such that it is held in position by the magnetic force between the transfer and the biasing means.
[0017] An advantage of this arrangement is that the device can be arranged with minimal loss of energy from the transducer into the housing.
[0018] Alternatively, the biasing means may be resilient and act between the transducer and the housing to press the transducer onto the transfer means. It may comprise a spring, such as a plastic coil or leaf spring. This will transfer some energy into the housing, and should be designed such that this is minimised.
[0019] The housing is preferably arranged to cover the transducer to protect it from damage but to provide minimal or no path for the transfer of energy from the transducer into the housing. It may include a cavity into which the transfer means, transducer and biasing means are fitted substantially without contact. It may include one or more protrusions, preferably a minimum of three protrusions, into the cavity that locate the transducer and/or transfer means radially in the cavity with minimal contact.
[0020] The housing means may include a means for attachment to the seatbelt. It may, for example, be provided with two or more shallow spaced arms or cleats that surround the edges of the belt to grip the housing in place.
[0021] There may be more than one transducer and each one may have its own transfer means. This has the advantage of minimising the risk of out of phase vibrations cancelling each other out. There may, for example, in a most preferred arrangement be four transducers arranged in a two by two grid. Each may be separately actuable, i.e. can be made to vibrate independent of the others.
[0022] Where there are more than one transducer, each may be housed in a separate cavity in the housing. The housing may be flexible to permit the transducers to move relative to one another as the seatbelt is bent. It may be segmented. It may be articulated to permit it to flex in use and permit relative movement of the transducers. This will help the belt to conform to a drivers shape, better to transfer signals to the driver by ensuring close contact over as large an area as possible.
[0023] In an alternative, more than one housing could be provided to permit the transducers to be spaced along a seatbelt.
[0024] A control means may be provided for generating signals to drive the or each transducer. The signals may be produced which are dependent upon hazard information determined from one or more sensors fitted to a vehicle. For example the control signal may cause or more transducers to vibrate when a vehicle is drifting out of a lane.
[0025] The device may vary the number of transducers that vibrate depending on the severity of the warning. For example, different control signals may be provided which cause each transducer to behave in a predefined way. Different patterns and sequences of vibration can be used depending on the application. For example with the transducers could be connected in pairs.
[0026] In a simple arrangement, all transducers may be vibrated at a low magnitude if a vehicle drifts towards a lane boundary, and vibrated more as the vehicle gets nearer to leaving or leaves the lane.
[0027] Alternatively, more transducers may be vibrated as the vehicle gets nearer to leaving a lane (or at some other hazard).
[0028] In another, alternative transducers at different locations in the housing may be vibrated to give some additional meaning to the haptic signal. Transducers towards the left side of the housing (from the wearers viewpoint looking towards the front of the vehicle) could be made to vibrate whilst the others are still (or vibrating less) to indicate a hazard towards the left. This could indicate that the vehicle is drifting left or that a hazard is approaching from the left. The opposite could be applied to indicate hazards to the right or drifting right by vibrating the ones on the right more. They could even all be vibrated at once, or just transducers towards the centre where provided to indicate a hazard straight ahead. Thus, the control means may also vary the intensity of vibration (its magnitude) and or the frequency to provide difference signals and/or the number vibrated at any time or the sequence in which they vibrate.
[0029] The control means may comprise a signal processor. It may be provided at least partially within the device housing or may be fitted elsewhere on the vehicle and connected to the device.
[0030] The device may be connected wirelessly to a control unit that comprises a processor on the vehicle. It may be connected using a radio frequency link. It may be self-powered, and include one or more batteries such as Ni—Cd type batteries. It may include a receiver, a processing circuit, which interprets signals received by the receiver, and a driver circuit, which acts upon the signals received to drive one or more transducers causing them to vibrate.
[0031] The receiver may comprise a radio frequency (RF) receiver, which may be adapted to receive signals from a transmitter fitted to the vehicle. This transmitter may in turn be driven by a control circuit that forms part of a vehicles hazard warning system.
[0032] In a preferred arrangement, the receiver, processing circuit and driver circuit may be mounted to a single pcb (printed circuit board), which may be flexible. The processing circuit may include a microprocessor with memory containing program instructions. An inductive loop may also be provided for charging the battery through inductive coupling to a power source located on the vehicle.
[0033] The device is preferably arranged such that it is substantially on the face of the seatbelt that faces away from the driver. This ensures that in the event of an accident causing the driver to be pushed into the belt the device is not pushed into the driver's skin.
[0034] By this, we may mean that no active parts of the device are on the side of belt facing the driver. This may include the transducer (or transducers), the transfer means and the biasing means and most, if not all of the housing.
[0035] The transfer means may therefore be glued to the outward facing side of the seatbelt.
[0036] The device may be fitted to a seatbelt in proximity to a lower end of the belt whereby in use the device will be positioned in contact with a stomach or lap region of a driver. It may include a means for attachment to a rivet eye at the end of a stopper bar for the seatbelt.
[0037] One or more wires may connect the device to a processor fitted to the vehicle. The or each wire may be fastened to the seatbelt. They may, in a most preferred arrangement be stitched in position on the seatbelt, along an edge for example.
[0038] According to a second aspect the invention provides apparatus adapted to be fitted to an item worn by a person comprising:
[0039] a transducer which is adapted to convert electrical energy of a control signal into mechanical energy such that it can vibrate when driven by a suitable control signal;
[0040] a housing, which surrounds the transducer;
[0041] transfer means which is secured to the item worn by the person which transfers energy from the transducer into the item, and
[0042] biasing means, which is adapted to bias the transducer into contact with the transfer, means the device being arranged such that when a signal is applied to the apparatus it vibrates such as to provide a haptic signal to the wearer of the item.
[0043] The item may comprise a seatbelt. Alternatively, it may comprise an item of clothing.
[0044] The device may be adapted to provide haptic signals to the wearer, which assist the wearer in driving the vehicle.
[0045] The device may alternatively or additionally be fitted to a seatbelt and be adapted to provide haptic signals that have a therapeutic effect on the wearer so as to reduce the effects of travel sickness.
[0046] The device may reduce these effects by applying haptic signals which distract the wearer and this has been found to reduce the incidence of travel sickness in many people, and in particular in young children and infants.
[0047] According to a third aspect, the invention provides a retro-fittable device which includes means for securing itself to an item worn by a user, the device being in accordance with the second aspect of the invention.
[0048] According to a fourth aspect, the invention provides a method of providing haptic information to a driver of a vehicle, the method comprising providing a device which is fitted to a seatbelt and applying one or more control signals to the device so as to cause the device, in use, to vibrate at least a part of the seatbelt.
[0049] According to a fifth aspect, the invention provides a method of reducing discomfort to a person travelling in a vehicle comprising vibrating a seatbelt worn by the person.
[0050] The method may be performed using a device according to one of the preceding aspects of the invention.
[0051] It has been shown that vibrations applied to a person in a vehicle can prove effective in reducing discomfort such as that associated with the feeling of travel sickness.
[0052] Other advantages of this invention will become apparent to those skilled in the art from the following detailed description of the preferred embodiments, when read in light of the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0053] FIG. 1 is an isometric view from above and to one side of a device in accordance with a first aspect of the invention fitted to a seatbelt;
[0054] FIG. 2 is a cut-away view of the device of FIG. 1 showing a cross section through the device;
[0055] FIG. 3 is an isometric from above and to one side of the device of FIG. 1 with the cover removed;
[0056] FIG. 4 is a cross sectional view of the device showing the location of the steel disks fixed to the seatbelt and the actuators;
[0057] FIG. 5 is an enlarged part cross section showing in detail the location of the actuator and magnet in one section of the housing;
[0058] FIG. 6 is an isometric view from below and to one side of the device fitted to a seatbelt;
[0059] FIG. 7 shows the device incorporated into a vehicle system for providing haptic signals to a person wearing a seatbelt;
[0060] FIG. 8 shows an alternative partial schematic view of an alternative embodiment of a device according to the first aspect of the invention; and
[0061] FIG. 9 is a partial isometric view from above and to one side of a device that incorporates a spring in accordance with the principles of FIG. 8 .
DETAILED DESCRIPTION OF THE INVENTION
[0062] The device 100 comprises a thin, generally rectangular, housing 200 (shown best in FIG. 3 ) and a complementary cover 300 that clips over it. The cover is divided into four sections 310 , 320 , 330 , and 340 . The cover 300 also has a tab 350 extending from one end which includes a hole 355 for receiving a rivet (not shown) that attaches it to a portion of seatbelt 400 . The cover 300 is a snap fit onto the housing 200 and can also be secured by four screws that each pass through a respective countersunk opening 315 , 325 , 335 , and 345 in each of the cover sections. Soft foam spacers (not shown) between the housing and the cover help isolate the cover from the housing against vibrations.
[0063] Each of the four sections of the cover 300 correspond with one of four sections 210 , 220 , 230 , and 240 of the housing 200 . These sections are arranged in a grid. Each section of housing comprises a cylindrical opening 21 , 221 , 231 , and 241 that passes completely through the housing to allow access to a portion of the seatbelt 400 through the opening. The cover 300 fits over the housing 200 so as to cover the openings and, as will become apparent, ensure retention of various components within each opening. The housing 200 has four thin arm portions 361 , 362 arranged in pairs that clip the housing around a portion of a seat belt webbing. This can best be seen in FIG. 4 , where the pairs of arms and underside of the housing form a C-shape which receives the seatbelt
[0064] As best seen in FIG. 5 , each opening contains an assembly comprising a transfer means 500 , a transducer 600 and a biasing means 700 . The transfer means comprises a magneto-steel disk of about 12 mm diameter that is glued to the seatbelt. Two such assemblies can be seen in the cross section of FIG. 4 , although since four openings are provided it will be appreciated that there are four disks glued in a 2 by 2 grid. The centre of each steel disk 500 is chosen to coincide with the centre of its respective opening in the housing 200 .
[0065] Above the disk 500 within the opening is a cylindrical transducer 600 . This is also in the shape of a disk of about 12 mm diameter and 3.5 mm thickness. A pair of wires (not shown) lead from the transducer 600 through an outlet in the housing 200 , which opens in to the opening. The wires from each of the four transducers pass out of the housing 200 and are stitched along the side of the seatbelt.
[0066] Above the transducer 600 is a biasing means 700 , which comprises a magnet. This is also shown as a disk but could be of a different shape. The magnet 700 is attracted to the metal disk 500 and so clamps the transducer 600 in place. This arrangement ensures that energy from the transducer is coupled into the disk and therefore into the seatbelt.
[0067] The height of the disk is chosen such that when the cover is in place there is room for the transducer and the biasing means in a stack without the biasing means touching the inside of the cover 300 . This ensures that the amount of energy transfer to the cover is minimal.
[0068] Additionally the diameter of the opening is greater than that of any of the components it contains. Three small inwardly extending tangs (not shown) are provided which help to centralise the metal disk 500 in the opening, and these also minimise energy transfer to the housing whilst helping located the housing and hence cover in position. No other form of fixing to the seatbelt 400 is therefore needed once assembled, other than the use of a rivet to locate the housing (although this is optional).
[0069] In use, each of the wires from the transducers of the device 100 is connected to an output port of a vehicle control system as shown in FIG. 7 . This can be achieved by connecting a connector that forms part of the vehicles wiring loom to a control unit 710 which receives signals from a vehicle processing unit 720 such as used for determining vehicle position in a lane. The processing unit derives signals from various sensors including a radar unit 730 , a speed unit 740 , a yaw sensor 750 and a steering position sensor 760 . Of course, other combinations of sensor could be used as well as other types of sensors. A voltage is applied to one or more of the wires to cause the transducer connected to that wire to vibrate. The control unit 710 is configured to apply a different voltage to one or more of the transducers to either cause them all to vibrate at the same time, in a sequence or in sets such as in pairs. This allows different messages to be signalled to the wearer of the belt.
[0070] Various modifications are possible. In one alternative embodiment 800 shown in FIGS. 8 and 9 a spring 810 is used in place of the magnet. Otherwise, the parts of the device are substantially the same and are marked with the same reference numerals as for the first embodiment for clarity. The spring 810 acts between the cover and the top of the transducer.
[0071] In another arrangement, not shown, the housing may also contain a control unit, a source of electrical power such as a battery and an RF receiver. The vehicle is also fitted with an RF transmitter. When a haptic signal is required, the vehicle transmits a signal at a strength and frequency that can be detected by the RF receiver. On receiving the signal, the control unit generates the required signal to apply to one or more of the transducers to cause them to vibrate. If required the transmitted signal could contain information about the type of haptic signal required, e.g. vibrate all transducers, vibrate one, etc.
[0072] The device can be used to provide a haptic warning signal to a driver in the event that a crash may occur, such as when a vehicle is drifting out of a lane.
[0073] It may also be used as a device for alleviating discomfort to a person travelling in a vehicle. It is known that many people, especially children, suffer from motion sickness (sometimes called travel sickness) which is somewhat discomforting. Vibrating the person's seatbelt whilst the vehicle is in motion may help to reduce this discomfort and tests have shown that providing haptic stimulae to persons during travel can help make them more comfortable. | An apparatus for generating haptic signals is disclosed which is adapted to be fitted to a seatbelt of a vehicle and which is adapted to vibrate when a signal is received from a control unit such that the vibration can be felt by a driver of the vehicle wearing the seatbelt. It can serve in the method of reducing discomfort to a person travelling by vibrating their seatbelt. | 1 |
TECHNICAL FIELD
[0001] The invention relates to munitions and firearms. This invention has particular, but not exclusive, application to a barrel assembly having a plurality of rounds stacked axially within a barrel together with discrete selectively ignitable propellant charges for propelling the rounds sequentially through the muzzle of the barrel. Such barrel assemblies will be referred to hereinafter as “of the type described”.
BACKGROUND ART
[0002] This invention concerns barrel assemblies for munitions and firearms, particularly of the type described, such as illustrated in earlier International Patent Applications Nos. PCT/AU94/00124 and PCT/AU96/00459 filed by the present inventor.
[0003] Whilst tubular rounds are known in certain limited applications such as supersonic projectiles, the applicant is unaware of any tubular rounds suitable for stacking within a barrel with selectively ignitable propellant charges, and particularly no tubular rounds suited to barrel assemblies of the type described.
DISCLOSURE OF INVENTION
[0004] It is desirable to provide barrel assemblies for electronically controlled munitions and firearms, particularly of the type described, that are adapted to firing tubular type rounds, and to provide tubular rounds for that purpose.
[0005] According to one aspect this invention provides a barrel assembly of the type described including:
[0006] a barrel having a muzzle;
[0007] a plurality of tubular rounds stacked axially within the barrel and arranged for operative sealing engagement with the barrel;
[0008] closure means interposed between the tubular rounds for effecting both an operative barrel closure between the tubular rounds; and
[0009] a selectively ignitable propellant charge within each round and ignitable for propelling an adjacent leading round and associated closure means through the muzzle of the barrel.
[0010] Preferably the tubular rounds are stacked in abutting relationship, although they could be spaced apart by the propellant. It is also preferred that each round includes a tubular body having a closure means associated with at least its trailing end.
[0011] The closure means may also act to close the leading end of the trailing round. Alternatively, separate closure means could be used for the leading and trailing ends of each round provide that the closure for the leading end is made inoperative upon ignition of the charge therein to enable the combustion effects to propel the leading round from the barrel.
[0012] The closure means may be arranged to discard from the tubular body or it may be fixed to the leading tubular body. The tubular rounds may be configured to have desired flight characteristics by their aerodynamic form. The form of the inner face of the tubular body, when used with a discarding closure means, may act to maintain axial alignment of the round with the flight path. Alternatively the tubular body may be weighted whereby one end is heavier than the other end.
[0013] The closure means is suitably a closure wall member sandwiched between adjacent tubular body portions. Each closure wall member may extend to and engages sealably with the barrel. Alternatively the tubular rounds may have complementary outer end wall portions which abut or lie closely adjacent one another, with the closure wall member being sandwiched between inner end wall portions.
[0014] In the former arrangement, the closure wall member may be sandwiched between end faces of adjacent tubular rounds. The closure wall member may be of a form which does not deform under operational conditions. Alternatively, the peripheral portion of the closure wall member may be formed so as to spread outwardly between the adjacent tubular rounds into operative sealing engagement with the barrel by axial compression applied by the end faces. For low pressure applications, such deformation for effecting a tight sealing engagement with the barrel should not be necessary.
[0015] The end faces of adjacent tubular rounds may extend radially of the barrel or the end faces of adjacent tubular rounds may be formed to engage with respective complementary wedging surfaces on the peripheral portion of the sandwiched closure wall member.
[0016] The tubular bodies of adjacent rounds may overlap one another to provide a telescoped engagement between adjacent rounds. For this purpose the rounds may include outer end wall portions which overlap inner end wall portions of the adjacent round and the closure wall members may be sandwiched between inner complementary end wall faces of the telescoped rounds.
[0017] If desired the telescoped portions of adjacent rounds may include a thin walled portion which may expand outwardly into sealing engagement with either the adjacent telescoped round portion so as to prevent escape of propellant into the barrel or blow by into the adjacent propellant charge. Alternatively the outward expansion may be of the outer telescoped portion so as to enhance the sealing engagement of the round being fired and the barrel.
[0018] Each sandwiched closure wall member may also be arranged to react to propellant charge pressure against its leading face to seal against the end face of the trailing round to prevent blow-by ignition of the charge contained in the adjacent trailing round. Such reactive sealing may also occur between abutting end face portions of the rounds and/or between the leading round and the closure wall member.
[0019] The ignition of the propellant charges may be such as is described in my earlier International applications. For this purpose each selectively ignitable propellant charge may include an electrically actuated primer connected to a pair of spaced annular contacts extending about the round and contacting respective electrical contacts protruding through the barrel and suitably associated with electronic control means.
[0020] The closure means may be integral with the rounds and may include wall segments which may move, or a wall which may expand, forwardly from a closed attitude to an open attitude and substantially barrel conforming attitude. When in the closed attitude the wall segments may react to ignition of a leading propellant charge to maintain or enhance the closing effect of the closure means.
[0021] Suitably each round with its propellant charge is prepared prior to loading into the barrel but if desired the barrel may be loaded by sequentially loading a round tubular body having on open leading end, propellant charge followed by closure of the open end, either as a separate operation or as a result of placing the next round tubular body into its located position.
[0022] In another aspect, the invention resides in a round for firing from the barrel assembly of a munition or firearm, said round including:
[0023] an open ended tubular body adapted for loading into a barrel of the barrel assembly and for operative sealing engagement with the barrel;
[0024] a closure wall member adapted to be interposed between said tubular body and the tubular body of an adjacent round for effecting an operative barrel closure between rounds; and
[0025] a selectively ignitable propellant charge within the tubular body of the adjacent round, which propellant charge is ignitable for propelling the tubular body of said round through the muzzle of the barrel.
BRIEF DETAILS OF THE DRAWINGS
[0026] In order that this invention may be more readily understood and put into practical effect, reference will now be made to the accompanying drawings which illustrate typical embodiments of this invention and wherein:
[0027] [0027]FIGS. 1A to 1 D diagrammatically illustrate, in section, one form of the invention and its mode of operation;
[0028] [0028]FIGS. 2A to 2 D diagrammatically illustrate, in section, a further embodiment of the invention and its mode of operation;
[0029] [0029]FIG. 3 is a perspective view illustrating one round of the embodiment illustrated in FIGS. 2A to 2 D;
[0030] [0030]FIG. 4 diagrammatically illustrates, in section, another form of the invention; and
[0031] [0031]FIG. 5 diagrammatically illustrates, in section, yet another form of the invention.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0032] In the embodiment illustrated in FIGS. 1A to 1 D, the barrel assembly 10 has a plurality of rounds 11 stacked in axial abutting relationship within the barrel 12 and which are adapted to be fired electrically or otherwise in sequence, such as is illustrated in the inventor's earlier International applications or as is otherwise known in the art.
[0033] Each round 11 comprises a tubular body 13 associated with a barrel closure member 14 disposed between and separating adjacent tubular bodies 13 a, 13 b, 13 c and 13 d from one another, and with a propellant charge 15 arranged behind a closure member 14 . The propellant charge 15 a is, for example, supported within a trailing tubular body 13 b between respective barrel closure members 14 a and 14 b. In the embodiment a further propellant charge 15 d is contained in a rear extension 16 of the barrel assembly 10 for propelling the rearmost tubular body 13 d.
[0034] It will be seen in FIG. 1A that the leading annular end 18 of each body 13 extends inwardly and rearwardly to form a part conical end face 19 . The part conical end face co-operates with a complementary part conical face 22 formed about the outer trailing peripheral portion of the barrel closure member 14 , as shown in FIG. 1B. A further complementary part conical leading face 23 is formed about the outer edge of the closure member 14 , as shown in FIG. 1C. The further complementary part conical leading face 23 is associated with a return face 24 so as to provide a recess 25 which receives the complementary shaped trailing end wall 26 of each tubular body 13 .
[0035] It will be seen that the end walls 26 return inwardly whereas the remainder of the tubular body 13 is of constant tubular section, although it could be formed to provide a venturi shape through the body 13 if desired.
[0036] The return wall portion 26 is captured by the closure member 24 during firing of the leading body 13 from the barrel as illustrated in FIG. 1B. As depicted in FIG. 1C the closure member 14 may be discarded from the tubular body 13 during flight, such as the result of rotation of the body 13 due to rifling provided in the barrel 12 or it may stay with the body 13 during flight as depicted in FIG. 1D. For this purpose, the closure member 14 could be secured to the body 13 by screwing, pinning, gluing, swaging or otherwise as required.
[0037] In use, the barrel assembly 10 is stacked with rounds 11 wherein an empty tubular body 13 a is the leading projectile. When the leading propellant charge 15 a is ignited in the next adjacent body 13 b, the resultant gas pressure will act upon both the leading and trailing end closure members 14 a, 14 b enclosing the ignited propellant charge. The action of the gas pressure causes the leading closure member 14 a to be propelled from the barrel 12 together with the leading body 13 a. At the same time the gas pressures will force the trailing closure member 14 b into axial compression with the trailing body 13 b, resulting in radial expansion of the part conical end face 19 of the trailing body.
[0038] This arrangement will wedge the leading annular end 18 of the trailing body 13 b into sealing engagement with the barrel 12 and wedge the closure member 14 b into sealing engagement with the part conical end face 19 , ensuring there is no leaking of combustion gasses into the propellant of the next trailing charge 15 b. Thereafter, the empty body 13 b as shown in FIG. 1B may be propelled from the barrel assembly 10 by ignition of the propellant 15 b in the next trailing body 13 c.
[0039] In the embodiment of the barrel assembly illustrated in FIGS. 2A to 2 D, each round 30 has a tubular body portion 31 provided with outwardly converging wall segments 33 which abut or overlap to form respective closures for the tubular body 31 . These segments 33 provide a central land portion 35 which mutually abut when the rounds 30 are disposed along the length of a barrel 36 .
[0040] The preferred form of wall segments 33 is an opposing pair of segments as illustrated in FIG. 3, disposed between body extensions 38 having end walls 39 which abut when disposed in the barrel 36 .
[0041] The leading segments 33 open to lie alongside the barrel 36 upon ignition of the propellant 37 contained within the round 30 . Propellant ignition also propels the leading round 30 , shown partially in FIG. 2A. This action provides the next leading round 30 with a substantially tubular body 31 in the barrel, which body is closed only at its rear end by the trailing closure segments 33 which diverge rearwardly to provide a land portion 35 , as shown in FIG. 2B. The land portion 35 abuts the land portion 35 formed at the front of the forwardly diverging segments 33 of the next adjacent trailing round 30 .
[0042] When the propellant 37 in that next adjacent trailing found 30 is ignited, its leading segments 33 will open to place the pressure of the combustion gasses into contact with the trailing faces of the segments 33 at the trailing end of the leading body 31 and thus propel that body from the barrel 36 . In this action, the next body is made ready for firing.
[0043] The segments could alternatively be a plurality of substantially triangular segments having their bases disposed about the periphery of the body 31 and extending inwardly to form a pyramid shaped closure.
[0044] If desired, the trailing closure segments 33 may be coupled to the tubular body 31 by hinge means 32 , which segments open upon exiting the barrel due to air pressure passing through the tubular body 31 , as illustrated in FIG. 2D. If desired, these segments 33 may be provided with flights or other projections to stabilise the flight of the body 31 or make it spin as required.
[0045] It will be seen from the above that the high pressure resulting from propellant burn which propels the leading body 31 acts on the rear section of the trailing round, pressing it against the leading edge of the following round, and sealing against undesired blow-by ignition of the propellant in that following round, thus ensuring consistent operation of the firearm at a desired firing rate.
[0046] In operation barrel closure members 14 may be the free floating and behave as a discarding section, separated by the rotation of the tubular round if fired from a rifled barrel, or separated by air pressure during flight. With the section discarded the round would have improved aerodynamic performance for relatively long range engagements, such as need when fired from an aircraft or when used to engage incoming missiles in such areas as ship self defence.
[0047] However, in certain applications there may be-advantage in fixing the closure members 14 to the tubular body 31 . For example, the closed rounds may be fired from multiple barrels against a buried land mine. Such a round would then act to scoop earth into the body 31 and carry it away from the mine location. That effect would be into addition to the usual disturbance of earth due to the kinetic impact of the round on the ground. Firing multiple rounds from multiple barrels thus has the potential to provide improved means of exposing and/or neutralizing buried land mines.
[0048] The rounds make contact with each other while stacked in a barrel, and are positively located in their intended position. In effect, the rounds utilize a cartridge case which also doubles as the projectile itself.
[0049] In the barrel assembly 40 illustrated in FIG. 4, the barrel 41 is shown cutaway at its leading end or muzzle so that only the two rearmost rounds 42 and 43 are illustrated, a leading round (not shown) having been recently fired from the barrel. It will be seen that in this embodiment the rounds 42 and 43 are telescoped, with the outer leading end portion 44 of the trailing round 43 extending about the inner trailing end portion 45 of the intermediate round 42 .
[0050] All end face portions are part conical with the respective complementary outer end face portions 46 and 47 terminating adjacent one another, and the inner end face portions 48 and 49 terminating in spaced apart relation with one another and in abutting relationship with the closure wall member 50 . The closure wall member includes a peripheral portion 52 also having a part conical end face 54 . In this embodiment the telescoped wall portions 44 and 45 are relatively long and are formed as a close fit, one within the other.
[0051] In use during discharge of the leading round (not shown), propellant pressure acts against the closure wall member 50 of the intermediate round 42 which contains the ignited propellant. This urges the end face 54 of the wall member 50 against the complementary inner end face portion 49 of the trailing round 43 . During exit of the leading round, pressure thus acts on the leading ends 47 , 49 of the trailing round 43 and forces the intermediate projectile 42 outward and rearward to wedge the trailing face 46 into the leading outer face 47 effecting a seal therebetween. The outward pressure also expands the leading end 51 of the leading outer end portion 44 of the trailing round 43 into engagement with the barrel 41 .
[0052] The inner faces 48 , 49 also wedge into sealing engagement with the peripheral portion 52 of the closure wall member 50 , preventing blow by ignition of the propellant for the trailing round 43 . Furthermore, the propellant pressure will tend to expand the inner trailing end portion 45 of the intermediate round 42 into tight engagement with the outer leading end portion 44 of the trailing round 43 so as minimise leakage to the barrel 41 .
[0053] As illustrated a primer 55 is located within each selectively ignitable propellant charge 56 and connected to positive and negative slip ring type contacts 57 , 58 spaced along the outer periphery of the rounds 42 , 43 . The barrel 41 is provided with correspondingly located spring contacts 53 , 59 protruding into the barrel for effecting a contact with the respective contact rings 57 , 58 .
[0054] Suitable electronic controls are provided for actuating the primer and igniting the propellant charges 56 . These peripheral contacts 57 , 58 are suitably utilised on all the illustrated rounds such as is shown in FIG. 3.
[0055] The barrel assembly 60 illustrated in FIG. 5 is similar to the embodiment illustrated in FIG. 4, the difference being reversal of the rounds 61 and the annular skirt portion 63 provided in the barrel 64 . That is in the FIG. 4 embodiment, the rounds 42 , 43 have an inner wall which reduces rearwardly whereas the inner wall 62 of the rounds 61 is of constant diameter throughout the majority of its length and then expands outwardly. It is believed that this arrangement will provide a more aerodynamic configuration but less effective sealing than the embodiment of FIG. 4.
Industrial Application
[0056] The barrel assembly and tubular rounds of this invention could be utilised in small arms but it is envisaged that they would be more suited to rounds of 20 mm diameter and above. It will be seen that each barrel closure may cooperate with the leading annular end of the adjacent tubular round, either by forcing the annular end outwardly into contact with the bore of the barrel and wedge a barrel closure into sealing engagement with the barrel or the leading annular end, or by causing the closure member to wedge into close sealing contact with the part-conical inner end of the tubular round and without significant expansion of that leading end into engagement with the barrel.
[0057] This wedging may be achieved by maintaining the wedging angles relatively steep, by providing a stop on the leading end which stops rearward movement of the closure at a point at which sealing between the closure and tubular round is effected but prior to radial expansion of the leading end of the tubular round occurring. Alternatively the leading end may be formed sufficiently robust to resist outward splaying under the influence of the wedging action created by the propulsion force from a leading round. Such a sealing action is more suited to low pressure, low muzzle velocity applications.
[0058] While illustrated as being stacked rounds supplied in situ in a barrel, the rounds may also be supplied individually to a weapon from an external magazine by conventional means. For this purpose each round may include the closure wall suitably fixed to the trailing end of the round and a wad closure or the like for securing the propellant in the round.
[0059] The barrel assemblies of this invention which utilise open tubular rounds may also be useful for firing from underwater locations such as from ships, submarines or as concealed land based surface piercing defence installations. For example submarines may utilise such barrel assemblies for self-defence, for underwater mine destruction or anti-torpedo or missile activity.
[0060] It will of course be realised that the above has been given only by way of illustrative example of the invention and that all such modifications and variations thereto as would be apparent to persons skilled in the art are deemed to fall within the broad scope and ambit of the invention as is set forth in the following claims. | A barrel assembly ( 10 ) for munitions and firearms, said barrel assembly including a barrel ( 12 ) having a muzzle with a plurality of tubular rounds ( 11 ) stacked axially within the barrel together with discrete selectively ignitable propellant charges ( 15 ). The rounds ( 11 ) suitably include tubular bodies ( 13 a, 13 b, 13 c, 13 d ) and closure means ( 14 a, 14 b, 14 c, 14 d ) interposed between the tubular rounds for effecting both an operative barrel closure between the tubular rounds ( 11 ) and operative sealing engagement with the barrel ( 12 ). The propellant charges ( 15 ) are contained within each round ( 11 ) and selectively ignitable ( 15 a ) for propelling an adjacent leading round ( 13 a ) and associated closure means ( 14 a ) through the muzzle of the barrel. | 5 |
BACKGROUND
Different techniques can be used to characterize pathology samples such as tumors. One of such techniques investigates homogenized samples and determines information from the homogenized sample, e.g., within a test tube, and the other collects spatially orientated information.
Homogenized tissue sample tests can test for different characteristics. However, the whole contents of the test tube is averaged for the test. Tests of these types include polymerase chain reaction or PCR, Western blotting that can be used to quantify concentrations of types of proteins in a sample, DNA arrays, that can be used to quantify the amount of DNA in sequences, RNA arrays that can be used to quantify messenger RNA and thus determine the expression level of many different genes, and others. These kinds of tests can be very specific—for example, quantitative PCR can be used to determine the level of PCR differing by only a single mutation. However, the specificity is reduced since the test is specific to the entire sample.
Staining techniques can also be used. In slide based tests the sample is sectioned into thin sections (typically 5 microns) and placed on a microscope slide for observation with a microscope, photo microscopy or image analysis. Stains are used on the tissue to make certain features visible. One stain is the classic H&E stain. This stain allows pathologists to view the overall morphology of a tissue and identify areas of tumor based on morphological features that show up under the stain. Other stain techniques produce other results. For example, IHC (Immunohistochemistry) creates and links custom antibodies to proteins or other chemical species on a stain. IHC can be used to visualize contents of a slide to determine that a target molecule is present. IHC can also be used to specify which cells or even sub cellular structures in which the target molecule is present. By using several stains linked to different antibodies, it is possible to characterize the extent of co-localization of several targets or determine that they are found in different cells or organelles.
FISH (Fluorescent in-situ hybridization) can locate the position on a chromosome of a given genetic sequence by using several probes linked to different colored dyes. Fish makes it possible to see the spatial relationship of different loci. For instance FISH can be used to detect chromosome translocation that cause leukemia by marking two loci known to be brought together by a translocation that causes leukemia with red and green fluorochromes. If the translocation has occurred, these 2 probes will be brought next to each other and will appear to be a single yellow dot. Thus FISH can produce detailed spatial data on the location of gene sequences.
In general, the operation on homogenized tissue make many measurements but are in effect averaging over the entire block that was homogenized. This has limited their utility in practical diagnosis because the tissue sample delivered to a pathologist is rarely entirely cancerous. In cancer surgery, the goal is to remove tissue until the margins are clear (that is free of cancer). In biopsy samples, there is often no way to assure that only tumor is sampled. Further, it is known that many cancers are themselves genetically and metabolically heterogeneous. This means that the numbers produced by all of the homogenization methods may be averages of tumor and non tumor tissue or different regions of the tumor.
Slide based methods overcome the localization limitations but suffer from restrictions on the number of chemical species that can be detected at once. While DNA arrays can test for thousands of sequences at once, FISH is restricted to 4 or 5 probes at a time. Similarly IHC is limited by the number of stains that can be attached and visualized, e.g., 3 or 4.
These limitations mean that in practice it is possible to know the amount of various types of DNA, RNA and protein in a tissue in detail but not the precise location of those species or it is possible to know the location of a few species with high spatial accurately.
Other techniques collect spatially oriented information from slides. Laser capture microdissection, for example, uses a laser to release a chosen section of the tissue, e.g. while observing the tissue on a slide under a microscope (with no cover slip). The released sample is captured in a vial, and the localized sample is tested using one of the methods mentioned above. This allows obtaining test information for a known location. While this is difficult at the sub cellular level, it is possible to select one or a few cells that are known to be part of a tumor.
Laser capture microdissection has not been widely used because of its disadvantages. One is the cost and complexity of the equipment involved. Also, since the sample is collected after it has been fixed and possibly stained these processes may disrupt the target molecules and prevent some chemical methods from operating correctly. Also, since the size of the area sampled is inherently limited by the collection technique, it may be too small relative to the tumor that is to be characterized.
SUMMARY
The present application describes using image analysis in conjunction with laser microdissection to automatically determine areas within the sample.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1A-1E show multiple slides sections; and
FIG. 2 shows a composite slide section.
DETAILED DESCRIPTION
When carrying out laser capture microdissection, one is faced with a tradeoff. One typically processes the unstained slides, to avoid effects from the staining and fixing of the slide portions. However, it is often difficult to determine items of interest (e.g. tumors) from the unstained slides within those sections. Therefore, it is very time consuming and labor intensive. Many laser microdissection users attempt to identify the areas of interest within the untreated slide. This adds to the difficulty of determining the area.
The inventors recognize that usually when slides are taken, they are serial cut sections, cut from a block, about 4 microns apart, into a water bath. The sections are then pulled from the water bath, and may be in random locations on the slide. However, the serial sections have similar information.
Multiple serial sections are obtained. One section, or more preferably plural sections, are stained using different staining techniques. Another section/slide is unstained.
An interesting area is identified on one or multiple stained sections. For example, FIG. 1A illustrates a stained section 111 . Other techniques may be used, including manual drawing or automated image analysis to mark the interesting region.
Shape analysis of the shapes, e.g. 106 , within slide 101 is then used to project one slide image 106 on top of another image 108 . These multiple serial sections are rotated and superimposed onto one another. The multiple stained sections can be rotated and superimposed on to an unstained section. The staining can be used to determine which regions are interesting. The determination can be automated, or it can be done remotely, for example by drawing on the screen. This avoids certain labor-intensive parts of the laser microdissection. The sections which are shown to be interesting by the stain are then translated into the unstained image. This can be used to form rules for guiding the laser by studying the stained sections, and then to use them on the unstained sections.
The area determination and orientation can identify an area, and once identified, the outline or whole image is correlated with another area. A similarity measure can be carried out by cross correlation, which rotates and translates across every possible rotation and translation value, and finds similarity values at each relative orientation (e.g., using least mean squares measures). The closest match is used as a final match. This allows each tissue level feature to be accurately matched from a region on one slide to another slide.
FIG. 1A-1E illustrate an embodiment. A number of different sections are shown in FIGS. 1A , 1 B, 1 C, 1 D and 1 E. Each of these sections are serial sections from the same area. The section from FIG. 1A has a stained area 111 which is stained with a first stain, here H&E. FIG. 1C shows another serial section 103 stained with a second stain, showing a second stained area 112 . Section slide 104 shows a third stain and a third stained area 113 . Slide 105 shows a fourth stain, and a fourth stained area 114 .
Slide 102 is unstained. All of the stained areas are transposed and superimposed on the non-stained area 107 . FIG. 2 illustrates a closeup view of the unstained slide 102 , in which all of the stained areas 111 , 112 , 113 and 114 are shown. Laser capture microdissection can be used for any of these areas. Each area has been projected onto the unstained slide. Area 115 is a projection of 112 onto area 107 taking into account translation and rotation between 108 and 107 . In a similar way, 116 is a projection of 111 ; 117 is a projection of 113 , and 118 is the intersection of the different stained regions. This allows a number of different stains to each be individually used on different slides. The system determines the translation and rotation between the areas, and uses that same translation and rotation to translate and rotate the slide. The intersection area may be used to identify, for example, areas of interest that are viewable only when stained with multiple stains.
In the embodiment, the unstained slide is the one that is actually laser microdissected. In the embodiment, the unstained slide is between multiple stained slides. In this way, the slide that is microdissected is serially between stained slides, preferably in the middle of the sections. In this way, the dissected slide is between the other slides and forms a median of the other slides.
The general structure and techniques, and more specific embodiments which can be used to effect different ways of carrying out the more general goals are described herein.
Although only a few embodiments have been disclosed in detail above, other embodiments are possible and the inventors intend these to be encompassed within this specification. The specification describes specific examples to accomplish a more general goal that may be accomplished in another way. This disclosure is intended to be exemplary, and the claims are intended to cover any modification or alternative which might be predictable to a person having ordinary skill in the art. For example, other data formats, other kinds of slides, etc, may be used.
The term serial means that the different sections are formed in series, but includes a situation where there are unused slides between the serially obtained sections. Also, the inventors intend that only those claims which use the words “means for” are intended to be interpreted under 35 USC 112, sixth paragraph. Moreover, no limitations from the specification are intended to be read into any claims, unless those limitations are expressly included in the claims. The computers that carry out the processing described herein may be any kind of computer, either general purpose, or some specific purpose computer such as a workstation. The computer may be an Intel (e.g., Pentium or Core 2 duo) or AMD based computer, running Windows XP or Linux, or may be a Macintosh computer. The computer may also be a handheld computer, such as a PDA, cellphone, or laptop.
The programs may be written in C or Python, or Java, Brew or any other programming language. The programs may be resident on a storage medium, e.g., magnetic or optical, e.g. the computer hard drive, a removable disk or media such as a memory stick or SD media, wired or wireless network based or Bluetooth based Network Attached Storage (NAS), or other removable medium or other removable medium. The programs may also be run over a network, for example, with a server or other machine sending signals to the local machine, which allows the local machine to carry out the operations described herein.
Where a specific numerical value is mentioned herein, it should be considered that the value may be increased or decreased by 20%, while still staying within the teachings of the present application, unless some different range is specifically mentioned. Where a specified logical sense is used, the opposite logical sense is also intended to be encompassed. | Multiple different samples are obtained from a bulk material and are separately stained. The differently stained materials look different with the different stains but also have similar characteristics. A computer is used to reorient the images so that the samples are oriented with one another. The thus oriented samples can have their like parts either reoriented. Once the stained areas are analyzed, the identified area in the unstained sample can be removed by laser capture microdissection. | 6 |
FIELD OF THE INVENTION
The present invention relates generally to the field of integrated circuit fabrication, and more particularly relates to a method of improving film adhesion in thin film integrated circuit structures.
BACKGROUND OF THE INVENTION
The design and manufacture of semiconductor integrated circuits is well known in the art. With the many recent advances in integrated circuit technology, device dimensions are continuously decreasing while the packing density and complexity of these devices are correspondingly increasing. Coincident with these advances are also increasingly stringent requirements for electrical interconnection materials. Briefly, these requirements are low resistivity, the ability to withstand the chemicals and high temperatures used in fabrication processes, and the capability of being patterned into fine lines.
In a typical MOSFET structure, for example, an epitaxially grown single-crystal silicon layer provides a base or substrate, while polycrystalline silicon ("polysilicon") is the standard material for both gate and interconnect structures. The polysilicon is insulated from electrically conductive overlayers and the single crystal silicon substrate by layers of silicon dioxide. Although polysilicon provides the requisite stability to processing chemicals and high temperatures, a major limitation now restricting its utility as an interconnection material in high performance devices is its limited conductivity. Even heavily doped polysilicon has a conductivity of only about 300 micro-ohm-cm., thus imposing a serious limitation on circuit performance. One proposed solution has been to replace polysilicon with pure metals such as aluminum, tungsten or titanium, which have a conductivity far higher than that of polysilicon. However, these materials are also limited in that they may react with the silicon substrate at the high temperatures used in integrated circuit fabrication and may additionally be unable to withstand the chemical reagents used in processing.
An alternative solution has been the incorporation of refractory metal silicides into integrated circuit fabrication technology. Silicides offer several advantages over single-layer doped polysilicon. In contrast to doped polysilicon, which at a typical thickness of 4500 angstroms has a sheet resistivity of 15 ohms per sheet or more, silicides provide on the order of 2 ohms per sheet or less. Tantalum and tungsten silicides each have sheet resistivities of about 2 ohms per sheet, molybdenum silicide about 1.5 to about 2.0 ohms per sheet, and titanium silicide about 0.5 ohms per sheet. Silicides are also compatible with MOSFET and other integrated circuit fabrication processes as they can generally withstand high temperatures and caustic processing chemicals. Finally, providing there is sufficient silicon underlying the silicide layer, a self-passivating silicon dioxide layer can be thermally grown over the silicide without any degradation of chemical or electrical properties of the silicide film.
Metallic silicides provide the desired resistivity and the chemical and thermal stability necessary for use as interconnects, and they function well as FET gates. A layered structure having a polysilicon layer sufficiently thick to serve as a transistor gate, underlying the silicide, is often used. These "polycide" structures have resistivities on the order of 4 ohms per sheet or less where the combined thickness of both layers is about 4500 angstroms. The use of such polycide structures is fairly recent but is known in the art. U.S. Pat. No. 4,180,596 to Crowder et al., for example, discloses a method of providing a silicide layer on a polysilicon substrate by means of sputtering and subsequent annealing. U.S. Pat. No. 4,468,308 to Scovell et al. shows a method of providing a silicide layer on a semiconductor substrate using a vapor deposition technique. Other semiconductor circuit structures having silicide layers include those disclosed in the following: U.S. Pat. No. 4,276,557 to Levinstein et al., which shows a tantalum or titanium silicide layer sandwiched between a layer of doped polysilicon and a vapor-deposited layer of silicon dioxide; U.S. Pat. No. 4,332,839 to Levinstein et al. and U.S. Pat. No. 4,337,476 to Fraser et al., which show a silicide layer interposed between a layer of polysilicon and a thermally grown layer of silicon dioxide; and U.S. Pat. No. 4,450,620 to Fuls et al., which shows an MOS integrated circuit device having both silicide and polysilicon layers.
One problem noted in the fabrication of polycide structures is poor adhesion of the silicide layer, both during silicide formation and in subsequent fabrication processes. During silicide formation, volume shrinkage can result in large tensile stresses in the range of 1-3×10 10 dynes per square cm. Because the coefficients of thermal expansion for silicides and polysilicon differ substantially, the high temperatures used in subsequent fabrication processes such as annealing can cause additional stress. Furthermore, cracking and delamination can occur during etching as well.
One proposed solution to the problem is the use of dual target sputtering in silicide formation, where both the silicide and the silicon targets are subjected to the same sputtering conditions. Such a system is shown, for example, in U.S. Pat. No. 4,443,930 to Hwang et al. While this system is effective in reducing tensile stress during formation of silicide, cracking and delamination can nevertheless occur in later fabrication processes. The solution proposed by the method of this invention addresses this latter problem, and relates to ion implantation of the silicide layer as a stress reduction technique.
Ion implantation offers a number of advantages as a method of introducing impurities into a host material. Among these advantages are: (1) precise control over the number of impurities implanted; (2) low temperature operation; (3) complete introduction of impurities below the host surface; and (4) control over the depth of implantation. The use of ion implantation as a method of doping silicon during device fabrication is well known. U.S. Pat. No. 4,373,251 to Wilting, for example, shows a polycide structure having a polysilicon layer doped by means of ion implantation. U.S. Pat. No. 4,450,620 to Fuls et al. similarly shows the use of ion implantation to dope the polysilicon layer of a polycide structure. The use of ion implantation to dope silicide and thereby reduce tensile stress and corresponding cracking and delamination problems is, however, novel.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide a method of reducing tensile stress during integrated circuit fabrication.
It is another object of the invention to provide a method of improving film adhesion during the fabrication of thin film integrated circuit structures.
It is still another object of the invention to provide a method of reducing tensile stress and thereby improving film adhesion in thin film integrated circuit structures having a silicide layer.
It is a further object of the invention to reduce tensile stress and thus improve film adhesion in a thin film integrated circuit structure having a silicide layer by implanting selected ions of predetermined energy and at a predetermined dose into the silicide layer of such a structure, such that the likelihood of cracking and delamination during fabrication processes is substantially reduced.
Additional objects, advantages and novel features of the invention will be set forth in part in the description which follows, and in part will become apparent to those skilled in the art on examination of the following.
To achieve the foregoing and other objects, and in accordance with the purpose of the present invention, the method comprises depositing a metallic silicide on a substrate and then implanting the silicide layer with selected ions at a predetermined energy and at a predetermined dose. In one aspect of the invention, a refractory metal silicide is deposited on a substrate having a polysilicon surface layer and then implanted with either phosphorus, arsenic or boron at energies ranging from 0 to 300 keV and at a dose of from about 10 15 to about 10 17 cm -2 . The silicide is preferably a silicon-rich silicide of the formula MSi x , where M is a refractory metal such as tungsten, titanium, tantalum or molybdenum, and x is greater than 2.
In a further aspect of the present invention, the silicide layer is implanted with selected ions such as phosphorus, arsenic or boron at energies ranging from 40 to 150 keV and at a dose of from about 5×10 15 to about 3×10 16 cm -2 . The method of this invention as described herein substantially reduces the tensile stress and corresponding cracking and delamination problems normally associated with heat treatment and other fabrication processes.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional representation of a semiconductor element partially formed;
FIG. 2 shows the same element of FIG. 1 after further processing;
FIG. 3 shows the semiconductor element of FIGS. 1 and 2 after yet further processing steps have been performed; and
FIG. 4 is a schematic representation of a common ion implantation apparatus.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIGS. 1 and 2, a known technique for forming polycide conductors is described. The example given is the formation of a metal-oxide-silicon (MOS) field effect transistor (FET). A silicon semiconductor substrate 11 initially has thick field oxide (FOX) thermally grown in all areas other than where active devices are to be formed. This field oxide is usually grown after those same areas are doped to isolate the active devices from one another. The ionization may be done by implanting boron ions in such regions. The top surface of the wafer 11 is initially flat but growth of the field oxide layers 13 consumes a layer of silicon at the top surface, thus forming the depressed regions shown in FIG. 1.
The next step in standard integrated circuit formation techniques is to grow a thin layer 15 of very high quality silicon dioxide over the wafer surface. This oxide layer will serve as the gate oxide of the active devices.
Next, a layer 17 of polysilicon is formed by standard techniques over the entire surface of the wafer. Next, a layer 19 of a refractory metal silicide is formed in a known manner, preferbly by sputtering. The silicide layer 19 may be any one of a number of specific compounds satisfying the formula MSi x , where x ranges from about 2.2 to about 2.6, and M is a metal selected from the group consisting of tantalum, tungsten, titanium, molybdenum and mixtures thereof. The wafer is then annealed at a temperature greater than about 800 degrees Centigrade for at least 5 minutes. Preferred temperatures range from about 900 degrees to 950 degrees Centigrade, and preferred times from about 10 to 30 minutes.
After the silicide layer 19 is deposited, selected ions of predetermined energy are implanted into the layer at a predetermined dose. It is this implantation step which is the subject of the improved technique of the present invention. FIG. 4 shows a commonly known commercial ion implantation system. Gas source 29 houses an appropriate gas 31 maintained at an accelerating potential V. A boron-containing gas such as BF 3 is used in boron implantation, and, correspondingly, an arsenic-containing compound such as AsH 3 is used in the implantation of arsenic. Gas 31 is introduced into ion source 37 by means of adjustable valve 33. Ion source 37 thus contains an ionic plasma of the selected species, at pressures of approximately 10 -3 torr, and is energized by ion source power supply 35 which maintains the source at a high potential. Source diffusion pump 39 establishes lower pressures for transport of the ion beam 43 through column 41. Focussing magnet 45 selects the ionic species of interest which beam then passes through resolving slit 49 and into accelerator tube 51.
Ion beam 43 is then scanned and directed by vertically positioned deflection plates 53 and by horizontally positioned deflection plates 55 such that a uniform implantation is achieved. Beam-line and end-station diffusion pumps 57 and 59 maintain a low pressure so that charge-exchange effects are avoided. Faraday cage 63 houses wafer target 65, into which ion beam 43 is finally directed. A target feeder 67 to replace implanted targets is optional.
Preferred ionic species for implantation include phosphorus, arsenic and boron at energies ranging from about 1 to 300 keV and more preferably from about 40 to 150 keV. Preferred doses range from about 10 15 to 10 17 cm -2 , and especially preferred doses range from about 5×10 15 to 3×10 16 cm -2 .
After implantation of silicide layer 19, that layer and the polysilicon 17 are removed from all areas of the wafer where conductors or gates are not to be permanently formed. The layers 17 and 19 are removed in unwanted areas by the use of standard photoresist masking and etching techniques. As shown in FIG. 2, this leaves a polycide gate structure formed of the layer 17' of polysilicon and layer 19' of selected metal silicide. The total thickness is preferably approximately 4500 angstroms with the polysilicon layer 17' being approximately 2000 angstroms of that total thickness. This provides enough polysilicon for the necessary gate function and enough silicide for the necessary low resistivity conductivity for connecting that gate with other areas of the integrated circuit chip being formed.
Source and drain regions 21 and 23 (FIG. 2) are usually formed at this point by an ion implantation technique similar to that described above. In the example being described, an NMOS process, N+ regions are formed as shown.
After the intermediate structure of FIG. 2 is formed, it is desired to cover the entire wafer with an insulating layer, usually silicon dioxide. This is to provide protection to the device as formed in a silicon wafer substrate 11, and also to allow conductors to be formed over this insulating layer without substantially interfering electrically with the devices formed in the substrate below. Accordingly, as shown in FIG. 3, layers 25 and 27 of silicon dioxide are formed. The layer 25 is thin, usually around 1000 angstroms, and is of very high quality. The thicker layer 27 is most conveniently formed by standard chemical vapor deposition (CVD) techniques. But since the quality of the CVD-deposited dioxide is not good enough, the initial layer 25 is formed. The wafer is then annealed at a temperature greater than about 800 degrees Centigrade for at least 5 minutes. Preferred temperatures range from about 900 degrees to 950 degrees Centigrade, and preferred times from about 10 to 30 minutes.
For most of the wafer surface, the layer 25 is easily formed on top of previously formed gate oxide layer 15 but the oxide layer 25 also needs to be grown over the metal silicide layer 19' that is part of the gate electrode. The layer 25 is formed by oxidation at temperatures of at least 800 degrees Centigrade, and preferably at temperatures between about 900 and 950 degrees Centigrade.
The following examples illustrate certain embodiments of the present invention, and are not intended to limit the scope of the invention as defined in the appended claims.
EXAMPLE 1
Stress measurements were made on ion-implanted polycide wafers as follows. Silicon-rich tungsten disilicide (WSi x , where x was about 2.3) was first sputter-deposited on substrates having a polysilicon surface layer, using a conventional dual-target sputtering-gun deposition system. Silicon was deposited at 1200 W, while tungsten was deposited at 300 W, over a period of about 26 minutes. The silicide layers were then implanted with either phosphorus or arsenic, using a Varian-Extrion DF-3000 ion implant system. Several different doses and energies were tested. After implantation, wafers were annealed at 950 degrees Centigrade in a dry nitrogen atmosphere for approximately 30 minutes. Results of stress measurements made after silicide deposition, implantation and annealing may be seen in Tables 1 and 2.
As illustrated by Tables 1 and 2, ion implantation of silicide films can substantially reduce the tensile stress normally encountered both during formation and after annealing.
TABLE 1__________________________________________________________________________PHOSPHORUS IMPLANTATION Film Stress, dynes/cm.sup.2 * After SilicideEnergy, keV Dose, cm.sup.-2 Deposition After Implantation After Anneal__________________________________________________________________________ 80 0 0.05 × 10.sup.10 0.50 × 10.sup.10 0.95 × 10.sup.10 5 × 10.sup.15 0.02 × 10.sup.10 -0.95 × 10.sup.10 -0.90 × 10.sup.10 1 × 10.sup.16 0.15 × 10.sup.10 -0.55 × 10.sup.10 -0.92 × 10.sup.10 3 × 10.sup.16 -0.33 × 10.sup.10 -0.85 × 10.sup.10 -1.05 × 10.sup.10100 0 0.03 × 10.sup.10 0.50 × 10.sup.10 0.93 × 10.sup.10 5 × 10.sup.15 -0.15 × 10.sup.10 -0.65 × 10.sup.10 -0.70 × 10.sup.10 1 × 10.sup.16 0.10 × 10.sup.10 -0.35 × 10.sup.10 -0.72 × 10.sup.10 3 × 10.sup.16 0.15 × 10.sup.10 0.13 × 10.sup.10 -0.60 × 10.sup.10130 0 0.03 × 10.sup.10 0.47 × 10.sup.10 0.94 × 10.sup.10 5 × 10.sup.15 0.10 × 10.sup.10 -0.80 × 10.sup.10 -0.95 × 10.sup.10 1 × 10.sup.16 0.15 × 10.sup.10 -0.70 × 10.sup.10 -0.65 × 10.sup.10 3 × 10.sup.16 0.07 × 10.sup.10 -0.10 × 10.sup.10 -0.55 × 10.sup.10__________________________________________________________________________ *+ = tensile stress - = compressive stress
TABLE 2__________________________________________________________________________ARSENIC IMPLANTATION Film Stress, dynes/cm.sup.2 After SilicideEnergy, keV Dose, cm.sup.-2 Deposition After Implantation After Anneal__________________________________________________________________________ 80 0 0.02 × 10.sup.10 0.47 × 10.sup.10 0.95 × 10.sup.10 5 × 10.sup.15 0.17 × 10.sup.10 -0.43 × 10.sup.10 -0.77 × 10.sup.10 1 × 10.sup.16 0.08 × 10.sup.10 -0.10 × 10.sup.10 -1.05 × 10.sup.10 3 × 10.sup.16 -0.15 × 10.sup.10 -2.10 × 10.sup.10 -2.50 × 10.sup.10100 0 0.04 × 10.sup.10 0.50 × 10.sup.10 0.95 × 10.sup.10 5 × 10.sup.15 0 -0.24 × 10.sup.10 -0.65 × 10.sup.10 1 × 10.sup.16 0 -0.55 × 10.sup.10 -1.00 × 10.sup.10 3 × 10.sup.16 0.15 × 10.sup.10 0.60 × 10.sup.10 -0.70 × 10.sup.10130 0 0 0.48 × 10.sup.10 0.95 × 10.sup.10 5 × 10.sup.15 0 -0.38 × 10.sup.10 -0.58 × 10.sup.10 1 × 10.sup.16 0 -0.65 × 10.sup.10 -0.93 × 10.sup.10 3 × 10.sup.16 0 -1.70 × 10.sup.10 -2.65 × 10.sup.10__________________________________________________________________________ | A method of improving film adhesion during the fabrication of thin film integrated circuits is disclosed. The method includes the steps of depositing a metallic silicide on a substrate and then implanting selected ions at predetermined doses and energies into the silicide layer, whereby tensile stress generated during fabrication processes is reduced. In one embodiment of the invention, the substrate is provided with a polycrystalline silicon layer and the silicide is of the structure MSi x , where M is a refractory metal and x is greater than 2. Preferred doses range from 10 15 to 10 17 cm -2 , while preferred energies range from 40 to 150 keV. | 7 |
TECHNICAL FIELD
The subject invention relates to the analysis of data obtained during the measurement of periodic structures on semiconductors. In particular, an approach is disclosed which allows accurate, real time analysis of such structures.
BACKGROUND OF THE INVENTION
The semiconductor industry is continually reducing the size of features on wafers. These features include raised profiles and trenches that have a particular height (or depth), width and shape (contour). Accurate measurement of these features is necessary to insure appropriate yields.
Technologies suitable for measuring these small periodic features (critical dimensions) are quite limited. Optical measurement technology is the most desirable since it is a non-contact technique. However, the smallest spot size of conventional optical probe beams is larger than the size of the periodic features which need to be measured.
FIG. 1 illustrates a substrate 8 having basic periodic pattern 10 formed thereon. The pattern will have a certain characteristic height (H), separation (S) and width (W). Note that in this illustration, the side walls of the structure are not vertical, so the width varies over the height of the structure. FIG. 1 also schematically indicates a probe beam spot 12 which is larger than the spacing between the individual features.
The difficulty in directly measuring such small structures has lead to the development of scatterometry techniques. These techniques have in common the fact that light reflected from the periodic structure is scattered and can be treated mathematically as light scattered from a grating. A significant effort has been made to develop metrology devices that measure and analyze light scattered from a sample in order to evaluate the periodic structure.
For example, U.S. Pat. No. 5,607,800 discloses the concept of measuring reflected (scattered) light created when a broad band probe beam interacts with a sample. The reflected light intensity as a function of wavelength is recorded for a number of reference samples having known periodic features. A test sample is then measured in a similar manner and the output is compared to the output obtained from the reference samples. The reference sample which had the closest match in optical response to the test sample would be assumed to have a periodic structure similar to the test sample.
A related approach is disclosed in U.S. Pat. No. 5,739,909. In this system, measurements from a spectroscopic ellipsometer are used to characterize periodic structures. In this approach, the change in polarization state as a function of wavelength is recorded to derive information about the periodic structure.
Additional background is disclosed in U.S. Pat. No. 5,987,276. This patent describes some early efforts which included measuring the change in intensity of a probe beam as a function of angle of incidence. Measurements at multiple angles of incidence provide a plurality of separate data points. Multiple data points are necessary to evaluate a periodic structure using a fitting algorithm. In the past, systems which took measurements at multiple angles of incidence required moving the sample or optics to vary the angle of incidence of the probe beam. More recently, the assignee herein developed an approach for obtaining scatterometry measurements at multiple angles of incidence without moving the sample or the optics. This approach is described in U.S. Pat. No. 6,429,943, issued Aug. 6, 2002.
U.S. Pat. No. 5,867,276, like the other prior art discussed above, addresses the need to obtain multiple data points by taking measurements at multiple wavelengths. This patent is also of interest with respect to its discussion of analytical approaches to determining characteristics of the periodic structure based on the multiple wavelength measurements. In general, these approaches start with a theoretical model of a periodic structure having certain attributes, including width, height and profile. Using Maxwell's equations, the response which a theoretical structure would exhibit to incident broadband light is calculated. A rigorous coupled wave theory can be used for this analysis. The results of this calculation are then compared to the measured data (actually, the normalized data). To the extent the results do not match, the theoretical model is modified and the theoretical data is calculated once again and compared to the measured data. This process is repeated iteratively until the correspondence between the calculated data and the measured data reaches an acceptable level of fitness. At this point, the characteristics of the theoretical model and the actual sample should be very similar.
The calculations discussed above are relatively complex even for the most simple models. As the models become more complex (particularly as the profiles of the walls of the features become more complex) the calculations become exceedingly long and complex. Even with today's high speed processors, the art has not developed a suitable approach for analyzing more complex structures to a highly detailed level on a real time basis. Analysis on a real time basis is very desirable so that manufacturers can immediately determine when a process is not operating correctly. The need is becoming more acute as the industry moves towards integrated metrology solutions wherein the metrology hardware is integrated directly with the process hardware.
One approach which allows a manufacturer to characterize features in real time is to create “libraries” of intensity versus wavelength plots associated with a large number of theoretical structures. This type of approach is discussed in PCT application WO 99/45340, published Sep. 10, 1999 as well as the references cited therein. In this approach, a number of possible theoretical models are created in advance of the measurement by varying the characteristics of the periodic structure. The expected optical response is calculated for each of these different structures and stored in a memory to define a library of solutions. When the test data is obtained, it is compared to the library of stored solutions to determine the best fit.
While the use of libraries does permit a relatively quick analysis to be made after the sample has been measured, it is not entirely satisfactory for a number of reasons. For example, each time a new recipe is used (which can result from any change in structure, materials or process parameters), an entirely new library must be created. Further, each library generated is unique to the metrology tool used to make the measurements. If the metrology tool is altered in any way (i.e. by replacing an optical element that alters the measurement properties of the tool), a new library must be created. In addition, the accuracy of the results is limited by the number of models stored in the library. The more models that are stored, the more accurate the result, however, the longer it will take to create the library and the longer it will take to make the comparison. The most ideal solution would be to develop a system which permitted iterative (fitting) calculations to be performed in real time and which is easily modified to account for changes in the metrology tool and the process begin monitored.
One approach to speeding up the fitting calculation can be found in U.S. Pat. No. 5,963,329. (The latter patent and the other publications cited above are all incorporated herein by reference.) This patent discloses a method of reducing the number of parameters needed to characterize the shape or profile of the periodic structure. In this approach, the structure is mathematically represented as a series of stacked slabs. The authors suggest that the structure must be divided into about 20 slabs to permit proper characterization of the structure. However, the authors note that performing an analysis with 40 variables (the width and height of 20 slabs) would be too computationally complex. Accordingly, the authors suggest reducing the complexity of the calculation by using sub-profiles and scaling factors. While such an approach achieves the goal of reducing computational complexity, it does so at the expense of limiting the accuracy of the analysis. Accordingly, it would be desirable to come up with an approach that was both highly accurate and could be performed on a real time basis.
SUMMARY OF THE INVENTION
To address this need, a system has been developed which permits the accurate evaluation of the characteristics of a periodic structure on a real time basis. In a first aspect of the subject invention, an improved analytical approach has been developed for increasing the efficiency of the calculations while maintaining a high degree of accuracy. In this aspect of the invention, a theoretical model of the structure is created. This initial model preferably has a single height and width defining a rectangular shape. Using Maxwell's equations, the model's response to the interaction with the probing radiation is calculated. The calculated response is compared with the measured result. Based on the comparison, the model parameters are iteratively modified to generate a rectangle which would produce calculated data which most closely matches to the measured data.
Using this information, a new model is created with more than one width and more than one layer. Preferably, a trapezoid is created with three layers. The model parameters are then adjusted using a fitting algorithm to find the trapezoidal shape which would produce the theoretical data most closest to the measured data.
Using the results of this fitting process, the model is again changed, increasing the number of widths and layers. The fitting processes is repeated. The steps of adding widths and layers and fitting the model to the data are repeated until the level of fitness of the model reaches a predetermined level.
During these iterative steps, the thickness of the layers (density of the layers) are permitted to vary in a manner so that a higher density of layers will be placed in regions where the change in width is the greatest. In this way, the curvature of the side walls can be most accurately modeled.
In this approach, the number of widths and layers is not fixed. It might be possible to fully characterize a structure with only a few widths and layers. In practice, this method has been used to characterize relatively complex structures with an average 7 to 9 widths and 13 to 17 layers.
The scatterometry calculations associated with the early iterations of the models (square, trapezoid) are relatively simple and fast. However, as the number of widths and layers increase, the calculations become exponentially more difficult.
In order to be able to complete these calculations on a reasonable time scale, it was also necessary to develop a computing approach which minimized computational time. In another aspect of the subject invention, the scatterometry calculations are distributed among La group of parallel processors. In the preferred embodiment, the processor configuration includes a master processor and a plurality of slave processors. The master processor handles the control and the comparison functions. The calculation of the response of the theoretical sample to the interaction with the optical probe radiation is distributed by the master processor to itself and the slave processors.
For example, where the data is taken as a function of wavelength, the calculations are distributed as a function of wavelength. Thus, a first slave processor will use Maxwell's equations to determine the expected intensity of light at selected ones of the measured wavelengths scattered from a given theoretical model. The other slave processors will carry out the same calculations at different wavelengths. Assuming there are five processors (one master and four slaves) and fifty wavelengths, each processor will perform ten such calculations to each iteration.
Once the calculations are complete, the master processor performs the best fit comparison between each of the calculated intensities and the measured normalized intensities. Based on this fit, the master processor will modify the parameters of the model as discussed above (changing the widths or layer thickness). The master processor will then distribute the calculations for the modified model to the slave processors. This sequence is repeated until a good fit is achieved.
This distributed processing approach can also be used with multiple angle of incidence information. In this situation, the calculations at each of the different angles of incidence can be distributed to the slave processor.
Further objects and advantages will become apparent with the following detailed description taken in conjunction with the drawings in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is schematic diagram of a periodic surface feature.
FIG. 2 is a block diagram of a system for performing the methods of the subject invention.
FIG. 3 is a simplified schematic of the processor used for performing the methods of the subject invention.
FIG. 4 is a flow chart illustrating the subject approach for analyzing optical data to evaluate characteristics of a periodic structure.
FIG. 5 is illustrates the shape of the model in a first step of the subject method.
FIG. 6 is illustrates the shape of the model in a subsequent step of the subject method.
FIG. 7 is illustrates the shape of the model in a subsequent step of the subject method.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 2 is a block diagram of a system 16 for performing scatterometry measurements on a sample 8 having a periodic structure. For the purposes of this disclosure, the periodic structure means any repeating feature, where the feature size is about the same or smaller than the beam of light probing the sample such that at least some of the light is scattered rather than specularly reflected.
The system 16 includes a light source 20 . As noted above, scatterometry measurements are often made using a broad band light source generating a probe beam 22 having a plurality of wavelengths. As described in U.S. Pat. No. 6,429,943, cited above, the light can also be from a laser. In such a case, measurements would be taken as a function of angle of incidence, preferably without moving the sample.
Probe beam is directed to the sample. Typically a lens (not shown) is used to focus the probe beam to a small spot on the sample. The reflected probe beam is captured and measured by detector 26 . The measured intensity of the probe beam will be effected by the amount of light scattered by the periodic structure. More specifically, the proportion of light diffracted into higher orders varies as a function of wavelength and angle of incidence such the amount of light redirected out of the path to the detector also varies thereby permitting the scattering effects to be observed.
The configuration of the detector will be based on the type of measurement being made. For example, a single photodetector can be used to measure spectroscopic reflected intensity as long as a tunable wavelength selective filter (monochrometer) is located in the path of the probe beam. Given the desire to minimize measurement time, a spectrometer is typically used which includes a wavelength dispersive element (grating or prism) and an array detector to measure multiple wavelengths simultaneously. An array detector can also be used to measure multiple angles of incidence simultaneously. If spectroscopic ellipsometry measurements are to be made, the detection system will include some combination of polarizers, analyzers and compensators.
The various measurement modalities discussed above are well known in the art and will not be discussed herein. It should be noted that commercial devices are available that can make multiple measurements. Examples of such devices are described in U.S. Pat. No. 5,608,526 and PCT Application WO 99/02970, both of which are incorporated herein by reference.
The signals generated by the detector are supplied to a processor 30 . The processor 30 need not be physically located near the detector. It is only required that the measurements from the detector be supplied to the processor. Preferably, there is an electrical connection between the detector and the processor, either directly or through a network. As is well known to those skilled in the art, the processor will also be supplied with other signals from the system 10 to permit normalization of the signals. For example, a detector (not shown) would be provided to measure the output power of the light source so that variations in the output power of the light source could be taken into account during the calculations.
In the preferred embodiment, and as shown in FIG. 3, the architecture of the processor 30 consists of a plurality of microprocessor units linked by an Ethernet connection. The operating software is arranged to set one of the processors as a master 32 and the remainder of the processors as slaves 34 . The master handles the higher level functions and distributes the tasks and retrieves the results from the slaves. Such a system is available commercially from Linux Networkx. Inc. under the trade name Evolcity. In the system used to evaluate the subject invention, an eight processor configuration was selected with each processor operating at 1.3 gigahertz. When properly combined, the system will operate at a speed equivalent to about 10 gigahertz. The approach for distributing the processing tasks will be discussed below.
As noted above, a wide variety of methods have been developed for evaluating characteristics of a periodic structure based on measured data. The approach described herein falls within the general class of procedures where an initial model is created and calculations are performed to determine the expected response of that sample to interaction with light. The model is then iteratively modified until the results of the calculation are close to the actual measured (and normalized) data. The subject approach can be contrasted with the earlier approaches which required the fabrication of many references samples, each of which would be measured, with the results stored for later comparison to the test sample. This subject approach is also different from the library approach where large numbers of configurations and their associated optical responses are created and stored for later comparison.
The subject approach recognizes that the shape of the structure can be represented as a plurality of stacked layers. However, rather than evaluate the sample based on a preordained, fixed number of layers, the algorithm is designed to progressively add layers, while seeking a best fit at each model level. This progression allows a theoretical structure which is relatively close the actual structure to be efficiently determined. In this approach, only the minimum number of layers which is actually necessary to achieve the desired level of fitness must be analyzed.
The subject method will be described with respect to the flow chart of FIG. 4 and the drawings of FIGS. 5 to 7 .
In the initial step 102 , a rectangular model 50 (FIG. 5) is created. Typically, the model is created using seed values based on the expected characteristics of the sample. For example, the model will include information such as the index of refraction and extinction coefficient of the material. It is possible that this information can be obtained by measuring a region of the wafer which is not patterned. The model will also have a value for the height H 1 and width W 1 .
The processor will then calculate the expected intensity that would be measured from a sample having a periodic structure with these initial characteristics (step 104 ). For the purposes of this example, it will be assumed that the measured data is obtained from a spectroscopic reflectometer. Accordingly, for each of the measured wavelengths, the processor will determine, using Maxwell's equations and a rigorous coupled wave theory, the expected normalized measured intensity of light reflected from the theoretical model. In a typical example, a measurement might include 50 to 100 wavelengths.
Once this calculation has been performed for each of the wavelengths, the results are compared to the normalized measurements obtained from the sample (step 106 ). This comparison can be done with a conventional least squares fitting algorithm, for example Levenberg-Marquardt. The result of this comparison, will be used to modify the parameters of the model, in this case the starting height and width (step 108 ). The processor then calculates the expected intensity of reflected light at each wavelength from a structure with the modified attributes (step 110 ). These new values are compared to measured values and, if necessary, the model is once again modified. In practice, the iterative process usually needs to be repeated some 4 to 8 times before a suitable fit is achieved. The operator can define the desired level of fitness, i.e. when the differences between the model and the actual measurements as represented by the result of the comparison drops below a predetermined value. The best fit result will be a rectangle which most closely approximates the actual periodic structure.
The next step is to modify the model by increasing its complexity (step 114 ). More specifically, the shape or grating profile is changed from a simple rectangle to a trapezoid (see 54 in FIG. 6) having a top width W 1 and an independent bottom width W 2 . In addition, the structure will be divided in a plurality of rectangular layers, in this case preferably three. Rather than using a polynomial expansion, the modification of this model is done using spline coefficients. The starting point for the modification is the best fit rectangle determined in the previous step.
The grating profile is defined using a class of spline algorithms including the well known cubic spline, Bezier-curves, B-spline and its more generalized form of non-uniform rational B-splines(The NURBS Book, by Les Piegl and Wayne Tiller, Springer, 1995). The benefits of such an approach are that 1) the curves are controlled by a set of control points and 2) the shape described by splines is more flexible than that described by polynomial expansions. A B-spline curve is described as
C ( u )=sum j N jp ( u ) P j
Where P j are the control points which can be scalars or vectors depending the desired flexibility. To minimize the number of fitting parameters for cubic splines, a user has the flexibility to choose different ways to allocate the spline points, in the vertical direction. Assuming that the grating height is scaled between 0 and 1 and assuming that the points t j are evenly distributed between 0 and 1, we then use a sigmoid function of the following form to transform t j to u j : as (David Elliot, J. Australian Math. Soc. B40(E), pE77-E137, 1998):
u=f n ( t )/( f n ( t )+f n (1− t )) f ( t )= t (1+ c (1− t )),
where c=2(n/l−1) and n>max(1,1/2).
The effect of this transformation is that the spline points are more densely allocated at the two ends when n≧1. This is very close to how the nodes are distributed in Gaussian integration. It also corresponds to the more common periodic profiles which have more curvature near the top and bottom of the structure.
Another aspect of our algorithm involves how the system is divided into slices or layers (discretized). The simplest approach is to divide the grating evenly in each material. However, similar to how spline points are allocated, we can also discretize the system similar to the Gaussian integration which is again similar to the Sigmoid function described earlier. Significantly, we also use the idea of adaptively discretizing the system according to the curvature of the curve. In this approach, we allow the assignment of layers to be actively varied, along with the other characteristics of the model, during the fitting process. In this process, we define d=∫du/|dw/du|, then each segment (between spline points) should have d/n slices, where w is the width as a function of height u, and n is the total number of slices in the model.
Once the starting parameters are defined, the processor will calculate the expected intensity for this new structure at each of the measured wavelengths (step 116 ). The results are compared to the measured values (step 118 ) and if the fit is not acceptable, the model is modified ( 120 ). In accordance with the subject method, the algorithm is free to modify the widths and layer thicknesses regardless of the values obtained in previous steps. The algorithm is also designed to adjust the layer thickness such that the greater number of layers will be used to define regions where the width is changing the fastest. This procedure is repeated until a trapezoid which most closely approximates the actual periodic structure is determined.
Once the best fit trapezoid is defined, the complexity of the model is again increased to include one or more widths and layers (Step 130 , and FIG. 7 ). In the preferred embodiment, the model is modified by adding a single extra width. The number of layers is also increased. Preferably, the number of layers at each iteration is at least 2Y−1(where Y is the number of widths) but no greater than 2Y+1.
The processor will then calculate the expected intensity for this new structure at each of the measured wavelengths (step 134 ). The results are compared to the measured values (step 136 ) and if the fit is not acceptable, the model is modified ( 140 ). This procedure will repeat in an iterative fashion until the model with the selected number of widths and layers best fits the data. If that structure meets the overall predetermined level of fitness, the process is complete and the model will suitably match the actual periodic structure (step 142 ). If not, the processor will loop back (along path 144 ) to create a new model with additional widths and layers (See 56 in FIG. 7 ). In a initial experiments, the average number of widths and layers needed to adequately characterize a structure was about 7 to 9 widths and 13 to 17 layers. With these additional widths and layers, structures with various wall profiles can be analyzed.
As noted above, one feature of the subject method is its ability to permit the thickness and density of the theoretical layers to vary during each iteration. It should be noted, however, that some periodic structures under investigation will include actual physical layers. If so, these physical layers can be used as boundaries to further define or constrain the model.
The calculations required to determine the response of a sample to incident radiation are complex. As the number of widths and layers increases, the time required to make the calculations increases dramatically. Accordingly, in a second aspect of the subject invention, the processing tasks are distributed to a parallel processor system.
In the preferred embodiment, one of the eight processors (FIG. 3) is configured as the master processor 32 and the remaining seven processor are slaves 34 . The master processor controls the overall analysis and distributes certain of the functions to the slave processors. As noted above, the most time consuming portion of the calculation is the determination of the optical response of the model to a each of the different measured wavelengths or angles of incidence. The comparison of these theoretical results with the measured signals and the modification of the model can, by comparison, be handled relatively quickly.
Therefore, in the preferred embodiment of the subject invention, the master processor is responsible for distributing the calculations of theoretical data to the slave processors (such calculations being shown as steps 104 , 110 , 116 and 134 in FIG. 4 ). In the preferred embodiment, the master processor would also participate in these calculations.
A maximum reduction in computational time can be achieved if the workload is evenly distributed. The preferred approach to achieve uniformity is to distribute the wavelength or angle of incidence information serially across the processors. Thus, the first slave processor (in an eight processor system) would be responsible for calculating the first (shortest) wavelength as well as the ninth, seventeenth, etc. (n+8). The second slave processor would be responsible for the second (next shortest) wavelength as well as the tenth, eighteenth, etc. This approach can be used for both spectrophotometry and spectroscopic ellipsometry. A similar approach can be used with multiple angle of incidence measurements wherein the first, eighth, seventeenth measured angle would be calculated by the first slave processor, etc.
Once each of the calculations are made at each of the wavelengths (or angles), the master processor will compare the results at each of the wavelengths to the normalized measurements at the corresponding wavelengths. The difference will define the level of fitness of the result and will be used to determine if another iteration is required. The calculations necessary for each iteration of the model are again distributed to the slave processors in the manner discussed above.
While the subject invention has been described with reference to a preferred embodiment, various changes and modifications could be made therein, by one skilled in the art, without varying from the scope and spirit of the subject invention as defined by the appended claims. For example, it should be apparent that the inventions described herein are not specifically dependent upon the particular scatterometry approach used to collect the data. Data can be obtained from spectroscopic reflectometers or spectroscopic ellipsometers. It should be noted that spectroscopic reflectometers can obtain data from probe beams directed either at normal incidence or off-axis to the sample. Similarly, spectroscopic ellipsometers can obtain data from probe beams directed either at normal incidence or off-axis to the sample . Data can also be obtained from multiple angle of incidence devices. As noted in U.S. Pat. No. 6,429,943, applicant has developed a variety of simultaneous multiple angle of incidence devices that would be suitable. Detailed descriptions of assignee's simultaneous multiple angle of incidence devices can be found in the following U.S. Pat. Nos. 4,999,014; 5,042,951; 5,181,080; 5,412,473 and 5,596,411, all incorporated herein by reference. It should also be understood, that data from two or more of the devices can be combined to reduce ambiguities in the analysis. Such additional data can be combined in the regression analysis discussed above.
See also, U.S. Pat. No. 5,889,593 incorporated by reference. In this patent, a proposal is made to include an optical imaging array for breaking up the coherent light bundles to create a larger spot to cover more of the periodic structure. | A system for characterizing periodic structures formed on a sample on a real time basis is disclosed. A multi-parameter measurement module generates output signals as a function of either wavelength or angle of incidence. The output signals are supplied to a parallel processor. The processor creates an initial theoretical model and then calculates the theoretical optical response of that sample. The calculated optical response is compared to measured values. Based on the comparison, the model configuration is modified to be closer to the actual measured structure. The processor recalculates the optical response of the modified model and compares the result to the measured data. This process is repeated in an iterative manner until a best fit is achieved. The steps of calculating the optical response of the model is distributed to the processors as a function of wavelength or angle of incidence so these calculations can be performed in parallel. | 6 |
FIELD OF THE INVENTION
[0001] The present invention is directed to an apparatus for entertainment and education and a method of use, and in particular, to an apparatus employing a number of interlocking pieces that allow for the construction of three dimensional shapes, and that include indicia with the pieces for educational purposes during construction of the shapes.
BACKGROUND ART
[0002] In the prior art, various games and apparatus have been proposed that utilize interlocking pieces. U.S. Pat. No. 5,251,900 to Gallant discloses a three-dimensional puzzle structure that employs pieces that are irregular and polygonal shaped, and pieces that are flat planar blocks. The pieces are interlocked with dovetail joints.
[0003] U.S. Pat. No. 2,150,707 to Anderson discloses building blocks and a building assembly, wherein the blocks are joined together using a tongue and groove construction. The tongue and groove construction allows for constructing assemblies, which are basically right angled.
[0004] U.S. Pat. No. 4,212,130 to Walker discloses a playhouse with elements based on two modular units. The playhouse is made up of panels and bendable strips are used to link the panels together.
[0005] U.S. Pat. No. 5,487,690 to Stoffle et al. discloses clamps for a free standing play structure. The clamps connect panels together in right angle, straight or angled configurations.
[0006] While the prior noted above suggests tongue and groove connection in various game and building apparatus, none of the prior art noted above allows for construction of shapes in a wide variety of configurations and ones that allow for creativity input by the builder. As such, a need exists to provide improved apparatus allowing for construction of three dimensional shapes using a number of modular pieces, and including modes of construction that couple shape making with educational/entertainment objectives such as image or text message creations or combinations thereof.
SUMMARY OF THE INVENTION
[0007] It is a first object of the present invention to provide an improved apparatus having both entertainment and education use.
[0008] Another object of the invention is an apparatus that allows for the creation of three-dimensional shapes.
[0009] Yet another object of the invention is a method of using the inventive apparatus wherein the pieces are manipulated to make various shapes for entertainment and/or education.
[0010] Other objects and advantages of the present invention will become apparent as a description thereof proceeds.
[0011] In satisfaction of the foregoing objects and advantages, the present invention provides an interlocking apparatus for education and entertainment comprising a plurality of building pieces and a plurality of connector pieces. Each building piece further comprises a building piece portion having a periphery, a first thickness, and opposing first and second faces. The periphery includes a first connector portion extending along at least a portion of the periphery, the first connector portion having a second thickness, and having one of a slot or a protrusion.
[0012] Each connector piece has at least a pair of second connector portions, each second connector portion being complementary to the first connector portion by having a slot if the first connector portion has a protrusion or a protrusion if the first connector portion has a slot, so that one building piece can be connected to another building piece using a connector piece. A set of the plurality of the connector pieces have second connector portions that are right angled with respect to each other and another set of the plurality have second connector portions that are obliquely angled with respect to each other, whereby a three dimensional figure can be built using the building pieces and connector elements.
[0013] In a preferred embodiment, the first connector portions have a slot and the second connector portions have a protrusion. The first connector portion can extend along the entire periphery of the building piece. Each building piece and each connector piece is preferably made of a rigid non-metallic material, such as a hard plastic.
[0014] The plurality of connector pieces can include a number of configurations such as connector pieces that are: right-angled with a pair of second connector portions; are t-shaped with three connector portions; have a pair of right-angled connector portions (cross-shaped); and have a pair of second connector portions that are right-angled and a third connector portion which is angled at about 45° from one of the right-angled connector portions.
[0015] The connector portions of the building pieces can be sized so that a recess is formed portion in one face of the building piece, and the other opposing face can be generally flat.
[0016] A portion of the building pieces can have indicia on at least one of the first and second faces, and the indicia can form one of an image or text message, or a combination thereof particularly when pieces are joined together.
[0017] The periphery of each building piece can made up of a plurality of edges, with at least two edges being right angled. Dimensions of the right angled edges of the plurality of connector pieces are in multiples of a base dimension so that either individual building pieces can be connected together or an individual building piece can connect to at least two building pieces.
[0018] Each connector piece can have a body portion with each second connector portion extending therefrom, the body portion including a lip on either side of the connector portion, the lip abutting a peripheral edge of a the first connector portion when the connector piece is adjacent a building piece. The body portion is sized with respect to the second connector portion so that a body portion surface is interposed between surfaces of adjacent building pieces to form a continuous generally flat surface between the adjacent building pieces.
[0019] The invention also entails a method of forming a game apparatus by providing the building pieces and connector pieces, selecting a number of game pieces and connector pieces, and connecting the game pieces together using the connector pieces to make a desired structure. The structure can be assembled using indicia on the building pieces to create text, images or combinations thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] Reference is now made to the drawings of the invention wherein:
[0021] [0021]FIG. 1 is a perspective view of a shape constructed using the building and connecter pieces of the invention;
[0022] [0022]FIGS. 2 a - e are end views of connecter pieces of the inventive apparatus;
[0023] [0023]FIG. 3 a is a cross sectional view along a long dimension of one type of a rectangular building piece;
[0024] [0024]FIG. 3 b is a cross sectional view along the short dimension of the building piece of FIG. 3 a;
[0025] [0025]FIGS. 4 a and 4 b are ninety degree opposed cross sectional views of an alternative square building piece and connector piece combination;
[0026] [0026]FIGS. 5 a - 5 c show other embodiments of connector pieces;
[0027] [0027]FIG. 6 shows a portion of a pair of building pieces interconnected by a connector piece;
[0028] [0028]FIG. 7 shows a pair of non-linear building pieces joined by a non-linear connector piece;
[0029] [0029]FIG. 8 shows a plurality of square building pieces with indicia thereon.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0030] The present invention provides significant advantages in the field of toys and games for both entertainment and education. With the inventive apparatus, three-dimensional shapes can be constructed with easy-to-use connector pieces and building pieces. In addition, the building pieces can be modified with indicia such as images and/or text, or combinations thereof to integrate the shape construction with an image and/or text construction as well.
[0031] [0031]FIG. 1 shows one embodiment of the invention in a partially-built shape. The apparatus of this figure is made up of a number of building pieces. The building pieces have a number of shape configurations to allow for flexibility and creativity when putting the pieces together. In FIG. 1, there are shown square pieces 3 , large rectangular pieces 5 , smaller rectangular pieces 7 , and triangular pieces 9 . In this embodiment, the pieces are modularly dimensioned based on a base dimension, such as one inch. Of course, other base dimensions can be used. With the base dimension, and each piece having a side with the base dimension or a multiple thereof, the pieces can be put together in a number of ways.
[0032] As can be seen from FIG. 1, the large rectangle has an edge 11 , which is four times the base dimension, i.e., edge 17 of piece 7 . This edge 11 can accommodate the edge 13 of the square piece 3 , which is two times the base dimension, and the edge 15 of the triangular piece 9 .
[0033] In FIG. 1, a three dimensional shape is portrayed by a right angle connection between the small rectangular shape 7 and the square piece 5 and the large rectangular piece 5 . The pieces in FIG. 1 are held together by a number of connector pieces as shown in FIGS. 2 a - 2 e , and 5 a - 5 c . The connector pieces are not shown in FIG. 1 for clarity.
[0034] The connector pieces come in a variety of configurations, both in terms of cross section and length. FIG. 2 a depicts a connector piece 31 having four right-angled connector portions 33 joined at a center 35 . This connector can link up to four building pieces together.
[0035] [0035]FIG. 2 b shows a right-angled connector piece 37 having a pair of connector portions 39 , thus allowing for connecting two building pieces together in a right angle.
[0036] [0036]FIG. 2 c depicts a connector piece 41 allowing for a non-right angle or oblique connection. In this piece, one connector portion 43 extends at an oblique angle, shown as 45° degrees, from another connector portion 45 . A third connector portion 47 is right angled with respect to the connector portion 45 . It should be understood that the connector piece 41 is exemplary and other configurations can be employed that combine one connector portion that is obliquely or non-right angled with respect to at least one other connector portion. For example, the embodiment of FIG. 2 c could have another portion extending 90° from the portion 43 so that two obliquely-angled connector portions exist, forming y-shaped connector portions. The FIG. 2 c connector piece allows connection of at least two pieces whereby the angle between them is oblique rather than right angled.
[0037] [0037]FIG. 2 d shows a t-shaped connector 51 having three connecting portions 52 , 53 , and 54 . The adjacent portions 52 and 53 , and 53 and 54 are at 90° angles, respectively. This connector allows a three piece connection as shown at 14 in FIG. 1.
[0038] [0038]FIG. 2 e shows another connector piece 61 that has connecting portions 62 and 63 . This piece link two pieces together as shown in FIG. 1, pieces 3 and 9 to piece 5 .
[0039] The connector pieces can have any length. For example, the length could be the base dimension, or a multiple thereof. Alternatively, the length could be less than the base dimension.
[0040] The length of each connection portion relates to the manner of connection to the building pieces. Referring to the cross sectional views of FIGS. 3 a - 5 b , the building pieces are made with slots to receive the connecting portions of the connector pieces. FIGS. 3 a and 3 b shows the small rectangular piece 7 . The piece 7 has a periphery 71 , a body portion 73 , and a surrounding connector portion 72 having connection legs 75 . The piece 71 has a generally flat surface 77 and a recessed opposing surface 79 . The recessed surface is formed by the body portion 73 having a thickness less than that of the connecting portion 72 . The junction 74 between leg 75 and 73 is sloped to give the smooth recessed look of the pieces as shown in FIG. 1.
[0041] The connection legs 75 form a slot 81 that is sized to receive the connecting portions of the connection pieces of FIGS. 2 a - 2 e . When the pieces are connected, the connecting portion of the connector pieces engages the slot of the connection portions of the building pieces.
[0042] [0042]FIG. 4 a shows one view of an alternative square piece 3 ′ and connector piece combination in cross section, with FIG. 4 b showing another view juxtaposed 90 degrees. While each view shows that the adjacent sides are generally equal, FIG. 4 b shows a protrusion 82 in place of the slot 81 for connection purposes. A connector piece 86 is also shown in FIG. 4 b which combines a connector portion 88 and a connector slot 90 .
[0043] As noted above, the building pieces can have a variety of shapes in triangular. The corners of the pieces can be rounded as well. For example, the triangular piece shown in FIG. 1 can have radiused corners e.g., {fraction (1/64)} inch, or the corners can terminate at a point.
[0044] In a preferred embodiment, the base dimension is approximately one inch, preferably 0.939″, and the multiple dimensions then increase in increments of one inch, e.g., 1.939″, two inches, 3.939″, four inches, etc. Of course, other base dimensions could be employed.
[0045] The connector pieces are sized in conjunction with the connection portions of the building pieces to assure the right fit when assembling the pieces. For example, the thickness of each of the connecting portions of the pieces of FIGS. 2 a - 2 e is approximately 0.063″ to mesh with the width of each slot 81 . Each connector piece portion also has a length sized to fit in the slot 81 . Referring to FIG. 2 b , if the distance “b” is 0.375 inches, and the thickness of the potion 39 is 0.063 inches, the length of the connecting piece available to fit with in the slot is 0.312 inches, dimension “c”. As noted above, the dimensions of the connector piece portions and the slots 81 can vary.
[0046] The connector pieces can also have various lengths. Examples of lengths for the connector pieces to mesh with the exemplified building pieces include a short piece, 1.3125 inches, a medium piece, 3.3125 inches, and a long piece, 7.3125. Preferred dimensions for the width of the connector pieces is an overall width of opposing connector portions of 0.688 inches, “a” in FIG. 2 e . A preferred dimension for angled connector portions is 0.375 inches, see “b” in FIG. 2.
[0047] [0047]FIGS. 5 a - 5 c show alternative connector pieces, wherein the connector piece has one or more portions designed to provide a mating surface between two building pieces. FIG. 5 a shows a connector 41 ′ with a body portion 91 . The connector portions 43 , 45 , and 47 extend from the body portion 91 . The portion 91 has mating surfaces 93 which fill a gap between two building pieces so that the adjacent building pieces form a continuous surface.
[0048] [0048]FIG. 5 b shows connector 37 ′ having a body portion 95 , and connector portions 49 . As with connector 41 ′, the portion 95 has surfaces 97 that help form a continuous surface when two pieces are connected using connector portions 39 . Likewise, FIG. 5 c shows the t-shaped connector 51 ′, with a body portion 99 and mating surface 101 to perform the same function as connector pieces 41 ′ and 37 ′. In each embodiment, a step is formed between the connector portion and the body portion, see 78 in FIG. 5 b . The step interfaces with the legs of the building pieces as described below.
[0049] The thickness of each of the connecting legs 75 of the building pieces is preferably sized in FIG. 6 to approximates the size of the step 78 so that the surface 97 mates with the surface 98 of the piece 3 . This mating provides a smooth or continuous surface at the junction between the connector piece 37 ′, and the building piece 3 . In a preferred embodiment, the thickness of connecting portions of the connecting pieces 75 is also about the thickness of the connector piece portions, thus forming a total thickness of about 0.188 inches for the peripheral ends of the building pieces. The connector pieces having the body portion also define a length of the connector piece portions for mating with the slot 81 of the building pieces. That is, a preferred dimension “d”, see FIG. 5 c is 0.4375 inches, with the dimension “e” being 0.688 inches.
[0050] In another embodiment, the building pieces can have irregular shapes and the connector pieces can be correspondingly sized and shaped to connect the irregular shapes. Referring to FIG. 7, non-linear edges 103 and 105 of a portion of irregular building pieces 107 and 109 are linked by a connecting piece 111 . Piece 111 is similar to piece 61 shown in FIG. 2 e for connecting two pieces in a planar fashion, but it has a portion similar to 99 in FIG. 5 c to provide a surface 106 between the two building pieces.
[0051] [0051]FIG. 8 shows the aspect of the invention wherein connecting building pieces creates a text message. Piece 113 , 115 , and 117 are linked to piece the sentence “SEE JANE RUN”. Instead of a sentence, an image or a word could also be created by linking the appropriate and indicia-containing pieces together, e.g., “tr” and part of an image of a tree on one piece and “ee” and the remaining image of the tree on the other piece. When connecting these two pieces, the word “tree” is spelled Such can also be done by linking two or more than three pieces together. Other images, text, or combinations can be used as would be within the skill of the art. The indicia on the building pieces can be formed integrally therein, applied with stickers, paint, printing, or the like.
[0052] The building and connector pieces can be made of any durable material that will withstand numerous instances of handling and game play. Preferably, the pieces are made of a hard plastic. The building pieces can be made in a variety of colors to enhance play. The building and connector pieces when made of plastic can be made by any known means, including extrusions for the connectors, and molding processes for the building pieces. The connector pieces can be extruded with a hollow center portion or a solid core.
[0053] As such, an invention has been disclosed in terms of preferred embodiments thereof, which fulfills each and every one of the objects of the present invention as set forth above and provides new and improved apparatus for entertainment and educational use.
[0054] Of course, various changes, modifications and alterations from the teachings of the present invention may be contemplated by those skilled in the art without departing from the intended spirit and scope thereof. It is intended that the present invention only be limited by the terms of the appended claims. | A game apparatus of education and entertainment purposes comprises a number of building pieces and a number of connector pieces. The building pieces have peripheral edges that employ slots to receive complementary sized portions of the connector pieces. The connector pieces have a number of different configurations to permit creation of a variety of three dimensional shapes, including arranging building pieces at right angles, and oblique angles. The building pieces can have indicia thereon to create text, images, or combinations thereof when put together. The building pieces are modularly sized so that differently shaped and sized pieces can easily fit together. | 0 |
TECHNICAL FIELD
This invention relates to a cleaning apparatus for cleaning printing press plates.
BACKGROUND OF THE INVENTION
Applying images to substrates by utilizing pigment or dye based ink compositions is well known in the art. These images are generally applied for the purpose of making the article more aesthetically pleasing to the consumer.
One of the difficulties historically experienced with printed substrates that are printed with pigment based ink compositions is the tendency for the ink to rub-off of the surface of the paper upon exposure of the paper to liquids. This problem is even more pronounced for printed substrates printed with inks exhibiting relatively high color densities. This problem can be further compounded when printing on absorbent disposable paper products (nonlimiting examples of which include facial tissue, bath tissue, table napkins, wipes, diapers, woven disposable fabrics, nonwovens, wovens, cotton pads, and the like). Absorbent disposable paper products tend to produce more lint and associated contaminants than other grades of paper.
One way to control ink rub-off from the surface of the printed substrate is to utilize rub resistant inks. These inks tend to adhere much better to the surface of the substrate. However, one of the drawbacks associated with using rub resistant inks relates to printing press hygiene. Inks that adhere well to the substrate often exhibit similar properties when in contact with the printing press. In particular, the print plates tend to accumulate ink and paper fiber deposits that can eventually lead to print defects in the printed substrate. In order to prevent print defects more frequent cleaning of the printing press is necessitated. This can lead to reduced printing process efficiency. This is especially true in instances where printing press production has to be halted while the printing press is cleaned. Printing press cleaning devices are generally designed to be utilized either while the press is shut down or while the press is running (i.e.; on-line cleaning).
Prior art printing press plate cleaning devices have commonly utilized air, vacuum, cleaning fluids, brushes, and other mechanical devices either individually or in combination to remove contaminants from the print plate.
It has been found that the prior art printing press plate cleaning devices can cause print defects in the printed substrate. This problem is especially magnified when the cleaning device is used for on-line cleaning on a printing press utilizing segmented printing plates. As used herein, “segmented printing plates” refers to printing plates which are applied in separate sections across the width of the printing press. When printing with segmented printing plates, the clearance distance between the surface of the print plate and the bottom surface of the cleaning device generally needs to be higher than when printing with sleeved printing plates. While not wishing to be bound by theory, it is believed that because of the higher clearance distance requirement between the segmented print plate and the cleaning device it is more difficult to control the rebound angle of the spent cleaning fluid (i.e.; cleaning fluid plus any contaminants such as ink, fiber, etc. removed by the cleaning fluid) from the surface of the print plate to the cleaning device. Instead of rebounding back into the cleaning device, some of the spent cleaning fluid has a tendency to rebound onto the printed substrate. As a result, it is common to observe the formation of water streaks and drops on the printed substrate.
A further drawback of prior art printing plate cleaning devices relates to the entrapment of cleaning fluid into the cells comprising the individual print plate print elements as the fluid is being applied to the surface of the print plate. The cleaning device is unable to effectively remove the spent cleaning fluid that is trapped between individual print elements of the print plate resulting in the formation of streaks and spotting on the surface of the printed substrate.
Yet a further drawback of prior art cleaning devices appears to relate to the flow dynamics of these prior art devices. Prior art cleaning devices tend to have the propensity to form recirculation zones (i.e.; zones of eddy formation) within the collection areas of these devices. These zones can potentially interfere with the collection of the spent cleaning fluid thereby inhibiting the efficient removal of the spent fluid. The spent cleaning fluid is then free to fall back onto the surface of the print plate and/or the substrate after initially entering the cleaning apparatus. These recirculation zones can also cause the cleaning apparatus to plug.
The cleaning apparatus of the present invention addresses these drawbacks as it can be utilized at higher clearance distances without the formation of water streaks and drops on the printed substrate. Furthermore, the cleaning apparatus of the present invention penetrates the boundary layer of air associated with the surface to be cleaned resulting in efficient cleaning.
Yet further, the cleaning apparatus of the present invention is able to effectively remove spent cleaning fluid trapped between individual print elements of the print plate. Even yet further, the cleaning apparatus of the present invention minimizes recirculation zones within the device thereby providing more efficient collection of the spent cleaning fluid. In addition, the cleaning apparatus of the present invention tends to be self-cleaning. The benefits of the present invention include improved process efficiency and reliability.
SUMMARY OF THE INVENTION
The present invention relates to a cleaning apparatus. The cleaning apparatus comprises a plenum and a head connected to the plenum. The head includes: a nozzle, at least two banks of air jets wherein at least one bank of air jets is offset from a second bank of air jets and at least three vacuum ports. The nozzle may be positioned inside one of the vacuum ports. The head may also be positioned outboard of the vacuum ports. The local velocity within a substantial portion of the head and plenum is greater than the conveying velocity of the largest cleaning fluid droplet.
The cleaning apparatus may also include an aerodynamic surface. The aerodynamic surface may surround the interior surface of the cleaning apparatus. The aerodynamic surface may surround the interior of the head, the plenum, or a combination of both.
The cleaning apparatus includes at least one vacuum port and at least one bank of air jets. One or more of the vacuum ports may include a partition. The partition can separate the vacuum port from the bank of air jets. The partition can include a beveled edge. The beveled edge oriented in the upward direction of air flow. The beveled edge can comprise an angle of greater than about 0° but less than or equal to about 45°.
The cleaning apparatus can also optionally include an anti-plate stripping element.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of an embodiment of the cleaning apparatus of the present invention.
FIG. 2 is a perspective view of a second embodiment of the cleaning apparatus of the present invention.
FIG. 3 is a front view of the cleaning apparatus embodiment of FIG. 1 depicted as it would be used to clean the plate cylinder of a printing press.
FIG. 4 is a front view of the cleaning apparatus embodiment of FIG. 2 depicted as it would be used to clean the plate cylinder of a printing press.
FIG. 5 is a bottom view of the cleaning apparatus embodiment of FIG. 1 .
FIG. 6 is a bottom view of the cleaning apparatus embodiment of FIG. 2 .
FIG. 7 is a front view of the cleaning apparatus embodiment of FIG. 1 .
FIG. 8 is a cross-sectional view of FIG. 7 taken along lines 8 — 8 of FIG. 7 .
FIG. 9 is a cross-sectional view of FIG. 7 taken along lines 9 — 9 of FIG. 7 .
FIG. 10 is a top view of the cleaning apparatus embodiment of FIG. 1 .
FIG. 11 is a cross-sectional view of FIG. 10 taken along lines 11 — 11 of FIG. 10 .
FIG. 12 is a perspective view of a cleaning apparatus made according to the prior art.
FIG. 13 is a bottom view of the prior art cleaning apparatus of FIG. 12 .
DETAILED DESCRIPTION OF THE INVENTION
The apparatus of the present invention may be used in conjunction with any type of printing press print plate. Furthermore, the apparatus of the present invention may also be used in conjunction with other types of processes where it is desirable to clean the equipment either while the process is idle or while it is running. Non-limiting examples include rolls such as idler rolls, rolls with irregular surface topography, and rolls utilized in the papermaking and converting processes (i.e.; including but not limited to embossing, laminating, and the like).
With regard to printing images on textured substrates, the printing plate may produce a nonuniform print image due to irregularities on the surface of the substrate which remain unprinted. For example, papers that are embossed or have significant texture imparted by the drying fabric of the paper machine often create regions that cannot be adequately covered with ink. It is not unusual to observe ink, lint and other contaminants building up on printing plates when printing these types of papers. This is even more commonplace when the textured paper is an absorbent disposable paper product.
The apparatus of the present invention can be used in conjunction with any type of printing process. A non-limiting list of these printing processes include flexography, direct gravure, offset gravure, lithography, letterpress, and intaglio. Ink or fiber deposits on the printing apparatus can require manual intervention to remove. In particular, inks which include binders that are highly rub resistant tend to cause more print defects due to buildup on the printing plates. This becomes especially problematic when using a flexographic printing process. Significant manual intervention causes unacceptable costs to be associated with the process. Therefore, it is desirable to limit the amount of manual intervention needed to print reliably and consistently.
Cleaning Apparatus
While not wishing to be bound by theory, it is believed that the cleaning apparatus 90 of the present invention provides three basic functions: a cleaning medium, a drying medium, and a removal medium. The cleaning medium includes a means for applying a cleaning fluid to the surface that is to be cleaned. The drying medium includes a means for drying the surface that has been contacted by the cleaning fluid. The removal medium includes a means for removing the spent cleaning fluid along with the contaminants from the surface that has been cleaned. If desired, the cleaning apparatus 90 may be indexed across a surface.
Referring to FIGS. 1, 2 , and 5 - 7 , the cleaning apparatus 90 of the present invention is comprised of a plenum 100 connected to a head 200 . The head 200 includes a nozzle 400 , a plurality of air jets, and one or more vacuum ports 700 . Optionally, the cleaning apparatus 90 can include one or more aerodynamic surfaces 800 .
Nozzle
The main purpose of the nozzle 400 is to convey a cleaning fluid to a surface. It is generally preferred that the nozzle 400 utilized for this purpose allow for the penetration of the cleaning fluid through the air boundary layer surrounding the surface. The nozzle 400 is connected to an external cleaning fluid source (not shown). Any cleaning fluid can be used including but not limited to water, detergents, solvents, and the like. The nozzle 400 can be internally placed within the head 200 as shown in the embodiment depicted in FIGS. 1, 3 , and 5 . The nozzle 400 may also be external to the head 200 as shown in the embodiment depicted in FIGS. 2, 4 , and 6 . In addition, it is conceivable that the cleaning apparatus 90 of the present invention could include both an external nozzle and an internal nozzle (not shown). Furthermore, it is also conceivable that the cleaning apparatus 90 of the present invention could include multiple internal nozzles, multiple external nozzles, or combinations thereof (not shown).
Nozzles 400 which produce a flat spray pattern are generally preferred, though other types of spray patterns may also be used. Generally, the nozzle 400 should be capable of delivering the cleaning fluid at a pressure of at least about 40 psi (2.8 kg/cm 2 ) of cleaning fluid. It should be understood however, that this number can be higher or lower depending upon the specific application. The angular relationship between the nozzle 400 and the surface to be cleaned should be such that the impingement angle of the cleaning fluid from the cleaning apparatus 90 to the surface provides effective removal of contaminants and the rebound angle of the spent cleaning fluid from the cleaned surface to the cleaning apparatus 90 is directed toward the vacuum ports 700 .
With regard to the internal nozzle 400 shown in FIG. 1, if the nozzle 400 is used to clean a moving surface, the placement of the nozzle 400 may be located such that the cleaning fluid contacts the surface to be cleaned counter to the direction of movement of the surface. The angular relationship between the nozzle 400 and the surface to be cleaned as measured in the direction relative to the normal of the surface to be cleaned is generally from about −6° to about 12° wherein an angle of 0° is normal to the surface, and a positive angle denotes orientation with the direction of the moving surface to be cleaned. This is illustrated in FIG. 3 . Referring to FIG. 3, the cleaning apparatus 90 of the present invention is shown as used in operation for cleaning a plate cylinder of a printing press.
With regard to the external nozzle 400 shown in FIG. 2, if the nozzle 400 is used to clean a moving surface, the placement of the nozzle 400 may be located such that it the cleaning fluid contacts the surface to be cleaned in the same direction as the movement of the surface. The angular relationship between the nozzle 400 and the surface to be cleaned as measured in the direction relative to the normal of the surface to be cleaned is generally from about −25° to about −75°, preferably about −35° to about −55°, and most preferably about −40° to about −50°, wherein an angle of 0° is normal to the surface to be cleaned. This is illustrated in FIG. 4 . Referring to FIG. 4, the cleaning apparatus 90 of the present invention is shown as used in operation for cleaning a plate cylinder of a printing press.
A non-limiting example of a suitable nozzle 400 which may be used with the present invention is the VeeJet® Flat Spray Nozzle having an orifice diameter of 0.021 inches (0.533 mm), Part No. H1/8VV 150067, available from Spraying Systems Company of Wheaton, Ill.
Air Jets
While not wishing to be bound by theory, it is believed that the air jets assist with the disruption and penetration of the air boundary layer surrounding the surface to be cleaned. It is also believed that the air jets assist in placing contaminants in suspension with the cleaning fluid thereby facilitating their removal from the surface. Additionally, it is thought that the air jets facilitate the drying of the surface after the cleaning fluid has been applied to the surface.
The air jets, which are connected to an external air source (not shown), are comprised of a plurality of orifices as shown in FIGS. 5 and 6. Though one bank 310 of air jets 300 may be used, it is generally preferred to have at least two banks 310 of air jets 300 . There are a number of ways in which the air jets may be configured. A non-limiting example of one configuration is shown in FIGS. 5 and 6. Referring to FIGS. 5 and 6, the number of orifices in one air bank 310 contains one additional air jet 300 as compared to the other air bank 310 . With the exception of the center air jet 300 , the air jets 300 in the air bank 310 containing the additional air jet 300 are offset approximately ½ pitch from the corresponding air jets 300 in the other air bank 310 as shown in FIGS. 5 and 6. While not wishing to be limited by theory, it is believed that this staggered configuration between the banks 310 of air jets 300 provides improved coverage of the surface to be cleaned and also facilitates directing the removal of the spent cleaning fluid into the cleaning apparatus 90 .
With respect to their orientation within the cleaning apparatus 90 , the individual air jets 300 may be configured at an angle if desired. One non-limiting example of such a configuration is shown in FIGS. 7-11. Referring to FIG. 8, with the angle θ 1 relates to the angular relationship of the individual air jets 300 with plane D 320 . Though angle θ 1 can be any suitable angle obvious to one of skill in the art, a non-limiting suitable range for angle θ 1 is from about 0° to 60°. Referring to FIG. 9, angle θ 2 relates to the angular relationship of the individual air jets 300 with plane D 320 . Though angle θ 2 can be any suitable angle obvious to one of skill in the art, a non-limiting suitable range for angle θ 2 is from about 0° to 60°. Referring to FIG. 11, angle θ 3 relates to the angular relationship of the individual air jets 300 with plane B 330 . Though angle θ 3 can be any suitable angle obvious to one of skill in the art, a non-limiting suitable range for angle θ 3 is from about 0° to 60°.
A non-limiting example of suitable orifice diameters for an individual air jet 300 may range from about 0.020 inches (0.508 mm) to about 0.125 inches (3.175 mm) and preferably from about 0.045 inches (1.143 mm) to about 0.055 inches (1.397 mm) though smaller or larger orifice diameters may be used. Suitable air pressure to the air jets 300 is generally at least about 45 psi (3.2 kg/cm 2 ). However, it should be understood that more or less air may be needed depending upon the specific application.
Vacuum Ports
The main purpose of the vacuum ports 700 is to remove the spent cleaning fluid from a surface that has been cleaned. The vacuum ports 700 provide a conduit for the spent cleaning fluid to travel from the cleaned surface through the head 200 and plenum 100 to an external removal location.
Though a unitary vacuum port may be used, it is generally preferred to have at least two vacuum ports 700 and more preferably at least three vacuum ports 700 . The vacuum ports 700 may be in any form including but not limited to slots, slits, or any other form familiar to those of ordinary skill in the art. Referring to FIGS. 3, 5 - 7 , and 10 - 11 , an embodiment of the cleaning apparatus 90 of the present invention is shown having three vacuum ports 700 . The vacuum ports 700 may be placed in any configuration suitable for removing spent cleaning fluid from the cleaned surface. One suitable configuration is shown in FIG. 5 wherein two vacuum ports 700 are each placed adjacent to a bank 310 of air jets 300 . The third vacuum port is adjacent to one of these two vacuum ports 700 . The nozzle 400 is positioned inside the third vacuum port.
Another suitable configuration is shown in FIG. 6 wherein two vacuum ports 700 are each placed adjacent to a bank 310 of air jet 300 . The third vacuum port is adjacent to one these two vacuum ports 700 . The nozzle 400 is positioned outboard of the third vacuum port. Generally, a minimum vacuum flow is needed to prevent the spent cleaning fluid from dripping onto the cleaned surface. A non-limiting example of a suitable minimum vacuum flow for cleaning a print plate wherein the clearance between the bottom of the head 200 of the cleaning apparatus 90 and the top surface of the print plate is approximately 0.130 inches (3.3 mm) is generally at least about 70 SCFM (1.8 SCMM). This is based on the use of the aforementioned nozzle and a head 200 whose open face area is about 3.4 inches 2 (21.94 cm 2 ).
Plenum
The plenum 100 provides a vacuum conduit that facilitates the removal of the spent cleaning fluid from the surface that has been cleaned. Though the plenum 100 may be comprised of more than one chamber 110 , a single chamber 110 is generally preferred as shown in FIGS. 1-4, 7 , and 11 . While not wishing to be bound by theory, it is thought that a plenum 100 having a single chamber 110 helps reduce recirculation zones within the plenum 100 thereby improving the flow dynamics of the cleaning apparatus 90 as compared to a plenum 100 having two or more chambers 110 . The plenum 100 is connected to an external vacuum source (not shown).
Anti-Plate Stripping Element
The cleaning apparatus 90 of the present invention may optionally include an anti-plate stripping element 900 . A non-limiting instance where it may be desirable to utilize the anti-plate stripping element 900 is when utilizing the cleaning apparatus 90 to clean segmented print plates. Segmented print plates, familiar to those of ordinary skill in the art, are magnetically or otherwise attached to the print cylinder. The anti-plate stripping element 900 can be utilized to prevent the print plate from lifting off the print cylinder. The anti-plate stripping element 900 may be comprised of any material or shape so long as it is capable of creating a downward force to push a print plate back into place on the print cylinder. A suitable anti-plate stripping element 900 is shown in FIGS. 1, 3 , and 5 .
Flow Dynamics
It is desirable to minimize the formation of recirculation zones within the cleaning apparatus 90 . As described herein, recirculation zones refer to zones of eddy or whirlpool formation. While not wishing to be bound by theory, it is believed that these zones have a deleterious impact on the cleaning and removal process as there is a reduction in the upward velocity in these areas. This can result in the spent cleaning fluid dropping back onto the clean surface or the substrate. Additionally, it can result in the plugging of the cleaning apparatus 90 because it provides airborne contaminants the opportunity to stick to the wall of the apparatus thereby greatly reducing the process efficiency and quality of product. The minimization of eddy formation can actually facilitate the self-cleaning ability of the cleaning apparatus 90 . In order to prevent this from occurring, it is desirable that the in-plane velocity of the vacuum at any point should remain above the droplet conveying velocity. The conveying velocity may be calculated as follows. The required conveying velocity is equal to the terminal falling velocity of a droplet of cleaning fluid. This is found by the equation:
V 2 =2 W/p f AC D
where V=velocity, W=droplet weight, p f =density of the bulk fluid, A=droplet cross-sectional area and C D =friction coefficient of the falling droplet (i.e.; drag coefficient). C D can be found in fluid dynamic handbooks such as the “ Applied Fluid Dynamics Handbook ”, edited by Blevins, 1992 edition, pages 332 and 338. As used herein, “bulk fluid” refers to the fluid that is the predominant fluid within the cleaning apparatus 90 . The bulk fluid is typically air.
Therefore, for a spherical droplet the equation becomes: V 2 = 8 rgp d 3 p f C D
where g=gravitational acceleration, P d =droplet density, and r=droplet radius. Assuming that the cleaning fluid has a mean drop size of 450 μm, the conveying velocity of the droplet is 2.0 m/s. Hence based on cleaning fluids having a mean drop size of 450 μm it is desirable that the local velocity within a substantial portion of the head 200 and plenum 100 be greater than about 2.0 m/s. The current invention is able to achieve this with a much lower vacuum flowrate than the prior art. As used herein, “local velocity”, refers to the velocity at any specific point.
Aerodynamic Surface
One or more aerodynamic surfaces 800 may be used to minimize the formation of recirculation zones. The aerodynamic surface may be placed in any area within the plenum 100 or head 200 . The aerodynamic surface 800 may comprise any type of medium which facilitates prevention of eddy formation. For instance, one non-limiting example of a suitable aerodynamic surface is a beveled or tapered edge in the head 200 and/or the plenum 100 which is tapered in the direction of vacuum flow smoothly combining the flow streams. In addition this beveled edge could also be used between the various chambers 110 of the cleaning apparatus 90 . For instance, the beveled edge could be utilized on the interior walls of the partitions 340 which separate the vacuum ports 700 from the banks 310 of air jets 300 . A non-limiting example of a suitable aerodynamic surface is shown in FIGS. 6 and 10. Referring to FIGS. 6 and 10 a beveled or tapered edge may be used around the interior surface of the head 200 and/or plenum 100 . The beveled edge may comprise an angle less than or equal to about 45°, preferably an angle less than 40°, and most preferably an angle less than 15°.
EXAMPLES
Two cleaning apparatus 90 embodiments made according to the present invention were compared to a prior art cleaning device for the purpose of cleaning print plates on a printing press. One of the embodiments made according to the present invention is described as Embodiment 1 as shown in FIGS. 1, 3 , 5 , and 7 - 11 . The second embodiment made according to the present invention is described as Embodiment 2 as shown in FIGS. 2, 4 , and 6 . The prior art cleaning device, commercially available from the Fabio Perrini Company of Lucca, Italy, is shown in FIGS. 12 and 13. The parameters and comparison results are provided in Table 1, 2, and 3. For purposes of the comparisons, the particular cleaning apparatus being evaluated was positioned above a plate cylinder of the printing press.
The apparatus was mounted on a traversing mechanism such that it could freely traverse back and forth parallel to the axis of rotation of the plate cylinder in a manner similar to that shown in FIG. 3 (Embodiment 1) and FIG. 4 (Embodiment 2). The prior art device was similarly mounted on a traversing mechanism. During the comparison periods, the printing press was running at the speeds indicated in the tables below. Referring to FIG. 3, the angle of the nozzle 400 of Embodiment 1 with respect to the normal tangent of the plate cylinder was positive 12° wherein an angle of 0° was normal to the surface of the plate cylinder. The placement of the nozzle was such that the water contacting the surface of the plate cylinder was sprayed counter to the direction of rotation of the plate cylinder.
Referring to FIG. 4, the angle of the nozzle 400 of Embodiment 2 with respect to the normal tangent of the plate cylinder was −50°. The placement of the nozzle 400 of Embodiment 2 was such that the water contacting the surface of the plate cylinder was in the direction of the rotation of the plate cylinder.
Referring to FIGS. 3, 5 , 7 , 9 , and 11 with respect to the angular relationship of the air jets 300 , for both Embodiments 1 and 2, angle θ 1 was 15°, angle θ 2 was 12°, and angle θ 3 was 20.
Referring to column 1, line 2 of Tables 1, 2, and 3, the type plate cylinder utilized on the printing press is indicated. The plate cylinder was either sleeved or segmented as indicated. Referring to column 1, line 3 of Tables 1, 2, and 3, the plate cylinder diameter is indicated. Referring to column 1, line 4 of Tables 1, 2, and 3, the speed of the printing press during the comparison period is indicated. Referring to column 1, line 5 of Tables 1, 2, and 3, the gap distance refers to the clearance distance between the bottom of the cleaning apparatus head and the surface of the print plate. Referring to column 1, line 6 of Tables 1, 2, and 3, water was utilized as the cleaning fluid. The approximate water pressure at the nozzle is indicated. Referring to column 1, line 7 of Tables 1, 2, and 3, the approximate pressure at the air jets is indicated. Referring to column 1, line 8 of Tables 1, 2, and 3, the approximate vacuum through the cleaning apparatus was noted. Referring to column 1, line 9 of Tables 1, 2, and 3, a visual observation was made as to whether water was dripping back onto the plate cylinder from the cleaning apparatus.
The tests indicate that the cleaning apparatus embodiments of the present invention allow for lower vacuum flows without water dripping back onto the plate cylinder as compared to the prior art cleaning device.
TABLE 1
Prior Art
Prior Art
Prior Art
Prior Art
Type Plate Cyl-
Sleeved
Sleeved
Segmented
inder
Plate Cylinder
9.75 inches
9.75 inches
17.83 inches
Diameter
(24.77 cm)
(24.77 cm)
(45.28 cm)
Printer Speed
1600 fpm
1600 fpm
1100 fpm
(487.68 mpm)
(487.68 mpm)
(335.28 mpm)
Gap Distance
0.130 inches
0.130 inches
0.130 inches
(3.30 mm)
(3.30 mm)
(3.30 mm)
Approximate
500 psi
500 psi
500 psi
Nozzle
Water Pressure
(35.153 kg/cm 2 )
(35.153 kg/cm 2 )
(35.153 kg/cm 2 )
Approximate
65 psi
65 psi
65 psi
Air Jet
Pressure
(4.570 kg/cm 2 )
(4.570 kg/cm 2 )
(4.570 kg/cm 2 )
Approximate
203 SCFM
75 SCFM
>168 SCFM
Vacuum
(5.75 SCMM)
(2.12 SCFM)
(>5.03 SCMM)
Water Dripping
No
Yes
Yes
TABLE 2
Embodiment 1 of the Present Invention
Embodiment
Embodiment
Embodiment
Embodiment
Embodiment
1
1
1
1
1
Type Plate
Sleeved
Sleeved
Sleeved
Sleeved
Segmented
Cylinder
Plate
9.75 inches
9.75 inches
9.75 inches
9.75 inches
17.83 inches
Cylinder
(24.77 cm)
(24.77 cm)
(24.77 cm)
(24.77 cm)
(45.28 cm)
Diameter
Printer
1600 fpm
1600 fpm
1600 fpm
1600 fpm
1550 fpm
Speed
(487.68
(487.68
(487.68
(487.68
(472.44
mpm)
mpm)
mpm)
mpm)
mpm)
Gap Dis-
0.130 inches
0.130 inches
0.130 inches
0.130 inches
0.130 inches
tance
(3.30 mm)
(3.30 mm)
(3.30 mm)
(3.30 mm)
(3.30 mm)
Approximate
500 psi
500 psi
500 psi
500 psi
500 psi
Nozzle
(35.153
(35.153
(35.153
(35.153
(35.153
Water
kg/cm 2 )
kg/cm 2 )
kg/cm 2 )
kg/cm 2 )
kg/cm 2 )
Pressure
Approximate
45 psi
45 psi
45
45 psi
45 psi
Air Jet
(3.164
(3.164
(3.164
(3.164
(3.164
Pressure
kg/cm 2 )
kg/cm 2 )
kg/cm 2 )
kg/cm 2 )
kg/cm 2 )
Approximate
163.6 SCFM
114.7 SCFM
82.4 SCFM
57.7 SCFM
122.5 SCFM
Vacuum
(4.63
(3.25
(2.33
(1.63
(3.47
SCMM)
SCMM
SCMM)
SCMM)
SCCM)
Water
No
No
No
Yes
No
Dripping
*VeeJet ® Flat Spray Nozzle having an orifice diameter of 0.021 inches (0.533 mm), Part No. H1/8VV 150067, available from Spraying Systems Company of Wheaton, Illinois.
TABLE 3
Embodiment 2 of the Present Invention
Embodiment
Embodiment
Embodiment
Embodiment
Embodiment
2
2
2
2
2
Type Plate
Sleeved
Sleeved
Sleeved
Sleeved
Sleeved
Cylinder
Plate
9.75 inches
9.75 inches
9.75 inches
9.75 inches
9.75 inches
Cylinder
(24.77 cm)
(24.77 cm)
(24.77 cm)
(24.77 cm)
(24.77 cm)
Diameter
Printer
1600 fpm
1600 fpm
1600 fpm
1600 fpm
1600 fpm
Speed
(487.68
(487.68
(487.68
(487.68
(487/68
mpm)
mpm)
mpm)
mpm)
mpm)
Gap Dis-
0.130 inches
0.130 inches
0.130 inches
0.130 inches
0.130 inches
tance
(3.30 mm)
(3.30 mm)
(3.30 mm)
(3.30 mm)
(3.30 mm)
Approximate
500 psi
500 psi
500 psi
500 psi
500 psi
Nozzle
(35.153
(35.153
(35.153
(35.153
(35.153
Water
kg/cm 2 )
kg/cm 2 )
kg/cm 2 )
kg/cm 2 )
kg/cm 2 )
Pressure
Approximate
45 psi
45 psi
45 psi
45 psi
45 psi
Air Jet
(3.164
(3.164
(3.164
(3.164
(3.164
Pressure
kg/cm 2 )
kg/cm 2 )
kg/cm 2 )
kg/cm 2 )
kg/cm 2 )
Approximate
174.5 SCFM
108.9 SCFM
78.3 SCFM
66.2 SCFM
54.2 SCFM
Vacuum
(4.94
(3.08
(2.22
(1.87
(1.54
SCMM)
SCMM
SCMM)
SCMM)
SCMM)
Water
No
No
No
No
Yes
Dripping
*VeeJet ® Flat Spray Nozzle having an orifice diameter of 0.021 inches (0.533 mm), Part No. H1/8VV 150067, available from Spraying Systems Company of Wheaton, Illinois.
While particular embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this invention. | A cleaning apparatus for a printing press. The cleaning apparatus of the present invention allows for effective removal of contaminants from printing press print plates while the printing press is running. Furthermore, the cleaning apparatus of the present invention effectively applies and removes cleaning fluids such as water from the printing plate without resulting in the formation of water drops and streaks on the printed substrate. | 1 |
FIELD OF THE INVENTION
This invention relates to a novel polyalkenylphenol compound. The compound of this invention is applicable as an intermediate for epoxy resins useful for matrix resins of fiber-reinforced composite materials, heat-resistant adhesives, paints, and resist materials; a curing agent and a comonomer for maleimide resins.
BACKGROUND OF THE INVENTION
Known alkenylphenol compounds include alkenylphenols obtained from phenols and allyl chloride as disclosed in Organic Rca-Lion II, p. 27 (1949) and diallylbisphenols obtained from bisphenols as disclosed in U.S. Pat. No. 2,910,455. Also known are compositions comprising the alkenylphenols and a maleimide compound (see JP-B-55-39242, the term "JP-B" as used herein means an "examined Japanese patent publication"), compositions comprising the alkenylphenols, a maleimide compound, and an epoxy resin (see JP-A-53-134099, the term "JP-A" as used herein means an "unexamined published Japanese patent application"), and compositions comprising the alkenylphenols, a maleimide compound, and a hydrazide.
When these conventional alkenylphenols are used for crosslinking reaction, a high temperature and a long time are required for completion of the crosslinking reaction, and the resulting crosslinked product has insufficient heat resistance. It has therefore been demanded to develop a compound free from these disadvantages.
SUMMARY OF THE INVENTION
This invention provides a novel polyalkenylphenol compound represented by formula (I) shown below, which is useful as an intermediate for epoxy resins excellent in heat resistance and moldability, a curing agent, and a comonomer of maleimide resins. ##STR2## wherein R represents a hydrogen atom or a methyl group; X represents a hydrogen atom or a halogen atom; and n represents 0 or an integer of from 1 to 10. If there are two or more R or two or more X, R's or X's may be the same or different.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1 and 2 show IR and NMR spectra of the compound obtained in Example 1, respectively.
DETAILED DESCRIPTION OF THE INVENTION
The polyalkenylphenol represented by formula (I) can be prepared by alkenylation of a specific polyphenol (precursor).
The precursor can easily be obtained by heating a phenol compound and hydroxybenzaldehyde in the presence of an acid catalyst according to the process described in JP-A-57-34122. The phenol compound is usually used in excess, e.g., in an amount of from 2 to 20 moles per mole of hydroxybenzaldehyde. The larger the excess, the smaller the molecular weight of the resulting polyphenol. The reaction is usually carried out at a temperature ranging from 80 to 180° C. for a period of from 2 to 8 hours. The higher the temperature, the shorter the reaction time. The produced water may remain in the reaction system, but continuous removal of the produced water out of the system, for example, by azeotropic distillation or distillation under reduced pressure helps progress of the reaction After completion of the reaction, the catalyst is removed, for example, by filtration, neutralization or washing with water. The excess phenol is then recovered from the reaction mixture under reduced pressure to thereby collect the polyphenol. If desired, it is possible to reduce the phenol of free form by steam distillation.
The starting phenol compound includes phenol, cresol, and bromophenol. The hydroxybenzaldehyde includes salicylaldehyde, p-hydroxybenzaldehyde, and m-hydroxybenzaldehyde. The acid catalyst to be used includes mineral acids, e.g., hydrochloric acid and sulfuric acid, organic acids, e.g., oxalic acid and p-toluenesulfonic acid, and solid catalysts, e.g., activated clay, zeolite, and ionexchange resins.
Techniques of alkenylation of phenols have hitherto been known as described, e.g., in Organic Reaction II, pp. 1-29 (1944), and they can be applied to the preparation of the polyalkenylphenol compound of the present invention. In general, a phenol compound is dissolved in an organic solvent, e.g., n-propanol, ethanol, methanol, acetone, etc., and reacted with an equimolar amount of a base, e.g., sodium hydroxide, to form a phenolate, which is then reacted with an equimole of an allyl halide, e.g., allyl chloride and allyl bromide, to effect allyl etherification. The etherification reaction is usually carried out by stirring at a temperature of from 50° to 100° C. for a period of from 1 to 10 hours. The by-produced salt is preferably removed by filtration or washing with water. This reaction proceeds substantially quantitatively. The resulting allyl ether is then subjected to Claisen rearrangement by heating at a temperature of from 100° to 250° C. to obtain an alkenylphenol in a yield of from 80 to 100%. The Claisen rearrangement can be effected in the presence or absence of a high-boiling solvent, e.g., carbitol, 2-ethoxyethanol, N,N-diethylaniline, N,N-dimethylaniline, tetraline, kerosene, paraffine oil, etc. It is known to accelerate the rearrangement reaction by addition of an inorganic salt, e.g., sodium thiosulfate and sodium carbonate. The polyalkenylphenol compound of the present invention can be synthesized in accordance with the above-described known process.
The compound according to the present invention is useful as a curing agent for epoxy resins or maleimide resins or as a starting material for epoxy resins.
(i) Curing Agent for Epoxy Resins:
A composition of an epoxy resin, the polyalkenylphenol compound of the present invention, and a curing catalyst, e.g., triarylphosphine such as triphenylphosphine, heterocyclic bases such as imidazole and benzimidazole, etc., is heated to obtain a cured product excellent in heat resistance. The resulting cured product is useful as a base of a printed circuit board, an IC sealant, a conductive paste, a paint for a resistant element, and a solder resist because of its superiority in moisture resistance, adhesiveness, and heat resistance. Upon use, the composition is dissolved in a general industrial solvent, coated on or impregnated into a substrate, and dried, followed by post-curing; or the composition is melted under heating followed by casting, or blended with a filler, e.g., silica, molybdenum disulfide, carbon, glass fibers, etc., by means of a roll, a kneader, etc. to prepare a molding powder, followed by curing by heating under pressure
(ii) Curing Agent for Maleimide Resins:
A composition of a maleimide resin and the polyalkenylphenol compound of the present invention is heated to obtain a cured product excellent in heat resistance. If desired, the composition may further contain a reaction accelerator, e.g., primary, secondary or tertiary amine, quaternary ammonium compounds, heterocyclic bases, alkali metal compounds, organic peroxides, acetyl-acetonates of the transition metals, etc. The composition is excellent particularly in heat resistance and thermal expandability in low temperatures and is therefore useful as a matrix resin of carbon fiberreinforced plastic (CFRP), a base of a multilayer printed circuit board, an IC sealant, and a material for precise molding. Upon use, known molding techniques, such as autoclave molding, press molding, transfer molding, and injection molding, can be employed As a matter of course, carbon fibers, glass fibers, or other fillers (e.g., silica, carbon, fluorine resins, molybdenum disulfide, and graphite) can be used in combination.
As compared with a conventional o,o'-diallylbisphenol A, use of the polyalkenylphenol compound of the present invention as a curing agent of epoxy resins or maleimide resins results in a higher crosslinking density to thereby provide a cured product having a so much increased glass transition temperature (Tg). Accordingly, the cured product exhibits markedly improved mechanical strength in high temperatures and an improved coefficient of thermal expansion. Further, since Tg can be increased in a reduced time, reduction of a molding cycle is also expected.
The present invention is now illustrated in greater detail by way of the following Examples, but it should be understood that the present invention is not deemed to be limited thereto.
EXAMPLE 1
Synthesis of Polyphenol
In a 1 l-volume three-necked flask equipped with a thermometer, a stirrer, and a condenser were charged 470 g of phenol, 61 g of salicylaldehyde, and 0.1 g of sulfuric acid. The inner temperature was raised up to 110° C., and the reaction was continued for 4 hours. After completion of the reaction, the reaction mixture was diluted with 500 ml of methyl isobutyl ketone (MIBK) by the use of a separatory funnel and washed three times with 300 ml portions of distilled water to remove the catalyst. The residual solution was tranferred to a rotary evaporator, and MIBK and the excess phenol were removed under reduced pressure to obtain a reddish brown glassy polyphenol precursor having a melting point of 91° to 99° C.
Synthesis of Alkenylphenol
In a 1 l-volume four-necked flask equipped with a stirrer, a thermometer, a condenser, and a dropping funnel were charged 700 ml of n-propyl alcohol and 41.3 g of sodium hydroxide, and the mixture was stirred to uniformity. To the uniform mixture was added 100 g of the polyphenol precursor as prepared above, followed by stirring for 1 hour. To the reaction mixture was added dropwise 87.8 g of allyl chloride over 10 minutes, and the reaction mixture was heated to 100° C., followed by stirring for 3 hours to complete allyl etherification. The sodium chloride produced was removed by filtration, and n-propyl alcohol was recovered from the filtrate under reduced pressure. The resulting allyl ether was dissolved in 200 ml of carbitol and heated at an inner temperature of 190° to 200° C. for 6 hours to effect Claisen rearrangement The carbitol was completely removed by distillation in vacuo to obtain 141 g of a reddish brown semi-solid alkenylphenol. The IR spectrum of the product was measured by Nujol Mull method by means of JISCOA-3 infrared spectrophotometer. The NMR spectrum of the product was measuted using TMS as a standard substance in chloroform-d 3 solvent by means of JEOL JNM-PMX 60 SI NMR spectrometer. The IR and NMR spectrums are shown in FIGS. 1 and 2, respectively.
EXAMPLES 2 TO 7
Polyalkenylphenols shown in Table 1 were prepared from the corresponding starting materials in the same manner as in Example 1. The properties of the resulting compounds are also shown in Table 1.
TABLE 1__________________________________________________________________________ Alkenylphenol Compound Pre- Allyl cursor Chloride Yield Visco-ExamplePrecursor (part by weight) (part by (part by (part by sity*.sup.4 Avg. Mol.No. Phenol Aldehyde Catalyst weight) weight) weight) Property (poise) Wt.*.sup.5__________________________________________________________________________1 phenol (470) SA*.sup.1 (61) sulfuric acid 100 87.8 141 Semi- 25.6 413 (0.1) solid2 phenol (188) SA*.sup.1 (61) p-toluene- 100 87.8 144 m.p. = -- 541 sulfonic acid 53-63° C. (0.2)3 phenol (188) HBA*.sup.2 (61) ion-exchange 100 87.8 140 m.p. = -- 560 resin*.sup.3 (3.0) 38-43° C.4 phenol (470) SA (40) activated 100 87.8 141 semi- 30.5 420 HBA (21) clay*.sup.3 (12.0) solid5 cresol (540) SA (61) hydrochloric 100 68.3 136 semi- 32.3 429 acid (0.1) solid6 bromophenol SA (61) hydrochloric 100 50.7 131 m.p. = -- 673(519) acid (0.4) 75-81° C.7 cresol (235) SA (40) hydrochloric 100 87.8 140 m.p. = -- 503 HBA (21) acid (0.4) 47-54° C.__________________________________________________________________________ Note: *.sup.1 Salicylaldehyde *.sup.2 pHydroxybenzaldehyde *.sup.3 Reaction temperature: 150-160° C.; The produced water was removed as a toluene azeotrope. After the reaction, the catalyst was removed by filtration. *.sup.4 Measured with an E type viscometer at 80° C. *.sup.5 Measured by gel permeation chromatography (Shodex KF802 × 1 tetrahydrofuran, 1.0 ml/min).
While the invention has been described in detail and with reference to specific embodiments thereof, it will be apparent to one skilled in the art that various changes and modifications can be made therein without departing from the spirit and scope thereof. | A polyalkenylphenol compound represented by formula (I): ##STR1## wherein R represents a hydrogen atom or a methyl group; X represents a hydrogen atom or a halogen atom; and n represents 0 or an integer of from 1 to 10. The compound is useful as a curing agent for epoxy resins or maleimide resins or a starting material for epoxy resins. | 2 |
BACKGROUND OF THE INVENTION
This invention relates to a bearing structure for an intermediate transmission shaft of the type used in a vessel propulsion and more particularly to an improved arrangement for preloading the thrust bearing associated with a driven bevel gear so as to facilitate adjustment of the gear mesh.
In a variety of applications, a bevel gear train is employed for driving an intermediate shaft. Normally, the intermediate shaft and bevel gear are supported by a thrust bearing arrangement since the bevel gear drive itself creates a thrust on the gear in an axial direction. With such an arrangement, it is necessary to both preload the thrust bearing and to preload the gear so as to adjust its meshing relationship with the driving gear. Obviously, such arrangements require complicated constructions.
In one form of mounting heretofore proposed, it has been the practice to assemble the driven gear and its thrust bearing in a separate assembly which is provided with its own housing. This gear assembly is then mounted in the overall transmission casing. However, the bearing preload of this type of arrangement must be adjusted when the bearing and housing are assembled to the second gear and a threaded fastener such as a nut is normally used for this purpose. However, when mounting the assemblage, the gear position must be adjusted upon assembly using shims and another fastening nut. Therefore, such constructions are quite complicated.
It is, therefore, a principal object of this invention to provide an improved driving arrangement for driving a shaft including a bevel gear and thrust bearing.
It is a further object of this invention to provide an improved structure for assembling a driven gear and supporting thrust bearing within a housing.
One typical application in which bevel gear drives of the type described are employed is in the outboard drive unit of a marine watercraft. Such outboard drive units, and particularly the outboard drive portion of an inboard-outboard drive, employ a bevel gear arrangement for driving the drive shaft from the input shaft of the outboard drive unit. The input shaft is driven by an engine that is mounted internally of the hull of the associated watercraft. Recently, there has been a demand for the use of twin outboard drives wherein two such outboard drive units are mounted on a given hull. With such an arrangement, it is desirable to insure that the propellers associated with the outboard drives rotate in opposite directions so as to achieve balancing of the driving thrust, one of the principal reasons why such twin drives are employed. The construction can be simplified if the same general overall construction is used for each unit of the twin drive. This can be accomplished by employing an arrangement for reversing the direction of rotation of the drive shaft internally of the outboard drive. However, conventional outboard drives are designed so as to take thrust of the drive shaft in only one direction.
It is, therefore, a still further object of this invention to provide an improved driving arrangement for a marine outboard drive wherein reverse thrusts may be taken on the drive shaft through an improved thrust bearing and mounting relationship.
SUMMARY OF THE INVENTION
This invention is adapted to be embodied in a drive arrangement for driving a drive shaft that is supported for rotation within a housing assembly from an input shaft that is rotatable about an axis that is offset from the axis of the drive shaft. The arrangement comprises a driven gear that has a hub portion and which is designed to be coupled for rotation with the drive shaft. A thrust bearing is affixed to the hub portion and is axially preloaded thereon by first fastening means. A mounting plate is secured relative to at least one of the driven gear and thrust bearing and second fastening means are employed for fixing the driven gear, the thrust bearing and the mounting plate as a unit to the housing assembly.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevational view, with portions shown in section, of a marine outboard drive constructed in accordance with an embodiment of the invention and set up for rotation in a first direction.
FIG. 2 is an enlarged view showing a portion of the construction illustrated in FIG. 1 and set up for counterrotation.
FIG. 3 is an enlarged cross-sectional view taken along the line 3--3 of FIG. 2.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
A marine outboard drive constructed in accordance with an embodiment of the invention is identified generally by the reference numeral 11. In the illustrated embodiment, the outboard drive 11 is comprised of the outboard drive unit of an inboard-outboard drive. It is to be understood, however, that certain facets of the invention may be applied equally as well with outboard motors or in other applications in which power transfer is employed. The invention, however, has particular utility in connection with arrangements wherein it is desirable to have the outboard drive and specifically its propulsion unit rotate in either normal or counterrotation modes.
The outboard drive 11 is powered by a remotely positioned internal combustion engine (not shown) which drives an output shaft 12 that rotates in a constant direction, indicated generally by the arrow A and which is, in the illustrated construction, counterclockwise. The output shaft 12 is coupled by means of a universal joint 13 to an input shaft 14 of the outboard drive 11. The input shaft 14 has an extending portion 15 that is journaled within a drive shaft outer housing 16 of the outboard drive 11 by means of a pair of spaced apart thrust bearings 17 and 18, in a manner to be described.
A vertically extending drive shaft 19 is supported in the housing 16 by means of bearings to be described and depends into a lower unit 21. The drive shaft 19 is driven from the input shaft 15, in a manner to be described, so as to rotate either in a forward direction indicated by the arrow B in FIG. 1 or a reverse or counterdirection indicated by the arrow C in FIG. 2.
The drive shaft 19 is journaled by means of a first thrust bearing 22 that is positioned between the drive shaft housing 16 and lower unit housing 21 and an anti-friction bearing 23 which is journaled adjacent it. The thrust bearing 22 is designed to take vertically upward thrusts transmitted to the drive shaft 19.
At its lower end, a bevel gear 24 is affixed for rotation with the drive shaft 19 in a known manner. The bevel gear 24 forms a portion of a forward, neutral, reverse transmission, indicated generally by the reference numeral 25. The forward, neutral, reverse transmission 25 includes a pair of counterrotating bevel gears comprised of a forward drive gear 26 and a reverse drive gear 27 that are in mesh with the driving bevel gear 24 on diametrically opposite sides of it. The bevel gears 26 and 27 are journaled upon a propeller shaft 28 to which a propulsion device such as a propeller 29 is affixed in a known manner.
A dog clutching sleeve 31 has a splined connection with the propeller shaft 28 so as to rotate with it and also to be axially movable along it. A shifting mechanism, shown partially at 32, is provided for shifting the dog clutching sleeve 31 between a neutral position as shown in FIG. 1 and a forward position wherein the dog clutching sleeve 31 rotatably couples the forward bevel gear 26 with the propeller shaft 28. Alternatively, the shifting mechanism 32 may shift the dog clutching sleeve 31 rearwardly so as to engage with the reverse gear 27 so as to rotatably couple this gear with the propeller shaft 28 for driving the propeller 29 in a reverse direction. This mechanism is generally conventional and, for that reason, further description of it is not believed to be necessary to understand the construction and operation of the inventive features of this embodiment.
It will be noted that a bevel gear 33 is affixed to the upper end of the drive shaft 19 in a manner to be described. The bevel gear 33 has its pitch circle arranged so that it intersects a point 34 at which the input shaft 15 is intersected by the axis of rotation of the drive shaft 19. The upper end of the drive shaft 19 and specifically the driven bevel gear 33 is supported in a manner also to be described by means of a double taper bearing 35 so as to take driving thrusts on the bevel gear 33 in opposite directions. This is in contradistinction to conventional constructions wherein a single acting thrust bearing is normally employed in this area. However, in accordance with the embodiment of the invention, the drive shaft 19 is adapted to be rotated in either the forward B or reverse C directions by the mechanism not to be described. As a result, the thrust bearing 35 is designed to take thrusts in either direction.
It will be noted that the input shaft portion 15 is provided with spaced splined sections 36 and 37 that are spaced equidistant from the point of intersection 34 of the input shaft 14 and the drive shaft 19. A driving bevel gear 38 is designed to be selectively engaged with either the splined section 36 (FIG. 1) for forward rotation in the direction of the arrow B or with the splined section 37 (FIG. 2) for counterrotation in the direction of the arrow C. A spacer sleeve 39 cooperates with the bevel gear 38 so as to insure proper alignment in each condition. It should be noted that the spacer sleeve 39 is formed with a hub portion 41 which is complementary in configuration to a hub portion 42 of the bevel gear 38 so as to facilitate this reversing in the direction of rotation.
In the forward degree of rotation as shown in FIG. 1, the hub 42 of the driving bevel gear 38 is journaled in the thrust bearing 17 and the hub 41 of the spacer shaft 39 is journaled in the thrust bearing 18. The assemblage is held together by means of a lock nut 43 and lock washer 44 that are received on a threaded end of the input shaft 14. A bearing cap 45 serves to hold and locate the thrust bearing 18. At the opposite end, a bearing cap 46 holds and locates the thrust bearing 17. A removable cover plate 47 affords access to the nut 43 so as to facilitate reversal of the bevel gear 38 and spacer sleeve 39 on the input shaft section 16 for reversal of the direction of rotation. Shims 48 are interposed between the thrust bearings 17 and 18 and the gear 38 and spacer sleeve 39 so as to provide axial alignment between the bevel gears 38 and 33.
Referring now primarily in detail to FIGS. 2 and 3, the thrust bearing arrangement for the bevel gear 33 and upper end of the drive shaft 19 and its manner of assembly will now be described. The thrust bearing assembly 35 includes a first thrust bearing 51 which is disposed so as to take vertically downward thrusts acting on the bevel gear 33. The inner race of the first thrust bearing 51 is engaged with the backside of the bevel bear 33 and thus is axially loaded thereagainst. A second thrust bearing 52 is disposed beneath the thrust bearing 51 and acts to take vertically upward thrusts on the gear 33. The inner race of the bearing 52 is engaged with a spacer ring 53 which; in turn; engages the inner race of the bearing 51. A lock nut 54 is threaded onto a threaded portion of a hub 55 of the bevel gear 33 which passes through the inner races of the bearings 51 and 52. A lock washer 56 holds the lock nut 54 in its adjusted position. By tightening of the lock nut 54 on the bevel gear hub 55, the preload of the thrust bearings 51 and 52 can be adjusted. It should be noted that this adjustment is made before the assembly comprised of the bevel gear 33 and thrust bearing 35 is supported in the drive shaft housing 16.
The bevel gear 33 has a splined hub that mates with an externally splined portion 60 of the drive shaft 19 so as to rotatably couple these shafts together. A mounting plate 57 is put in position between the outer race of the thrust bearing 51 and the backside of the bevel gear 33 so as to fix the mounting plate 57 axially relative to this assemblage when the nut 54 and lock washer 56 are put in place. As a result, the mounting plate 57 forms a portion of the assemblage which is mounted into the drive shaft housing 16.
It should be noted that the drive shaft housing 16 has a generally upwardly opening flange portion 58 into which the assemblage is placed. A spacer plate 59 and shims 61 are positioned between the outer race of the lower thrust bearing 52 and a shoulder formed at the base of the housing portion 58 so as to provide adjustment of the meshing relationship between the bevel gears 33 and 38. Bolts or other threaded fasteners 62 are then passed through openings in the mounting plate 57 and threaded into tapped openings in the drive shaft housing portion 58 so as to fix the assemblage in position. After this has been assembled, the input shaft 14 and upper portion of the drive may be assembled in a manner which is believed to be obvious from the foregoing description.
It should be readily apparent from the foregoing description that a very simple and high effective drive arrangement has been provided for permitting a bevel gear and its supporting thrust bearing to be assembled into a housing assembly. The arrangement also permits reversal of the direction of drive because of the use of a double tapered thrust bearing.
The foregoing description is that of a preferred embodiment of the invention and various changes and modifications may be made without departing from the spirit and scope of the invention, as defined by the appended claims. | A marine outboard drive particularly adapted for use in a twin stern drive arrangement which facilitates reversal of the degree of rotation of the output shaft. A bevel gear train drives a drive shaft of the outboard drive and because of the counterrevolution is supported by a pair of oppositely acting thrust bearings. An improved arrangement is provided for preloading the thrust bearings and for positioning the driven bevel gear within the drive shaft housing so as to adjust the meshing relationship between the gears. | 5 |
BACKGROUND OF THE INVENTION
Field of the Invention
The invention relates to the field of orthopedic, elastic support devices for a wrist and hand, and in particular for wrist and hand supports used by construction workers, athletes and other persons who work with their hands. Its primary use is to help prevent injury and to help protect aggravation of any preexisting wrist or carpal tunnel problems.
The wrist is a complex bone and muscular structure prone to injury upon overextension or upon unusual lateral movement. Certain activities, such as hammering, drilling, computer operation, repetitive motions, bowling, etc., are particularly difficult on the wrist. In addition, the wrist may suffer a trauma, or become accidentally injured and require support. In addition, a person may have carpal tunnel syndrome requiring the person to wear a support garment on his/her wrist to secure the wrist. Surgical, rigid wrist and hand braces and casts are available, but since their goal is to immobilize the area on which they are worn, the wearer is generally unable to move his/her arm easily about. In addition, simple elastic braces are available but they have a tendency not to provide enough support to protect the wrist and hand from injury.
Other prior art wrist and hand braces are available, such as the one shown in U.S. Pat. No. 4,584,993, but they do not provide adequate support of the hand and thumb area, as does the device of the present invention, since the prior art devices merely provide support to the wrist. Further, these prior art devices, while limiting flexure of the hand and wrist in the up and down direction, do not limit the motion of the wrist from side to side, as does the device of the present invention. Additionally, the prior art devices tend to close on the upper side of the arm proximate the wrist. Since most wrist injuries tend to occur to the underside of the wrist, additional support is needed, such as provided for in the present invention. Further, they are not as adaptable to any hand size or shape or use as does the device of the present invention.
SUMMARY OF INVENTION
The present invention relates to a flexible elastic wrist support device for use by construction workers and other persons requiring wrist and hand support. The wrist and hand support device offers lateral support to the wrist to limit the flexure and hyperextension of the wrist. The wrist and hand support device includes a base comprised as a flat sheet member of elastic material stretchable in a single direction circumferentially around the wrist so as to form a form fitting sleeve around the wrist of the user. A plurality of spaced apart longitudinal pockets are sewn onto the middle area of the base in a direction perpendicular to the circumference thereof. Flat flexible stay members are enclosed in the pockets to provide firm lateral support to the under side of the wrist. Each end of outer portion of the base is comprised of hook and loop closure or other suitable attachment means. On the underside of one end of the base is the reciprocal area of hook and loop closure or other suitable attachment means so that the base can be fixedly enclosed around the wrist of the user.
A specially configured rigidity strap extends from the base proximate the longitudinal pockets, to wrap around the thumb allowing freedom of motion for the thumb. The rigidity strap is pulled around the thumb, over the back of the hand and is releasably fastened to the back of the base proximate the back of the hand and also fastened to the base proximate the underside of the hand. This rigidity strap fixes the position of the support device on the wearer and offers support to both the hand pad and the wrist such that the motion of the wrist is limited from side to side as well as up and down motion.
One or more additional releasable flexible elastic straps comprised of a flat sheet stretchable in a single direction circumferentially around the wrist may also be affixed to the back of the base for adding additional tension to the base support. The support device is adjustable to fit varying sizes of wrists. The elastic straps provide additional tension to the base support.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the front of the underside of the preferred embodiment of the wrist and hand support device as worn by a user of the device;
FIG. 2 is a perspective view of the top side of the preferred embodiment of the wrist and hand support device as worn by a user of the device;
FIG. 3 is a plan view of the interior of the preferred embodiment of the wrist and hand support device in an unwrapped condition;
FIG. 4 is a plan view of the exterior of the preferred embodiment of the wrist and hand support device in unwrapped condition;
FIG. 5 is an elevational view of the preferred embodiment of the wrist and hand support device in a partially installed condition;
FIG. 6 is a perspective view of the top side of an alternate embodiment of the wrist and hand support device as worn by a user of the device;
FIG. 7 is a plan view of the interior of an alternate embodiment of the wrist and hand support device in an unwrapped condition; and
FIG. 8 is a plan view of the exterior of an alternate embodiment of the wrist and hand support device in unwrapped condition.
DESCRIPTION OF PREFERRED EMBODIMENTS
Referring first to the drawings, there is shown in FIGS. 1 through 5 a wrist and hand support device 10 having a flat base 12. Base 12 is preferably formed of a substantially rigid, linearly elastic fabric, capable of being stretched circumferentially around the wrist of the wearer. Base 12 has an exterior side 13 and an interior side 15 and a proximate and a distal end 14 and 17, respectively. Affixed proximate the distal end 17 of the base 12 is a fastening means 19.
As shown more clearly in FIG. 3, affixed to the interior 15 of the base proximate and extending substantially along its distal end 14 is a first fastening means 16. The fastening mean 16 is fastened along the first end 14 of the interior 15 of base 12 by suitable means such as sewing. Additional fastening means 50, and 52 are also fastened to the interior 15 of base 12 proximate distal end 17.
Referring more specifically to FIG. 4, a second fastening means 18 is attached to the exterior 13 of base 12 proximate its distal end 17. Fastening means 18 is attached to base 12, by suitable means such as sewing, so that it is proximate and parallel to its upper lateral edge 20. A third fastening means 22 is also attached to the exterior 13 of base 12 so that it is approximately midway between and parallel to proximate and distal ends 14 and 17, respectively.
Referring specifically to FIGS. 1, 3 and 4, a plurality of elongated, parallel longitudinal pockets 26 are affixed next to the proximate end 17 of the exterior 13 of the base 12. The pockets 26 extend perpendicularly to the bottom edge 21 of base 12. An elongated flexible supporting stay member (not shown) is fixedly located in each of the pockets 26. In the preferred embodiment, the outer pockets 26a and 26c contain stays that are shorter than the interior pockets 26b. Each stay member is comprised as a resilient flat stay member that cannot be compressed longitudinally. The stay members provide resistance against flexure of the wrist when the wrist support device is properly fixed in place and also prevents overextension and hyperextension of the wrist muscles and joints. In the preferred embodiment, there are 5-9 stays and the material enclosing the stays provides padding.
An elongated elastic support strap 30 (see FIGS. 3, 4 and 5) is formed of a linearly elastic fabric preferably stretchable circumferentially around the wrist of the wearer. Strap 30 is affixed proximate the center 31 of pocket 26c on the exterior 13 of base 12. In the preferred embodiment, the strap 30 is affixed so that it is centered between and parallel to the lateral edges 20 and 21 of base 12. The strap 30 has an end 32 which is extendable around the wrist with base 12 in place on the wrist to offer the appropriate tension of the device around the wrist. Coextensive with the lateral edge of the interior of end 32 of strap 30 is fastening strip 33. A second fastening means 34 is fastened along the exterior of strap 30, such that it is located substantially above fastening means 22 on base 12. The amount of tension is adjustable according to where fastening strip 33 is affixed onto fastening strip 34 on the exterior of strap 30 as it is wrapped around the wrist of the wearer. (See FIGS. 1 through 5.)
Referring specifically to FIGS. 3 and 4, a specially configured rigidity strap 40 extends from the base 12 proximate the longitudinal pockets 26, to wrap around the thumb (see FIG. 5) allowing freedom of motion for the thumb. The strap 40 is configured in a "C"-shape on the inner side 42 and has a gently sloping edge 44 extending from the upper lateral edge 20 of base 12. The strap 40 terminates in a substantially rounded edge triangular end 46 having a first tongue-shaped member 48 and a second narrower tongue-shaped member 49. Along the interior of end 46, at the tip of tongue-shaped members 48 and 49 are fastening means 50 and 52, respectively. Strap 40 is substantially narrow around the center of the "C" shape in order to comfortably fit around the thumb, between the thumb and the forefinger.
The base 12 is capable of surrounding the wrist so as to form a sleeve by fastening the ends of base 12 together.
Use of the wrist supporting device 10 is illustrated in FIGS. 1, 2, 5 and 6. The wrist support is used by placing the interior 15 of base 12 to which stays 26 are fastened, against the portion of the arm proximate the wrist. Free end 14 of base 12 is wrapped around the wrist of the user such that fastening means 16 is overlapped and fastened onto end 17 by releasably fastening strips 16 and 19 to each other to releasably hold base 12 in tension. The rigidity strap 40 is then pulled around the thumb, over the back of the hand and fastening means 50 is releasably fastened to fastening means 22 on the back of the base and fastening means 52 is releasably fastened to fastening means 18 on the back of the base. Due to the fact that the rigidity strap 40 is fastened to the base at two locations rather than one as in prior art devices, there is greater support of the hand pad and wrist and it is less likely to come off the hand during use. The rigidity strap also fixes the position of the brace around the wrist of the wearer.
The wearer then pulls the elongated elastic support strap 30 (see FIGS. 3, 4 and 5) circumferentially around the wrist of the wearer such that fastening means 33 is attached to fastening means 34. The mount of tension is adjustable according to where fastening strip 33 is affixed onto fastening strip 34 on the exterior of strap 30 as it is wrapped around the wrist of the wearer. (See FIGS. 1 through 5.)
Referring next to FIGS. 6, 7 and 8, an alternate embodiment of the present invention is shown. A base 112 is shown, which is identical in shape and size to base 12 shown in FIGS. 1-5. Base 112 is preferably formed of a substantially rigid, linearly elastic fabric, capable of being stretched circumferentially around the wrist of the wearer. Base 112 has an exterior side 113 and an interior side 115 and a proximate and a distal end 114 and 117, respectively.
As shown more clearly in FIG. 7, affixed to the interior 115 of the base proximate and extending substantially along its distal end 114 is a first fastening means 116. The fastening mean 116 is fastened along the first end 114 of the interior 115 of base 112 by suitable means such as sewing. Additional fastening means 150, and 152 are also fastened to the interior 115 of base 112 proximate distal end 117.
Referring more specifically to FIG. 8, a second fastening means 118 is attached to the exterior 113 of base 112 proximate its distal end 117. Fastening means 118 is attached to base 112, by suitable means such as sewing, so that it is proximate and parallel to its upper lateral edge 120. A third fastening means 122 is also attached to the exterior 113 of base 112 so that it is approximately midway between and proximate and distal ends 114 and 117, respectively and vertical to the lateral edge 120 of the device.
Referring specifically to FIGS. 6, 7 and 8, a first set of a plurality of elongated, parallel longitudinal pockets 126 are affixed next to the distal end 117 of the exterior 113 of the base 112. The pockets 126 extend perpendicularly to the bottom edge 121 of base 112. A second set of a plurality of elongated, parallel longitudinal pockets 127 are affixed to the base 112 under the fastening means 122 so that they are approximately half way between the distal and proximate ends 114 and 117 of the base 112. The pockets 127 extend perpendicularly to the bottom edge 121 of base 112. An elongated flexible supporting stay member (not shown) is fixedly located in each of the pockets 126 and 127. In the preferred embodiment, the outer pockets 126a and 126c contain stays that are shorter than the interior pockets 126b. Likewise the pockets 127a contain stays that are the approximate size of stays 126a and 126c. Each stay member is comprised as a resilient flat stay member that cannot be compressed longitudinally. The stay members provide resistance against flexure of the wrist when the wrist and hand support device is properly fixed in place and also prevents overextension and hyperextension of the wrist muscles and joints. In the preferred embodiment, there are 5-9 stays and the material enclosing the stays provides padding.
Elongated elastic support straps 130 and 131 (see FIGS. 6, 7 and 8) are formed of a linearly elastic fabric preferably stretchable circumferentially around the wrist of the wearer. Strap 130 is affixed proximate the upper portion 129 of pocket 126c on the exterior 113 of base 112. Strap 131 is affixed proximate the lower portion 127 of pocket 126c on the exterior 113 of base 112. In the preferred embodiment, straps 130 and 131 are affixed so that they are centered between and parallel to the lateral edges 120 and 121 of base 112. Straps 130 and 131 have ends 132 and 135, respectively, which are extendable around the wrist with base 112 in place on the wrist to offer the appropriate tension of the device around the wrist. Coextensive with each of the lateral edges of the interior of end 132 of strap 130 and the interior of 135 of strap 131 are fastening strips 133 and 137, respectively. Fastening means 134 and 139 are fastened along the exteriors of straps 130 and 131, respectively, such that they are located substantially above fastening means 122 on base 112. The amount of tension is adjustable according to where fastening strips 133 and 137 are affixed onto fastening strips 134 and 139, respectively, on the exterior of straps 130 and 131, respectively, as they are wrapped around the wrist of the wearer. (See FIGS. 6 through 8.)
Referring specifically to FIGS. 7 and 8, a specially configured rigidity strap 140 extends from the base 112 proximate the longitudinal pockets 126, to wrap around the thumb (see FIG. 5) allowing freedom of motion for the thumb. The strap 140 is configured in a "C"-shape on the inner side 142 and has a gently sloping edge 144 extending from the upper lateral edge 120 of base 112. The strap 140 terminates in a Substantially rounded edge triangular end 146 having a first tongue-shaped member 148 and a second narrower tongue-shaped member 149. Along the interior of end 146, at the tip of tongue-shaped members 148 and 149 are fastening means 150 and 152, respectively. Strap 140 is substantially narrow around the center of the "C" shape in order to comfortably fit around the thumb, between the thumb and the forefinger.
In use, the rigidity strap 140 is pulled around the thumb, over the back of the hand and fastening means 150 is releasably fastened to fastening means 122 on the back of the base and fastening means 152 is releasably fastened to fastening means 118 on the back of the base. Due to the fact that the rigidity strap 140 is fastened to the base at two locations rather than one as in prior art devices, there is greater support of the hand pad and wrist and it is less likely to come off the hand during use. The rigidity strap also fixes the position of the brace around the wrist of the wearer.
Use of the alternate embodiment of the wrist and hand supporting device is illustrated in FIGS. 6-8. The wrist and hand support is used by placing the interior 115 of base 112 to which stays 126 are fastened, against the portion of the arm proximate the wrist. Free end 114 of base 112 is wrapped around the wrist of the user such that fastening means 116 is overlapped and fastened onto end 117 by releasably fastening strips 116 and 117 to each other to releasably hold base 112 in tension. The base 112 is placed such that stays 127 are resting against the upper side of the wrist for additional support. The rigidity strap 140 is then pulled around the thumb, over the back of the hand and fastening means 150 is releasably fastened to fastening means 122 on the back of the base and fastening means 152 is releasably fastened to fastening means 118 on the back of the base. Due to the fact that the rigidity strap 140 is fastened to the base at two locations rather than one as in prior art devices, there is greater support of the hand pad and wrist and it is less likely to come off the hand during use. The rigidity strap also fixes the position of the brace around the wrist of the wearer.
The wearer then pulls the elongated elastic support straps 130 and 131 (see FIGS. 6, 7 and 8) Circumferentially around the wrist of the wearer such that fastening means 133 and 137 are attached to fastening means 134 and 139, respectively. The amount of tension is adjustable according to where fastening strips 133 and 137 are affixed onto fastening strips 134 and 139, respectively, on the exterior of straps 130 and 131, respectively, as they are wrapped around the wrist of the wearer. (See FIGS. 6 through 8.)
The fastening means referred to herein are formed of materials that releasable adhere to each other when pressed together such as Velcro.
The devices of the present invention provides much more support to the wrist and hand than does prior art devices. For example, the device disclosed in U.S. Pat. No. 4,584,993 provides a top closure, while the devices of the present invention provide a bottom closure, and thus an overlap of material on the bottom of the wrist. This provides additional support and rigidity to the wrist proximate the location where most wrist accidents occur. In the second embodiment of the invention, even more support is given due to the additional set of stays placed in the device proximate the wrist and hand area.
In the devices of the present invention, the stays are shorter proximate the outsides of the palm of the hand, so as to conform to the contour of the hand, therefore providing more and more comfortable support in the area where carpal tunnel syndrome occurs most, i.e. in the center of the hand and up the center of the wrist.
In addition, all the binding of the edges of the devices of the present invention are elastic in order to provide maximum support of the wrist. The rigidity straps 40 and 140 are shaped so as to support the wrist during lateral movement i.e. from side to side, in addition to the up and down motion of the prior art devices.
While particular embodiments of the invention have been shown and illustrated herein, it will be understood that many changes, substitutions and modifications may be made by those persons skilled in the art, such as, by way of example and not limitation, additional stays, straps, etc. The configurations may be reversed to accommodate left handed, as well as, right handed wearers. It will be appreciated from the above description of presently preferred embodiments that other configurations are possible and within the scope of the present invention. Thus, the present invention is not intended to be limited to the particular embodiments specifically discussed hereinabove. | A flexible elastic adjustable wrist and hand support device for use by persons requiring wrist and hand support or protection is shown. The wrist support device offers generalized support to the wrist as well as lateral support to limit flexion of the wrist. The support device includes a base comprised as a flat sheet member of elastic material stretchable in a single direction circumferentially around the wrist. A plurality of longitudinal pockets are sewn into the base. Flat flexible stay members are located in the pockets to provide lateral support to the wrist. At least one flexible elastic strap is sewn onto the back of the base, such that when it surrounds the wrist of the wearer, it provides additional support and tension. The base further comprises a rigidity strap extending from said base proximate the longitudinal pockets so as to wrap around the thumb of the wearer, said strap configured in a "C"-shape on the inner side thereof and having a gently sloping edge extending from the upper edge of base which terminates in a substantially rounded edge triangular end having a first tongue-shaped member and a second narrower tongue-shaped member, which are releasably fastened to the exterior of the base, when the device is in use. | 0 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a National Phase Entry Application under 35 U.S.C. §371 of International Application No. PCT/CA01/01252, filed Sep. 4, 2001, which designated the United States, and which claims benefit under 35 U.S.C. §119(e) of a U.S. provisional application Ser. No. 61/230,414.
BACKGROUND OF THE INVENTION
(a) Field of the Invention
The invention relates to novel oligonucleotide chimera used as therapeutic agents to selectively prevent gene transcription and expression in a sequence-specific manner. In particular, this invention is directed to the selective inhibition of protein biosynthesis via antisense strategy using oligonucleotides constructed from arabinonucleotide or modified arabinonucleotide residues, flanking a series of deoxyribose nucleotide residues of variable length. Particularly this invention relates to the use of antisense oligonucleotides constructed from arabinonucleotide or modified arabinonucleotide residues, flanking a series of deoxyribose nucleotide residues of variable length, to hybridize to complementary RNA such as cellular messenger RNA, viral RNA, etc. More particularly this invention relates to the use of antisense oligonucleotides constructed from arabinonucleotide or modified arabinonucleotide residues, flanking a series of deoxyribose nucleotide residues of variable length, to hybridize to and induce cleavage of (via RNaseH activation) the complementary RNA.
(b) Description of Prior Art
The Antisense Strategy
Antisense oligonucleotides (AON) are therapeutic agents that can inhibit specific gene expression in a sequence-specific manner. Many AON are currently in clinical trials for the treatment of cancer and viral diseases. For clinical utility, AON should exhibit stability against degradation by serum and cellular nucleases, show low non-specific binding to serum and cell proteins (since this binding would diminish the amount of antisense oligonucleotide available to base-pair with the target RNA), exhibit enhanced recognition of the target RNA sequence (in other words, provide increased stability of the antisense-target RNA duplex at physiological temperature), and to some extent, demonstrate cell-membrane permeability. Antisense inhibition of target gene expression is believed to occur by at least two main mechanisms. The first is “translation arrest”, in which the formation of a duplex between the antisense oligomer and its target RNA prevents the complete translation of that RNA into protein, by blocking the ability of the ribosome to recognize the complete mRNA sequence. The second, and probably more important, mechanism concerns the ability of the antisense oligonucleotide to direct the ribonuclease H (RNaseH) catalyzed degradation of the target mRNA. RNaseH is an endogenous cellular enzyme that specifically degrades RNA when it is duplexed with a complementary DNA oligonucleotide (or antisense oligonucleotide) component. For example, when an antisense DNA oligonucleotide hybridizes to a cellular mRNA via complementary base pairing, cellular RNAseH recognizes the resulting DNA/RNA hybrid duplex and then degrades the mRNA at that site. Antisense oligonucleotides that can modulate gene expression by both mechanisms are highly desirable as this increases the potential efficacy of the antisense compound in vivo.
Oligonucleotide Analogs
Oligonucleotides containing natural (ribose or deoxyribose) sugars and phosphodiester (PO) linkages are rapidly degraded by serum and intracellular nucleases, which limits their utility as effective therapeutic agents. Chemical strategies to improve nuclease stability include modification of the sugar moiety, the base moiety, and/or modification or replacement of the internucleotide phosphodiester linkage. To date, the most widely studied analogues are the phosphorothioate (PS) oligodeoxynucleotides, in which one of the non-bridging oxygen atoms in the phosphodiester backbone is replaced with a sulfur. Numerous S-DNA oligonucleotide analogues are undergoing clinical trial evaluation for the treatment of cancer, infectious diseases and other human pathologies, and some are already subjects of New Drug Application (NDA) filings. S-DNA antisense are able to elicit RNaseH degradation of the target mRNA and they are reasonably refractory to degradation by serum and cellular nucleases. However, PS-DNA antisense tend to form less thermodynamically-stable duplexes with the target RNA nucleic acid than oligodeoxynucleotides with phosphodiester (PO) linkages. Furthermore, S-DNA antisense can be less efficient at eliciting RNaseH degradation of the target RNA than the corresponding PO-DNA.
Specificity of action may be improved by developing novel oligonucleotide analogues. Current strategies to generate novel oligonucleotides are to alter the internucleotide phosphate backbone, the heterocyclic base, and the sugar ring, or a combination of these. Alteration or complete replacement of the internucleotide linkage has been the most popular approach, with over 60 types of modified phosphate backbones studied since 1994. Apart from the phosphorothioate backbone, only two others have been reported to activate RNaseH activity, i.e., the phosphorodithioate (PS 2 ) and the boranophosphonate backbones. Because of the higher sulfur content of phosphorodithioate-linked (PS 2 ) oligodeoxynucleotides, they appear to bind proteins tighter than the phosphorothioate (PS) oligomers, and to activate RNaseH mediated cleavage with reduced efficiency compared to the PS analogue. Boranophosphonate-linked oligodeoxynucleotides activate RNaseH mediated cleavage of RNA targets, but less well than PO- or PS-linked oligodeoxynucleotides.
Among the reported sugar-modified oligonucleotides most of them contain a five-membered ring, closely resembling the sugar of DNA (D-2-deoxyribose) and RNA (D-ribose). Example of these are α-oligodeoxynucleotide analogs, wherein the configuration of the 1′ (or anomeric) carbon has been inverted. These analogues are nuclease resistant, form stable duplexes with DNA and RNA sequences, and are capable of inhibiting β-globin mRNA translation via an RNaseH-independent antisense mechanism. Other examples are xylo-DNA, 2′-O-Me RNA and 2′-F RNA. These analogues form stable duplexes with RNA targets, however, these duplexes are not substrates for RNaseH. To overcome this limitation, mixed-backbone oligonucleotides (“MBO”) composed of either phosphodiester (PO) and phosphorothioate (PS) oligodeoxynucleotide segments flanked on both sides by sugar-modified oligonucleotide segments have been synthesized (Zhao, G. et al., Biochem. Pharmacol. 1996, 51, 173; Crooke, S. T. et al. J. Pharmacol. Exp. Ther. 1996, 277, 923). Among the MBOs most studied to date is the [2′-OMe RNA]-[PS DNA]-[2′OMe RNA] chimera The PS segment in the middle of the chain serves as the RNaseH activation domain, whereas the flanking 2′-OMe RNA regions increases affinity of the MBO strand for the target RNA. MBOs have increased stability in vivo, and appear to be more effective than phosphorothioate analogues in their biological activity both in vitro and in vivo. Examples of this approach incorporating 2′-OMe and other alkoxy substituents in the flanking regions of an oligonucleotide have been demonstrated by Monia et al. by enhanced antitumor activity in vivo (Monia, P. B. et al. Nature Med. 1996, 2, 668). Several pre-clinical trials with these analogues are ongoing.
The synthesis of oligonucleotides containing hexopyranoses instead of pentofuranose sugars has also been reported. A few of these analogues have increased enzymatic stability but generally suffer from a reduced duplex forming capability with the target sequence. A notable exception is 6′→4′ linked oligomers constructed from 1,5-anhydrohexitol units which, due to their highly pre-organized sugar structure, form very stable complexes with RNA. However, none of these hexopyranose oligonucleotide analogues have been shown to elicit RNaseH activity. Recently, oligonucleotides containing completely altered backbones have been synthesized. Notable examples are the peptide nucleic acids (“PNA”) with an acyclic backbone. These compounds have exceptional hybridization properties, and stability towards nucleases and proteases. However, efforts to use PNA oligomers as antisense constructs have been hampered by poor water solubility, self-aggregation properties, poor cellular uptake, and inability to activate RNaseH. Very recently, PNA-[PS-DNA]-PNA chimeras have been designed to maintain RNaseH mediated cleavage via the PS-DNA portion of the chimera.
Arabinonucleosides and Arabinonucleic Acids (ANA)
Arabinonucleosides are isomers of ribonucleosides, differing only in the stereochemistry at the 2′-position of the sugar ring. We have previously shown that antisense oligonucleotides constructed entirely from nucleotides comprising arabinose or modified arabinose (especially 2′-F arabinose) sugars are able to elicit RNaseH degradation of the complementary target RNA (Damha, M. J. et al. JACS 1998, 120, 12976; Noronha, A. M. et al. Biochemistry 2000, 39, 7050). We also noted that the thermal stability of duplexes consisting of an arabinose oligonucleotide with RNA was less than that of the analogous DNA/RNA duplex (Noronha, A. M. et al. Biochemistry 2000, 39, 7050). In contrast however, the thermal stability of duplexes consisting of an oligonucleotide synthesized with 2′-F arabinose nucleotides hybridized with RNA is generally greater than that of the analogous DNA/RNA duplex (Damha, M. J. et al. JACS 1998, 120, 12976). Giannaris and Damha found that replacement of the phosphodiester (PO) linkage in ANA oligonucleotides with phosphorothioate (PS) linkages significantly decreased the stability of the PS-ANA/PO-RNA duplex (Giannaris, P. A.; Damha, M. J. Can. J. Chem. 1994, 72, 909). This destabilization was greater than that observed when the PO linkages of an analogous DNA oligonucleotide were replaced with S internucleotide linkages (Giannaris, P. A.; Damha, M. J. Can. J. Chem. 1994, 72, 909).
Watanabe and co-workers incorporated 2′-deoxy-2′-fluoro-□-D-arabinofuranosylpyrimidine nucleosides (2′-F-ara-N, where N═C, U and T) at several positions within an oligonucleotide primarily comprised of a PO-DNA chain and evaluated the hybridization properties of such (2′-F)ANA-DNA “chimeras” towards complementary DNA (Kois, P. et al. Nucleosides & Nucleotides 1993, 12, 1093). Substitutions with 2′-F-araU and 2′-F-araC destabilized duplex stability compared to the all-DNA/RNA duplex, whereas substitutions with 2′-F-araT stabilized the duplex. Marquez and co-workers recently evaluated the self-association of a DNA strand in which two internal thymidines were replaced by 2′-F-araT's (Ikeda et al. Nucleic Acids Res. 1998, 26, 2237). They confirmed the findings of Watanabe and co-workers that internal 2′-F-araT residues stabilize significantly the DNA double helix. The association of these (2′-F)ANA-DNA “chimeras” with complementary RNA (the typical antisense target) was not reported.
Elicitation of Cellular RNaseH Degradation of Target RNA by Antisense Oligonucleotides
One of the most important mechanisms for antisense oligonucleotide directed inhibition of gene expression is the ability of these antisense oligonucleotides to form a structure, when duplexed with the target RNA, that can be recognized by cellular RNaseH. This enables the RNaseH-mediated degradation of the RNA target, within the region of the antisense oligonucleotide-RNA base-paired duplex (Monia et al. J. Biol. Chem. 1993, 268, 14514).
RNase H selectively degrades the RNA strand of a DNA/RNA heteroduplex. RNaseH1 from the bacterium Escherichia coli is the most readily available and the best characterized enzyme. Studies with eukaryotic cell extracts containing RNase H suggest that both prokaryotic and eukaryotic enzymes exhibit similar RNA-cleavage properties, although the bacterial enzyme is better able to cleave duplexes of small length (Monia et al. J. Biol. Chem. 1993, 268, 14514). E. coli RNaseH1 is thought to bind in the minor groove of the DNA/RNA double helix and to cleave the RNA by both endonuclease and processive 3′-to-5′ exonuclease activities. The efficiency of RNase H degradation displays minimal sequence dependence and is quite sensitive to chemical changes in the antisense oligonucleotide. For example, while RNaseH readily degrades RNA in S-DNA/RNA duplexes, it cannot do so in duplexes comprising methylphosphonate-DNA, α-DNA, or 2′-OMe RNA antisense oligonucleotides with RNA. Furthermore, while E. coli RNaseH binds to RNA/RNA duplexes, it cannot cleave either RNA strand, despite the fact that the global helical conformation of RNA/RNA duplexes is similar to that of DNA/RNA substrate duplexes (“A”-form helices). These results suggest that local structural differences between DNA/RNA (substrate) and RNA/RNA (substrate) duplexes contribute to substrate discrimination.
Arabinonucleic Acids as Activators of RNaseH Activity
An essential requirement in the antisense approach is that an oligonucleotide or its analogue recognize and bind tightly to its complementary target RNA. The ability of the resulting antisense oligonucleotide/RNA duplex to serve as a substrate of RNaseH is likely to have therapeutic value by enhancing the antisense effect relative to antisense oligonucleotides that are unable to activate this enzyme. Apart from PS-DNA (phosphorothioates), PS 2 -DNA (phosphorodithioates), boranophosphonate-linked DNA, and MBO oligos containing an internal PS-DNA segment, the only examples of fully modified oligonucleotides that elicit RNaseH activity are those constructed from arabinonucleotide (ANA) or modified arabinonucleotide residues (International Application published under No. WO 99/67378; Damha, M. J. et al. JACS 1998, 120, 12976; Noronha, A. M. et al. Biochemistry 2000, 39, 7050). These ANA oligonucleotides retain the natural β-D-furanose configuration and mimic the conformation of DNA strands (e.g., with sugars puckered in the C2′-endo conformation). The latter requirement stems from the fact that the antisense strand of natural substrates is DNA, and as indicated above, its primary structure (and/or conformation) appears to be essential for RNaseH/substrate cleavage; the DNA sugars of DNA/RNA hybrids adopt primarily the C2′-endo conformation. ANA is a stereoisomer of RNA differing only in the stereochemistry at the 2′-position of the sugar ring. ANA/RNA duplexes adopt a helical structure that is very similar to that of DNA/RNA substrates (“A”-form), as shown by similar circular dichroism spectra of these complexes (Damha, M. J. et al. JACS 1998, 120, 12976; Noronha, A. M. et al. Biochemistry 2000, 39, 7050).
Mixed-backbone or “Gapmer” Oligonucleotide Constructs as Antisense Oligonucleotides
Mixed-backbone oligonucleotides (MBO) composed of a phosphodiester or phosphorothioate oligodeoxynucleotide “gap” segment flanked at both the 5′- and 3′-ends by sugar-modified oligonucleotide “wing” segments have been synthesized (Zhao, G. et al., Biochem. Pharmacol. 1996, 51, 173; Crooke, S. T. et al. J. Pharmcol. Exp. Ther. 1996, 277, 923). Probably the most studied MBO to date is the [2′-OMe RNA]-[PS DNA]-[2′OMe RNA] chimera. Oligonucleotides comprised of 2′-OMe RNA alone bind with very high affinity to target RNA, but are unable to elicit RNaseH degradation of that target RNA. In [2′-OMe RNA]-[PS DNA]-[2′OMe RNA] chimera oligonucleotides, the PS-DNA segment in the middle of the chain serves to elicit RNaseH degradation of the target, whereas the flanking 2′-OMe RNA “wing” regions increase the affinity of the MBO strand for the target RNA. MBOs have increased stability in vivo, and appear to be more effective than same-sequence PS-DNA analogues in their biological activity both in vitro and in vivo. Examples of this approach incorporating 2′-OMe and other alkoxy substituents in the flanking regions of an oligonucleotide have been demonstrated by Monia et al. by enhanced antitumor activity in vivo (Monia, P. B. et al. Nature Med. 1996, 2, 668). Several pre-clinical trials with these analogues are ongoing.
Nonetheless, because 2′-OMe RNA cannot elicit RNaseH activity, the DNA gap size of the [2′-OMe RNA]-[PS DNA]-[2′OMe RNA] chimera oligonucleotides must be carefully defined While E. coli RNaseH can recognize and use 2′-OMe RNA MBO with DNA gaps as small as 4 DNA nucleotides (Shen, L. X. et al 1998 Biorg. Med. Chem. 6, 1695), the eukaryotic RNaseH (such as human RNaseH) requires substantially larger DNA gaps (7 DNA nucleotides or more) for optimal degradation activity (Monia, B. P. et al 1993 J. Biol. Chem. 268, 14514). In general, with [2′-OMe RNA]-[PS DNA]-[2′OMe RNA] chimera oligonucleotides, eukaryotic RNaseH-mediated target RNA cleavage efficiency decreases with decreasing DNA gap length, and becomes increasingly negligible with DNA gap sizes of less than 6 DNA nucleotides. Thus, antisense activity of [2′-OMe RNA]-[PS DNA]-[2′OMe RNA] chimera oligonucleotides is highly dependent on DNA gap size (Monia, B. P. et al 1993 J. Biol. Chem. 268, 14514; Agrawal, S. and Kandimalia, E. R 2000 Mol. Med. Today, 6, 72).
Recently, oligonucleotides containing completely altered backbones have been synthesized. Notable examples are the peptide nucleic acids (“PNA”) with an acyclic backbone. These compounds have exceptional hybridization properties, and stability towards nucleases and proteases. However, efforts to use PNA oligomers as antisense constructs have been hampered by poor water solubility, self-aggregation properties, poor cellular uptake, and inability to activate RNaseH. Very recently, PNA-[PS-DNA]-PNA chimeras have been designed to maintain RNaseH mediated cleavage via the PS-DNA portion of the chimera
It would be highly desirable to be provided with oligonucleotides constructed from arabinonucleotide or modified arabinonucleotide residues, flanking a series of deoxyribose nucleotide residues of variable length, for the sequence specific inhibition of gene expression via association to (and RNaseH mediated cleavage of) complementary messenger RNA.
SUMMARY OF THE INVENTION
One aim of the present invention is to provide antisense oligonucleotides chimera constructed from arabinonucleotide or modified arabinonucleotide residues, flanking a series of deoxyribose nucleotide residues of variable length, that form a duplex with its target RNA sequence. Such resulting antisense oligonucleotide/RNA duplex is a substrate for RNaseH, an enzyme that recognizes this duplex and degrades the RNA target portion. RNaseH mediated cleavage of RNA targets is considered to be a major mechanism of action of antisense oligonucleotides.
The present invention relates to the discovery that certain antisense hybrid chimeras, specifically those constructed from 2′-deoxy-2′-fluoro-β-D-arabinonucleotides (FANA) flanking a defined sequence constructed from β-D-2′-deoxyribonucleotides (DNA), are superior to antisense hybrid chimeras constructed from 2′-O-methyl-β-D-ribonucleotides (OMeNA) flanking a defined sequence constructed from β-D-2′-deoxyribonucleotides (DNA).
Accordingly, antisense hybrid chimeras constructed from 2′-deoxy-2′-fluoro-β-D-arabinonucleotides (FANA) flanking a defined sequence constructed from β-D-2′-deoxyribonucleotides (DNA), have potential utility as therapeutic agents and/or tools for the study and control of specific gene expression in cells and organisms.
In accordance with the present invention there is provided an oligonucleotide ‘chimera’ to selectively prevent gene expression in a sequence-specific manner, which comprises a chimera of modified arabinose and 2′-deoxy sugars hybridizing to a single stranded RNA to induce at least one of the following: (a) nuclease stability, (b) binding strength of hybridization to complementary RNA sequences, (c) permeability of said oligonucleotide into cells; (d) cleavage of target RNA by RNaseH; or (e) physical blockage of ribose translocation (“translation arrest”).
Such an oligonucleotide has a general backbone composition of “[FANA WING]-[DNA GAP]-[FANA WING]”, or 5′RO(FANA-p)x-(DNA-p)y-(FANA-p)z-(FANA)3′OH, and more precisely has the general structure:
wherein,
x≧1, y≧1, and z≧0, and R is selected from a group consisting of hydrogen, thiophosphate, and a linker moiety that enhances cellular uptake of such oligonucleotide.
In accordance with the present invention there is provided an oligonucleotide which has the formula:
wherein,
x≧1, y≧1, and z≧0; R is selected from a group consisting of hydrogen, thiophosphate, and a linker moiety that enhances cellular uptake of such oligonucleotide; B is selected from the group consisting of adenine, guanine, uracil, thymine, cytosine, inosine, and 5-methylcytosine; Y at the internucleotide phosphate linkage is selected from the group consisting of sulfur, oxygen, methyl, amino, alkylamino, dialkylamino (the alkyl group having one to about 20 carbon atoms), methoxy, and ethoxy; X at the furanose ring (position 4′) is selected from the groups oxygen, sulfur, and methylene (CH 2 ); and Z at the 2′ position of the sugar ring is selected from the group consisting of a halogen (fluorine, chlorine, bromine, iodine), alkyl, alkylhalide (e.g., —CH 2 F), allyl, amino, aryl, alkoxy, and azido.
In accordance with the present invention there is provided an oligonucleotide which has the formula:
wherein,
x≧1, y≧1, and z≧0; R is selected from a group consisting of hydrogen, thiophosphate, and a linker moiety that enhances cellular uptake of such oligonucleotide; B is selected from the group consisting of adenine, guanine, uracil, thymine, cytosine, inosine, and 5-methylcytosine.
In accordance with the present invention there is provided an oligonucleotide which has the formula:
wherein,
x≧1, y≧1, and z≧0; R is selected from a group consisting of hydrogen, thiophosphate, and a linker moiety that enhances cellular uptake of such oligonucleotide; B is selected from the group consisting of adenine, guanine, uracil, thymine, cytosine, inosine, and 5-methylcytosine; Y at the internucleotide phosphate linkage is selected from the group consisting of sulfur, oxygen, methyl, amino, alkylamino, dialkylamino (the alkyl group having one to about 20 carbon atoms), methoxy, and ethoxy; X at the furanose ring (position 4′) is selected from the groups oxygen, sulfur, and methylene (CH 2 ); and Z at the 2′ position of the sugar ring is selected from the group consisting of a halogen (fluorine, chlorine, bromine, iodine), hydroxyl, alkyl, alkyihalide (e.g., —CH 2 F), allyl, amino, aryl, alkoxy, and azido.
In accordance with the present invention there is provided a method for cleaving single stranded RNA, which comprises the steps of:
(a) hybridizing in a sequence specific manner an oligonucleotide of the present invention to a single stranded RNA to induce RNase H activity, and (b) allowing said induced RNase H to cleave said hybridized single stranded RNA.
In accordance with the present invention there is provided a method to prevent translation of said single stranded RNA, which comprises hybridizing in a sequence specific manner chimeric oligonucleotides of claims 2 to 5 to single stranded RNA, and thereby prevent production of specific protein encoded by said single stranded RNA.
The RNA may be complementary RNA, such as cellular mRNA or viral RNA.
In accordance with the present invention there is provided the use of an oligonucleotide of the present invention for the preparation of a medicament for cleaving single stranded RNA, wherein said oligonucleotide hybridizes in a sequence specific manner to a single stranded RNA to induce RNase H activity in cleaving said hybridized single stranded RNA.
In accordance with the present invention there is provided the use of an oligonucleotide of the present invention for the preparation of a probe or laboratory reagent for cleaving single stranded RNA, wherein said oligonucleotide hybridizes in a sequence specific manner to a single stranded RNA to induce RNase H activity in cleaving said hybridized single stranded RNA
In accordance with the present invention there is provided a composition to selectively prevent gene expression in a sequence-specific manner; which comprises an effective amount of an oligonucleotide ‘chimera’ of the present invention in association with a pharmaceutically acceptable carrier.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates the efficacy of various antisense oligonucleotides to inhibit intracellular gene expression.
FIGS. 2A-C illustrate the comparison of PS-DNA and PS-FANA gapmer (10 DNA) antisense oligonucleotides to inhibit intracellular gene expression.
FIGS. 3A-B illustrate the effect of treatment with PS-DNA and PS-FANA gapmer (10 DNA) antisense oligonucleotides on cellular luciferase protein and mRNA.
FIG. 4 illustrates the effect of DNA “gap” size on the ability of gapmer antisense oligonucleotides to inhibit cellular specific gene expression.
FIG. 5 illustrates the effect of DNA “gap” size on the ability of gapmer antisense oligonucleotides to inhibit cellular specific gene expression—effect of antisense oligonucleotide concentration
DETAILED DESCRIPTION OF THE INVENTION
In accordance with the present invention, there is provided antisense oligonucleotides constructed constructed from nucleotides possessing β-D-arabinose or modified β-D-arabinose sugar moieties, flanking a series of deoxyribose nucleotide residues of variable length, that form a duplex with its target RNA sequence. from β-D-arabinose and its derivatives and the therapeutic use of such compounds. It is the object of the present invention to provide new antisense oligonucleotide analogues that hybridize to complementary nucleic acids which may be mRNA or viral RNA (including retroviral RNA), for the purpose of inhibiting the expression of specific genes. More particularly this invention relates to the use of antisense oligonucleotides constructed constructed from nucleotides possessing β-D-arabinose or modified β-D-arabinose sugar moieties, flanking a series of deoxyribose nucleotide residues of variable length, to hybridize to specific target RNA sequences and elicit the cleavage of said target RNA through the action of cellular RNaseH.
The oligonucleotides of this invention may be represented by the following formula (I):
where B includes but it is not necessarily limited to a common purine or pyrimidine base such as adenine, guanine, cytosine, thymine, and uracil. The oligonucleotides include stretches of DNA (DNA “gap”) flanked by a number of β-D-arabinofuranose or modified β-D-arabinofuranose nucleotides at the 5′- and 3′-ends (“wings”) of the antisense oligonucleotide, thereby forming “gapmers” such as ANA-DNA-ANA, 2′F-ANA-DNA-2′F-ANA, etc. The internucleotide phosphate linkage includes but it is not necessarily limited to oxygen, sulfur, methyl, amino, alkylamino, dialkylamino, methoxy, and ethoxy. The 2′-substituent of the arabinose sugar includes but is not limited to fluorine, hydroxyl, amino, azido, methyl, methoxy and other alkoxy groups (e.g., ethoxy, proproxy, methoxyethoxy, etc.).
The gapmer antisense oligonucleotide of this invention contains a sequence that is complementary to a specific sequence of a messenger RNA, or viral genomic RNA, such that the gapmer oligonucleotide can specifically inhibit the biosynthesis of proteins encoded by the mRNA, or inhibit virus replication, respectively. Partial modifications to the oligonucleotide directed to the 5′ and/or 3′-terminus, or the phosphate backbone or sugar residues to enhance their antisense properties (e.g. nuclease resistance) are within the scope of the invention.
A preferred group of oligonucleotides useful in this invention, are those wherein B is a natural base(adenine, guanine, cytosine, thymine, uracil), the sugar moiety of the “wings” is β-D-2′deoxy-2′-F-arabinofuranose, and the internucleotide phosphate linkages contain sulfur (as phosphorothioate linkages). These modifications give rise to oligonucleotides that exhibit high affinity for single stranded RNA In addition, these oligonucleotides have been shown to meet the requirements necessary for antisense therapeutics. For example, they elicit the degradation of the target RNA by cellular RNaseH, thereby decreasing the intracellular amount of and activity of the specific protein encoded by the target RNA.
The gapmer antisense oligonucleotides of this invention exhibit a number of desirable properties:
(1) They were found to bind to and cleave single stranded RNA by activating RNaseH. The gapmer oligonucleotides possessing “wings” comprised of β-D2′-deoxy-2′-F-arabinofuranose nucleotides in particular were found to have excellent affinity towards RNA targets, comparable to gapmer oligonucleotides possessing “wings” comprised of 2′-O-methylribonucleotides, and significantly better than that of identical sequence DNA. (2) The gapmer oligonucleotides possessing “wings” comprised of β-D-2′-deoxy2′-F-arabinofuranose nucleotides were found to better effect sequence-specific inhibition of intracellular gene expression than the same-sequence DNA oligonucleotides. With large DNA gaps (10 DNA oligonucleotides), the intracellular antisense activity of gapmer oligonucleotides possessing “wings” comprised of β-D-2′deoxy-2′-F-arabinofuranose nucleotides was equivalent to that of same-sequence gapmer oligonucleotides possessing “wings” comprised of 2′-O-methylribonucleotides. With smaller DNA gaps (6 DNA or less), the intracellular antisense activity of gapmer oligonucleotides possessing “wings” comprised of β-D-2′-deoxy-2′-F-arabinofuranose nucleotides was significantly better than that of same-sequence gapmer oligonucleotides possessing “wings” comprised of 2′-O-methylribonucleotides.
These observations establish that gapmer oligonucleotides possessing “wings” comprised of β-D-2′-deoxy-2′-F-arabinofuranose nucleotides flanking an internal sequence of DNA (the “gap”) are excellent models of antisense oligonucleotide agents, and should serve as therapeutics and/or valuable tools for studying and controlling gene expression in cells and organisms.
The present invention will be more readily understood by referring to the following examples which are given to illustrate the invention rather than to limit its scope.
EXAMPLE I
Preparation of Antisense Oligonucleotides Constructed from 2′-deoxy-2′-fluoro-β-D-arabinonucleotides (FANA) Flanking a Defined Sequence Constructed from β-D-2′-deoxyribonucleotides (DNA)
1. Synthesis of FANA, S-[FANA], and S-[FANA-DNA-FANA]
The synthesis of PO-FANA was conducted as previously described (Damha et al. J. Am. Chem. Soc. 120, 12976-12977 (1998). Synthesis of S-FANA and S-[FANA-DNA-FANA] chimeras were synthesized on a 1 micromol scale using an Expedite 8909 DNA-synthesizer. Long-chain alkylamine controlled-pore glass (LCAA-CPG) was used as the solid support. The synthesis cycle consisted of the following steps:
1) Detritylation of nucleoside/tide bound to CPG (3% trichloroacetic acid/dichloromethane): 150 sec. 2) Coupling of 2′-F-arabinonucleoside or 2′-deoxyribonucleoside 3′-phosphoramidite monomers: 15 min. Concentration of monomers used were 50 mg/mL for araF-T, araF-C and DNA monomers, and 60 mg/mL for araA and araF-G (acetonitrile as solvent). 3) Acetylation using the standard capping step: 20 sec. The capping solution consisted of 1:1 (v/v) of “capA” and “capB” reagents. CapA: acetic anhydride/collidine/THF (1:1:8 ml); cap B: N-Methylimidazole/THF (4:21 ml). 4) Extensive washing with acetonitrile (50 pulses). 5) Sulfuration with a fresh solution of 0.2M 3H-1,2-benzodithiol-3-one in acetonitrile: 10 min. 6) Washing with acetonitrile: 20 pulses. 7) Drying of the solid support by addition of the capping reagent (see step 3): 5 sec. 8) Washing with acetonitrile (20 pulses).
Following chain assembly, oligonucleotides were cleaved from the solid support and deprotected as previously described (Noronha et al. Biochemistry 39, 7050-7062 (2000)). The crude oligomers were purified by either (a) preparative gel electrophoresis (24% acrylamide, 7M Urea) following by desalting (Sephadex™ G-25), or (b) anion-exchange HPLC following by desalting (SepPak™ cartridges). Yields: 5-30 A 260 units
Conditions for HPLC Purification:
Column:
Protein Pak DEAE-5PW (7.5 mm × 7.5 cm, Waters ™),
Solvents:
Buffer A: H 2 O; Buffer B: 1M NaClO 4 ,
Gradient:
100% buffer A isocratic for 12 min,
100% A-15% B, linear (over 5 min),
15% B-55% B, linear (over 60 min).
Loading was 1-2 A 260 units for analysis and 30-50 A 260 units for preparative separation. Flow rate was set at 1 ml/min, temperature was adjusted at 50° C. The detector was set at 260 nm for analytical and 290 nm for preparative chromatography. Under these conditions, the desired full-length oligomer eluted last
2. Synthesis of S-DNA and S-[2′OMe-RNA-DNA-2′-OMe-RNA] Chimeras
Phosphorothioated DNA (S-DNA) and S-[2′OMe-RNA-DNA-2′OMe-RNA] chimeras were obtained commercially from the University of Calgary DNA Synthesis Laboratory (Calgary, ALTA). They were purified (HPLC) and desalted (SepPak™ cartridges) as described above (see part 1 above).
The base sequence and hybridization properties of the various oligonucleotides synthesized are given in Table 1.
TABLE 1
Antisense oligonucleotide (AON) sequences and
melting temperatures (Tm) of duplexes of AON
with complementary target RNA a
ID
AON
Tm
#
Designation
AON Sequence b
(° C.) c
1
S-FANA gap
S - ATA T cc ttg tcg ta T CCC
64
(10 DNA)
2
S-FANA gap
S - ATA TC c ttg tcg t AT CCC
65
(8 DNA)
3
S-FANA gap
S - ATA TCC ttg tcg TAT CCC
68
(6 DNA)
4
S-FANA gap
S - ATA TCC T tg tc G TAT CCC
70
(4 DNA)
5
S-FANA gap
S - ATA TCC TT g TC g TAT CCC
71
(2 × 1 DNA)
6
S-FANA
S - ATA TCC TTG TCG TAT CCC
72
7
PO-FANA
O - ATA TCC TTG TCG TAT CCC
82
8
2′OMe gap
S - ATA T cc ttg tcg ta T CCC
66
(10 DNA)
9
2′OMe gap
S - ATA TCC ttg tcg TAT CCC
68
(6 DNA)
10
2′OMe gap
S - ATA TCC T tg tc G TAT CCC
72
(4 DNA)
11
S-DNA
S -ata tcc ttg tcg tat ccc
62
12
PO-DNA
O -ata tcc ttg tcg tat ccc
70
a Aqueous solutions of 2.5 × 10 −6 M of duplex. Buffer: 140 nM KCl, 1 mM MgCl 2 , 5 mM Na 2 HPO 4 (ph 7.2).
b code: N = FANA nucleotide; n = DNA nucleotide; N = 2′OMe-RNA nucleotide; S- = containing phosphorothioate bonds; PO- = containing phosphodiester bonds.
c ±1° C.
EXAMPLE 2
Efficacy of Various Antisense Oligonucleotides to Inhibit Intracellular Gene Expression
Antisense oligonucleotides have the potential to inhibit expression of virtually any gene, based on the specific base sequence of the chosen target mRNA. We studied the ability of antisense oligonucleotides constructed from 2′-deoxy-2′-fluoro-β-D-arabinonucleotides (FANA) flanking a series of 2′-deoxyribose nucleotide residues of variable length (S-FANA gapmer) to interfere with the expression of a well-characterized marker model, namely expression of the enzyme luciferase, in cells stably transfected with the luciferase gene. The efficacy of the S-FANA gapmer to inhibit intracellular luciferase expression was compared with identical sequence antisense oligonucleotides constructed entirely from 2′-deoxy-2′-fluoro-β-D-arabinonucleotides or entirely from 2′-deoxyribonucleotides. Linkages between nucleotides were either phosphodiester (PO) or phosphorothioate (PS). The specific antisense oligonucleotide sequences were 5′-ATA TCC TTG TCG TAT CCC-3′, which is complementary to bases 1511-1528 of the coding region of the luciferase gene. As a control, randomized oligonucleotide sequences (5′-TAA TCC CTA TCG TCG CTT-3′) were used; these are of the same base composition as the specific AON sequence, but have no complementarity to any portion of the luciferase gene. These randomized oligonucleotides were unable to effect inhibition of target luciferase expression.
The ability of oligonucleotides complementary to a specific region of mRNA coding for luciferase was tested for inhibition of luciferase activity expression in Hela X1/5 cells (obtained from the European Collection of Cell Cultures, Salisbury, UK). Hela X1/5 cells are stably transfected with the luciferase gene and express functional luciferase enzyme.
Oligonucleotides were delivered to the cells by complexing the oligonucleotide with cytofectin GSV GS3815 (Glen Research, Sterling, Va., USA). Briefly, oligonucleotides were diluted with DMEM in the absence of fetal bovine serum (FBS) to provide a final concentration of oligonucleotide 10-fold higher than the final concentration to which the cells would be exposed. Cytofectin GSV was prepared in serum-free DMEM at a final concentration of 25 μg/ml. Equal volumes of oligonucleotide and cytofectin solutions were mixed in polystyrene plastic and incubated for 15 min at room temperature, then the mixture was diluted 5-fold with DMEM. containing 10% FBS.
X1/5 cells were plated in 96-well plates at a density of 1.5-2×10 4 cells/well and allowed to grow for 24 h in DMEM/10% FBS. This generally provided a cell density of 80% confluence, as assessed by microscopy. The culture medium was then removed from the cells, the cells were washed several times with phosphate-buffered saline, and then overlayed with the medium containing the oligonucleotide/cytofectin mixture. After 24 h incubation, the Hela cells were harvested, homogenized and assayed for luciferase activity. Luciferase activity was assayed by a luminometric method using the luciferase assay kit components obtained from Promega (Madison, Wis., USA).
The results of an experiment comparing the ability of antisense oligonucleotides (sequence 5′-ATA TCC TTG TCG TAT CCC-3′), constructed from a variety of different nucleotide and linkage chemistries, to inhibit X1/5 cell luciferase activity is given in FIG. 1 . In all cases, the cells were exposed to a final concentration of 250 nM of antisense oligonucleotide, for 24 h prior to assay of luciferase activity. The antisense oligonucleotide constructed entirely from β-D-2′-deoxyribose with phosphodiester bonds (PO-DNA, ID# 12 in Table 1) was unable to effect any inhibition of X1/5 cell luciferase activity, whereas the antisense oligonucleotide constructed entirely from β-D-2′-deoxyribose with phosphorothioate bonds (PS-DNA; ID# 11 in Table 1) provided approximately 60% inhibition. Antisense oligonucleotides constructed entirely from 2′-deoxy-2′-fluoro-β-D-arabinonucleotides with either phosphodiester bonds (PO-FANA; ID# 7 in Table 1) or phosphorothioate bonds (PS-FANA; ID# 6 in Table 1) provided approximately 55% and 25% inhibition of luciferase activity, respectively. Under the same conditions, the antisense oligonucleotide constructed from 2′-deoxy-2′-fluoro-β-D-arabinonucleotides flanking a series of ten 2′-deoxyribose nucleotide residues, all joined with phosphorothioate bonds (S-FANA gapmer; ID# 1 in Table 1), provided at least a 90% inhibition of X1/5 cell luciferase activity. No obvious cell toxicity was noted with any of the antisense oligonucleotides under the conditions used in this experiment.
The results ( FIG. 1 ) show that the S-FANA gapmer (10 DNA gap) is a significantly better inhibitor of X1/5 cell luciferase activity expression than any of PO-DNA, S-DNA, PO-FANA or S-FANA. X1/5 cells were incubated with various antisense oligonucleotides (250 nM final concentration), all directed against the same target sequence of luciferase mRNA. Following appropriate incubation, the residual level of intracellular luciferase activity was determined.
EXAMPLE 3
Comparison of S-DNA and S-FANA Gapmer (10 DNA) Antisense Oligonucleotides to Inhibit Intracellular Gene Expression
Solutions of S-DNA (ID# 11, Table 1) and S-FANA gapmer (ID# 1, Table 1) were prepared with Cytofectin GSV GS3815 as described in Example 2. Hela X1/5 cells were plated in replicate 6-well plates at a density of 5×10 5 cells/well and allowed to grow for 24 h in DMEM/10% FBS. The culture medium was then removed from the cells, the cells were washed several times with phosphate-buffered saline, and then overlayed with the medium containing the oligonucleotide/cytofectin mixture. After 24 h incubation, the Hela X1/5 cells were harvested and treated in a manner appropriate for the subsequent assay procedures (described below).
(a) Assay for Luciferase Enzyme Activity
Luciferase enzyme activity assays were performed using the luciferase assay kit system from Promega, Madison, Wis., USA, according to the manufacturer's protocol. Briefly, cells were washed with phosphate-buffered saline and then lysed with the cell lysis buffer provided in the kit. Replicate aliquots of the cell lysates were transferred to 96 well assay plates. Luciferin substrate solution was added and luminescence was measured immediately using a SPECTRAmax GEMINI XS microplate spectrofluorometer (Molecular Devices, Sunnyvale, Calif., USA) set at the luminescence reading mode. Results were normalized for any variation in total cell protein concentration in the individual samples (determined using the Bio-Rad protein assay reagent on identical aliquots).
(b) Assay for Luciferase Protein Expression.
Levels of luciferase protein in antisense-treated and untreated X1/5 cells were determined by Western blot analysis. Protein extracts of X1/5 cells were prepared by lysing the cells in the same lysis buffer used for preparation of the samples for luciferase enzyme assays, followed by clarification by centrifugation. The protein content of individual samples was measured using the Bio-Rad protein assay reagent (Bio-Rad, Hercules, Calif., USA). Samples containing identical amounts of cell protein (approximately 20 μg) were subjected to SDS-PAGE, then transferred to nitrocellulose membranes (0.45μ). The membrane was incubated in TTBS (20 mM Tris-HCl containing 500 mM NaCl and 0.05% Tween 20) containing 5% skim milk for at least one hour. The blots were then incubated with a goat antibody specifically reacting with firefly luciferase (obtained from Chemicon International Inc, Temecula, Calif., USA), using antibody at a concentration of 1 mg/ml in TTBS. After 1 h incubation, the membranes were washed extensively with TTBS, then incubated with horseradish peroxidase-conjugated anti-goat IgG (Chemicon International Inc., Temecula, Calif., USA) at a 1:10,000 dilution in TTBS. The peroxidase-reactive regions were then detected using the Renaissance Western blot Chemiluminescene Reagent Kit (NEN Life Science Products, Boston, Mass., USA) and Kodak X-OMAT film, according to manufacturer's instructions. Luciferase protein levels were then quantified by densitometric analysis of the developed film.
(c) Assay for Luciferase mRNA.
The isolation of total RNA from X1/5 cells and Northern blot assays for luciferase mRNA levels were carried. Normalized amounts of total cell RNA (10-20 μg) were size-fractionated on 1% agarose gels containing 2.2 M formaldehyde then transferred to 0.45μ nitrocellulose membranes (Bio-Rad, Hercules, Calif., USA). The hybridization probe for luciferase mRNA was 32 P-internally labeled DNA derived from the full-length cDNA for the firefly luciferase gene (from plasmid pGEM-Luc, Promega, Madison, Wis., USA) generated using the oligolabeling kit from Amersham-Pharmacia Biotech (Piscataway, N.J., USA). Hybridization of the radiolabeled probe with membrane bound RNA was carried out in 6×SSC buffer (900 mM sodium chloride containing 90 mM sodium citrate at pH 7.0) containing 50% formamide, 0.5% sodium dodecyl sulfate and blocking reagents. Hybridizations were carried out at 42° C. for 16 hours. The membranes were then washed twice with 1×SSC containing 0.1% SDS at room temperature, then 0.1×SSC containing 0.1% SDS at room temperature, and finally 1×SSC containing 0.5% SDS at 42° C. Membrane-associated radioactivity was localized by autoradiography, and quantified by densitometry.
The results of FIG. 2 show that S-FANA gapmer (10 DNA) was significantly more effective than S-DNA at inhibiting X1/5 cell luciferase activity over a range of concentrations varying from 15 nM to 250 nM antisense oligonucleotide (panel A).
Treatment of X1/5 cells with the S-FANA gapmer (10 DNA) resulted in a dose-dependent decrease in total luciferase protein (panel B) that was not evident in cells treated with the S-DNA antisense. In addition, treatment of X1/5 cells with the S-FANA gapmer (10 DNA) resulted in a dose-dependent decrease in total luciferase mRNA (panel C); this decrease was greater than that effected by the S-DNA antisense. Luciferase protein levels were assessed by Western blot analysis using an antibody specifically directed towards luciferase. Luciferase mRNA levels were assessed by Northern blot analysis using a DNA probe specifically directed towards a sequence of the luciferase mRNA.
EXAMPLE 4
Effect of Treatment with S-DNA and S-FANA Gapmer (10 DNA) Antisense Oligonucleotides on Cellular Luciferase Protein and mRNA
Solutions of S-DNA (ID# 11, Table 1) and S-FANA gapmer (D# 1, Table 1) were prepared with Cytofectin GSV GS3815 as described in Example 2. Hela X1/5 cells were plated in replicate 6-well plates at a density of 5×10 5 cells/well and allowed to grow for 24 h in DMEM/10% FBS. The culture medium was then removed from the cells, the cells were washed several times with phosphate-buffered saline, and then overlayed with the medium containing the oligonucleotide/cytofectin mixture to provide the indicated final concentrations of S-DNA or S-FANA gapmer (10 DNA) antisense oligonucleotides. After 24 h incubation, the Hela X1/5 cells were harvested and treated in a manner appropriate for analysis of luciferase protein levels or luciferase mRNA levels, exactly as described in Example 3.
The results in FIG. 3 , panel (A), show the Western blot analysis of luciferase protein levels in extracts of X1/5 cells treated with varying concentrations of S-DNA (upper series) or S-FANA gapmer (10 DNA) (lower series). (A) Variation in luciferase protein levels following exposure of X1/5 cells to increasing amounts of either PS-DNA or PS-FANA gapmer (10 DNA) antisense oligonucleotides.
It is readily seen that the cells treated with S-FANA gapmer (10 DNA) show a dose-dependent decrease in total luciferase protein, whereas this effect is much less apparent in cells treated with S-DNA. Quantitation of the luciferase protein levels is provided in panel (B) of FIG. 2 . (B) The PS-FANA gapmer (10 DNA) antisense oligonucleotide elicits RNaseH cleavage of intracellular luciferase mRNA. 1 corresponds to the full-length luciferase mRNA, 2 and 3 are the cleaved products. + represents mRNA isolated from cells treated with 250 nM PS-FANA gapmer (10 DNA), − represents mRNA isolated from cells not exposed to antisense.
The results in FIG. 3 , panel (B), show that treatment of X1/5 cells with 250 nM S-FANA gapmer (10 DNA) results in a readily discernible cleavage of luciferase rnRNA (lane +). Three species of luciferase mRNA are seen, full-length (1), and two smaller species (2 and 3) that correspond to the cleavage products expected from RNaseH degradation of the full-length mRNA in the region targeted by the antisense oligonucleotide. The luciferase mRNA profile in cells not exposed to any antisense is shown in the lane marked (−).
EXAMPLE 5
Effect of DNA “Gap” Size on the Ability of Gapmer Antisense Oligonucleotides to Inhibit Cellular Specific Gene Expression
We compared antisense oligonucleotides constructed from 2′-deoxy-2′-fluoro-β-D-arabinonucleotides (FANA) flanking a series of 2′-deoxyribose nucleotide residues of variable length with phosphorothioate internucleotide linkages (S-FANA gapmer) to similar MBO constructed with 2′-O-methyl RNA wings, and to non-gapmer PS-DNA and PS-FANA oligonucleotides, in their ability to inhibit the expression of intracellular luciferase activity in Hela X1/5 cells. The specific antisense oligonucleotide sequence was 5′-ATA TCC TTG TCG TAT CCC-3′, which is complementary to bases 1511-1528 of the coding region of the luciferase gene.
Oligonucleotides were delivered to the cells by complexing the oligonucleotide with cytofectin GSV GS3815 (Glen Research, Sterling, Va., USA), exactly as described for Example 2.
X1/5 cells were plated in 96-well plates at a density of 1.5-2×10 4 cells/well and allowed to grow for 24 h in DMEM/10% FBS. The culture medium was then removed from the cells, the cells were washed several times with phosphate-buffered saline, and then overlayed with the medium containing the oligonucleotide/cytofectin mixture, to provide a final concentration of 250 nM of antisense oligonucleotide. After 24 h incubation, the Hela cells were harvested, homogenized and assayed for luciferase activity by a luminometric method using the luciferase assay kit components obtained from Promega (Madison, Wis., USA).
The results of an experiment comparing the ability of antisense oligonucleotides (sequence 5′-ATA TCC TTG TCG TAT CCC-3′), constructed from a variety of different nucleotide, to inhibit X1/5 cell luciferase activity is given in FIG. 4 . The data represent residual intracellular luciferase activity following exposure to a final concentration of 250 nM antisense oligonucleotide. All antisense were directed to the same sequence of luciferase mRNA. S-DNA is PS-DNA, S-FANA is PS-FANA without a DNA gap, S-FANA gapmer is an antisense oligonucleotide constructed from 2′-fluoroarabinonucleotides flanking a series of deoxyribose nucleotide residues of defined length (indicated), 2′-OMe gapmer is an antisense oligonucleotide constructed from 2′-O-methylribonucleotides flanking a series of deoxyribose nucleotide residues of defined length (indicated).
In all cases, the cells were exposed to a final concentration of 250 nM of antisense oligonucleotide, for 24 h prior to assay of luciferase activity. The antisense oligonucleotide constructed entirely from β-D-2′-deoxyribonucleotides with phosphorothioate bonds (S-DNA; ID# 11 in Table 1) inhibited luciferase expression by about 65%, whereas that constructed entirely from β-D-2′-deoxy-2′F-arabinonucleotides with phosphorothioate bonds (S-FANA; ID# 6 in Table 1) was much less effective, providing only an average of 20% inhibition of luciferase expression. Both S-FANA and 2′-O-methyl RNA MBO gapmers with a ten DNA gap segment (ID# 1 and 8, respectively, in Table 1) were equally and very effective inhibitors, providing an approximate 85-90% decrease in intracellular luciferase activity. However, the antisense activity of 2′-O-methyl RNA MBO gapmers decreased dramatically with decreasing size of the DNA gap; indeed, the 2′-O-methyl RNA MBO gapmer with a 4 DNA gap (ID# 10, Table 1) showed little or no inhibitory activity against X1/5 cell luciferase expression. In sharp contrast, the antisense activity of the S-FANA was unaffected with decreasing DNA gaps, down to a 4 DNA length. Interestingly, the antisense activity of the S-FANA gapmer with a single DNA gap (ID# 5, Table 1) was as good as that of the corresponding all S-DNA oligonucleotide (D# 11, Table 1). This was unexpected, since the all S-FANA oligonucleotide was very poor in this respect.
The results of this experiment show that MBO antisense oligonucleotides constructed with wings comprised of S-FANA show minimal dependence on DNA gap size, unlike the strong DNA gap size dependence exhibited by the corresponding MBO constructed with wings comprised of S-2′-O-methyl RNA.
EXAMPLE 6
Effect of DNA “Gap” Size on the Ability of Gapmer Antisense Oligonucleotides to Inhibit Cellular Specific Gene Expression—Effect of Antisense Oligonucleotide Concentration
In order to better define the antisense activity of S-FANA gapmers compared to S-2′-O-methyl RNA gapmer MBO, we studied the dose-response relationships of inhibition of X1/5 cell luciferase expression as a function of antisense oligonucleotide concentration.
X1/5 cells were plated in 96-well plates at a density of 1.5-2×10 4 cells/well and allowed to grow for 24 h in DMEM/10% FBS. The culture medium was then removed from the cells, the cells were washed several times with phosphate-buffered saline, and then overlayed with the medium containing the oligonucleotide/cytofectin mixture, to provide final concentrations of antisense oligonucleotides ranging from 0 to 250 nM. After 24 h incubation, the Hela cells were harvested, homogenized and assayed for luciferase activity by a luminometric method using the luciferase assay kit components obtained from Promega (Madison, Wis., USA).
The results of this experiment are shown in FIG. 5 (panels A and B). The data represent residual intracellular luciferase activity following exposure of X1/5 cells to the various indicated final concentrations of antisense oligonucleotide. All antisense were directed to the same sequence of luciferase mRNA. S-DNA is PS-DNA, S-FANA gapmer is an antisense oligonucleotide constructed from 2′-fluoroarabinonucleotides flanking a series of deoxyribose nucleotide residues of defined length (indicated), OMe gapmer is an antisense oligonucleotide constructed from 2′-O-methylribonucleotides flanking a series of deoxyribose nucleotide residues of defined length (indicated).
In FIG. 5A , it can be seen that all of the S-FANA gapmers with gaps between 4 and 10 S-DNA nucleotides were very effective inhibitors of intracellular luciferase expression, much better than S-DNA alone. The IC 50 values for this inhibition ranged from about 15 nM (for the 10 DNA gap; ID# 1, Table 1) to <<15 nM (for the 8, 6 and 4 DNA gap oligonucleotides; ID# 2, 3 and 4 respectively, in Table 1). In contrast, the IC 50 value for S-DNA (ID# 11, Table 1) antisense inhibition was about 100 nM. The IC 50 for the S-FANA MBO with 1 DNA gaps (ID# 5, Table 1) was identical to that of the all S-DNA oligonucleotide.
In FIG. 5B , it can be seen that the IC 50 for the ability of the S-2′-O-methyl RNA gapmer (10 DNA gap; ID# 8, Table 1) was essentially identical to that of the corresponding S-FANA gapmer (ID# 1, Table 1). In contrast, the IC 50 values for the antisense activity of the other S-2′-O-methyl RNA gapmers tested (6 and 4 DNA gaps; ID# 9 and 10 respectively in Table 1) were >>250 nM. Indeed, the latter gapmers were virtually ineffective as antisense inhibitors of X1/5 cell luciferase expression.
While the invention has been described in connection with specific embodiments thereof, it will be understood that it is capable of further modifications and this application is intended to cover any variations, uses, or adaptations of the invention following, in general, the principles of the invention and including such departures from the present disclosure as come within known or customary practice within the art to which the invention pertains and as may be applied to the essential features hereinbefore set forth, and as follows in the scope of the appended claims. | The present invention relates to novel oligonucleotide chimera used as therapeutic agents to selectively prevent gene transcription and expression in a sequence-specific manner. In particular, this invention is directed to the selective inhibition of protein biosynthesis via antisense strategy using oligonucleotides constructed from arabinonucleotide or modified arabinonucleotide residues, flanking a series of deoxyribose nucleotide residues of variable length. Particularly this invention relates to the use of antisense oligonucleotides constructed from arabinonucleotide or modified arabinonucleotide residues, flanking a series of deoxyribose nucleotide residues of variable length, to hybridize to complementary RNA such as cellular messenger RNA, viral RNA, etc. More particularly this invention relates to the use of antisense oligonucleotides constructed from arabinonucleotide or modified arabinonucleotide residues, flanking a series of deoxyribose nucleotide residues of variable length, to hybridize to and induce cleavage of (via RNaseH activation) the complementary RNA. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application relates to International Application No. PCT/FR2007/051373 filed Jun. 4, 2007 and French Patent Application No. 0652675 filed Jun. 27, 2006, of which the disclosures are incorporated herein by reference and to which priority is claimed.
The present invention is applied particularly to advantage in the motor vehicle sector. It relates in particular to a process for the recovery of electrical energy in a motor vehicle equipped with a regenerative braking system.
BACKGROUND OF THE INVENTION
1. Field of the Invention.
When a motor vehicle is braked, kinetic energy is dissipated into the brake disks in the form of heat. In order to recover this kinetic energy, the current state of the art provides for regenerative braking systems. Devices of this type are able to recover the kinetic energy given off during braking and to convert this into electrical energy.
2. Description of Related Art.
In a motor vehicle, the regenerative braking device is connected to an electrical distribution circuit of the vehicle, which comprises a battery in which this electrical energy can be stored. This battery is usually a conventional lead/acid battery. The electrical distribution circuit returns the energy that is stored in the battery to the different electrical and electronic components in the motor vehicle.
In a general manner, the requirements that a motor vehicle has for electrical energy increase as the number of such items of electrical and electronic equipment increase. There are two possible ways of meeting the growing need of motor vehicles, firstly by increasing the power of the alternators and the storage capacity of the battery or secondly by improving the energy performance of the electrical supply system.
The regeneration of electrical energy by regenerative braking contributes to an increase in the mean output of the electrical supply system and increases the amount of energy available at the same nominal installed power.
Increasing the power of the alternators and the storage capacity of the battery involves a number of drawbacks in terms of costs, space, a problem of installation in a difficult location (under the bonnet) and also of weight.
Furthermore, the lead/acid batteries normally used in motor vehicles are not suitable for loading with very high current levels during a sufficient period to allow part of the energy given off by a braking device to be recovered. In this type of device, the management of the transitory energy given off by regenerative braking is not efficient enough to ensure that the voltage circulating in the electrical distribution circuit is properly regulated and the repeated charging of the lead/acid battery has an effect of prematurely ageing the latter.
Another system consists in equipping the electrical supply system of the vehicle with a second electrical distribution circuit having a different secondary storage system to that of the main battery or storage system. The second electrical distribution circuit sits alongside the first circuit with the principal storage system. The second circuit with the secondary storage system delivers a floating DC supply voltage and the first circuit with the main storage system delivers a low DC voltage supply, generally lower than that of the said floating voltage. In this way, a general two-layer electrical energy distribution is obtained.
The two storage systems are interconnected by means of a DC/DC reversible voltage converter. The function of the converter is to enable energy to be transferred between the two storage systems and the distribution circuits. An electrical current generator, comprising an alternator or a starter alternator coupled to the heat engine of the vehicle, directly supplies the both secondary storage system with electrical energy and, through the converter, the main storage system.
The practice of employing a pack of very high capacity condensers as a storage system is already known. These very high capacity condensers are usually known as “super-capacitors” or “super-condensers” to the expert in the sector. The secondary storage system, which is also referred to “the super-capacitor” in the following description, has the function of recovering as much electrical energy as possible when the electrical current generator operates in the form of regenerative braking.
In comparison with a conventional lead/acid battery, the super-capacitor can operate regardless of the number of charging/discharging cycles and the depth of these is not affected by the voltage level of the charge, which can vary significantly.
To select the range of regeneration voltage of the super-capacitor used in a motor vehicle, the limits of the starting voltage must be satisfied, as it is the starting phase that requires the greatest electrical output so as to guarantee a sufficiently high energy level for the starter-alternator operating in the starter mode to start the heat engine. When the driver starts the engine, the super-capacitor discharges and unless the braking system is operated to any great degree, the amount of electrical energy that is recovered is insufficient to fully charge the super-capacitor. If the vehicle stops and the driver attempts to restart it, the quality of the restart is lower with the super-capacitor than with the heat engine.
The solution known previously requires an interval so that energy can be regenerated in the super-capacitor at a level generally of between 18 and 24 V so that the associated upper limits associated with the starting of the heat engine can be satisfied.
BRIEF SUMMARY OF THE INVENTION
The aim of the present invention is to provide a process for the regeneration of electrical energy for a new type of motor vehicle which enables the mean output level of the electrical supply system of the vehicle to be improved.
The process for the regeneration of electrical energy according to the present invention by regenerative braking in a motor vehicle is implemented in a vehicle that is equipped for this purpose with an electrical capacitance device that can store electrical energy supplied by a rotary electrical machine in the vehicle when the regenerative braking operation is carried out.
Accordingly, in accordance with the present invention, on the basis of the initial speed of rotation of the said rotary electrical machine, the solution chosen is to apply an energy regeneration strategy using at least the two following means:
an initial energy regeneration stage, preferring a high level of power from the said rotary electrical al machine, and a second energy regeneration system, preferring a high performance from the said rotary electrical machine.
The process described briefly above thus provides for at least two means of optimisation, namely the optimisation of the power level on the one hand and an optimisation of the performance on the other. During the energy regeneration stage, it is considered that the front face of the engine of the vehicle does not limit the mechanical power that can be absorbed by the electrical machine. From this perspective, the optimisation is best obtained by attempting to maximise the mechanical power that is absorbed, and thereby the electrical energy that is regenerated during braking. For this reason, a strategy that aims to increase the electrical power regenerated by the electrical machine is preferred.
On the other hand, if the front face of the engine of the vehicle constitutes a limitation of the mechanical power absorbed by the heat engine, it would be necessary for the performance of the electrical machine to be improved. At the mechanical iso-power level in question, the electrical power regenerated from the electrical machine is at its greatest. For this reason, a strategy that aims to increase the performance will be preferred.
According to another particular feature, the first strategy of energy regeneration is chosen when the initial speed of rotation of the rotary electrical machine exceeds an initial threshold value, fixed at least as 10,000 rpm. Alternatively, the initial threshold value is fixed at a level equal at least to 12,000 rpm.
According to another particular feature of the invention, the second regeneration strategy is chosen when the initial speed of rotation of the rotary electrical machine is less than a second threshold value, fixed at a maximum of 8,000 rpm. Alternatively, the second threshold is fixed at a maximum of 6,000 rpm.
The process according to the present invention can also have at least one of the following features:
the regenerative braking system is activated at the start of the braking process in cases where the braking process is short and at a high initial speed; the regenerative braking system is activated at the end of the braking process, where this process is long; the regenerative braking system is activated in a transitory manner when the vehicle is driven by a heat engine in the vehicle, in such a way as to displace a torque/speed functioning point of the said heat engine.
The invention also relates to an energy regeneration installation in a vehicle, with the said installation having automatic means of controlling regenerative braking and allowing the operation of the process in accordance with the brief description of the invention above.
The invention can be used to particular advantage in combination with the bi-voltage system known as 14+X. This architecture comprises two independent electrical circuits, one of which, the 14+X, by virtue of its technology, is capable of functioning at a variable voltage. This enables new control strategies to be employed in a particularly effective manner in order to maximise the performance or the electrical power that is supplied during the regeneration stage.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
Other features and advantages of the invention will become apparent during a reading of the following description, for a better understanding of which reference is made to the attached drawings, in which:
FIG. 1 shows schematically an illustration of the means of implementing an embodiment of the invention;
FIG. 2 illustrates the different stages of the operation of the device in accordance with the present invention;
FIG. 3 is a graph illustrating the different levels of electrical power during the stages of regenerative braking of the vehicle;
FIG. 4 is a graph illustrating the different levels of electrical performance during the stages of regenerative braking of the vehicle.
DETAILED DESCRIPTION OF THE INVENTION
In a particular embodiment, FIG. 1 contains a schematic representation of an electrical energy regeneration system installed in a motor vehicle. An AC/DC converter 2 is connected firstly to a continuous bus 3 and secondly to a rotary electrical machine 4 . The AC/DC converter 2 and the machine 4 are of the multi-phase type, typically of the three-phase type. The AC/DC converter 2 here is an electrical device of a voltage rectifier type enabling the three-phase AC voltages supplied by the machine 4 , operating in an AC mode, to be converted into direct current. In other embodiments of the invention in which the machine 4 is reversible and functions as a starter-alternator, the AC/DC converter 2 is also reversible and comprises a wave mode to supply the machine 4 with three-phase voltages, which, is in this case an electrical machine or a starter.
The bus 3 comprises a reservoir 5 of electrical energy. This reservoir is a super-capacitor in this particular embodiment. In this situation, the super-capacitor is dimensioned for frequent urban braking conditions and not for major braking operations carried out by the driver of the vehicle. The super-capacitor 5 is supplied by the machine 4 through the AC/DC converter 2 .
The bus 3 comprises two circuits of consumer equipment. The first circuit supplies a fluctuating direct voltage designated as 14+X and is connected to the terminals of the super-capacitor. The consumer equipment connected to this first circuit includes preferably items that are able to operate under a fluctuating voltage (demisters, windscreen wipers etc.). A second circuit supplies a voltage in the region of 12 V, which is available at the terminals of a lead acid battery. The first and second circuits are connected by means of a reversible DC-CD converter 6 , which permits the transfer of energy at adequate voltages and enables in particular the second circuit to be supplied and the battery 7 to be charged.
Within the framework of the present invention, the notion of the battery covers any device constituting a reservoir of rechargeable electrical energy, at the terminals of which a non-nil DC voltage is available, at least in a state of non-nil charge of the device.
The electrical or electronic equipment are in particular connection lines, branched in parallel to the super-capacitor 5 or electrical consumers branched in parallel to the battery 7 . The electrical consumers in a motor vehicle can include, typically, headlights and indicators, a radio, an air conditioning system, windscreen wipers etc.
The machine 4 can therefore be a starter-alternator. The concept of a starter-alternator provides for a rotary electrical machine having a reversible AC/DC converter.
When the AC/DC converter is in an undulating mode, the rotating machine operates as an electrical machine, for example, to start the heat engine of the vehicle. The starter-alternator enables the engine to be started quickly and silently, as it operates entirely electronically.
When the AC/DC mode is in rectifier mode, AC voltage supplied by the rotating machine operating as an alternator is rectified to supply the electrical supply circuits of the vehicle.
The device according to the invention enables the performance of the energy regeneration and the power of the heat engine of the motor vehicle to be optimised by storing electrical energy in the super-capacitor during the functioning of the regenerative braking and by returning it to meet the needs of the vehicle.
FIG. 2 illustrates a particular embodiment described here in a non-limiting manner. FIG. 2 shows the operating stages employed by this particular embodiment at the level of a control logic, which is effected in a concrete manner with known equipment.
When the driver applies the brake of the vehicle, at stage 20 , the index F, which is intended to indicate the length of a braking phase, is reset to zero. At stage 21 , the control logic advances the index F by one unit. At stage 22 , the control logic measures the voltage at the terminals of the super-capacitor. At stage 23 the control logic measures the speed of the electrical machine 4 .
At stage 24 , if the voltage measurement is greater than a value of, for example, 24 V, the control logic applies stage 25 , otherwise it applies stage 26 . At stage 25 , the control logic verifies whether the index F is greater than a threshold value, indicating that the braking process is long. If the braking process is long, the control logic applies state 27 . Otherwise it applies stage 30 .
At stage 27 , the control logic verifies whether the speed of the electrical machine 4 is below a threshold SR, which here is preferably equal to about 8,000 rpm. In this case, the control logic applies stage 28 . Otherwise it applies stage 26 . At stage 28 , the control logic verifies whether the super-capacitor is completely full. In this case, the control logic applies stage 26 . Otherwise it applies stage 29 . At stage 26 , the control logic does not activate the regenerative braking and the functioning reverts to Stage 21 .
If the index F is lower than the long braking threshold value, this implies that the braking time is short. Stage 30 is then applied. The control logic determines whether the speed of the electrical machine 4 of the vehicle is greater than a threshold value SP, which in this case is preferably equal to about 10,000 rpm. In this case, the control logic applies stage 31 otherwise it applies stage 32 . At stage 31 , the control logic verifies whether the super-capacitor is completely full. If it is, it applies stage 32 , if not it applies stage 29 . At stage 32 , the control logic does not activate regenerative braking and the system reverts to stage 21 . At stage 29 , the control logic activates regenerative braking so that the electrical energy supplied by the electrical machine 4 can be stored.
When the vehicle is moving, the driver may be required to respond to situations that arise from two different types of braking, namely short or intermediary braking on the one hand and long braking on the other. It is useful to bear in mind that, when the driver brakes, the energy regeneration device enables an optimum amount of available energy to be stored in the super-capacitor.
For example, in a short braking process, for example of 3 seconds, which will frequently happen in urban driving, the regenerative braking device will not have sufficient time to completely fill the super-capacitor, In this case, during the braking window, it will be interesting to use greater power for greater performance and thus to preferentially activate regeneration at the start of the braking stage. According to the invention, the energy regeneration takes place when the speed of the electrical machine 4 is above a high-speed threshold, which, in the application in question, is in the region of 10,000 rpm and where the voltage supplied by the motor is higher than 24 V. This is an optimisation of the functioning, which concerns the electrical power of the super-capacitor.
Otherwise, if the braking stage is sufficiently long in relation to a predetermined threshold, there will only be an energy regeneration if the speed of the electrical machine 4 is less than a low speed threshold, which, in the case in question, would be equal to 8,000 rpm. This is then an optimisation of the functioning, affecting the electrical performance of the super-capacitor.
FIG. 3 is a graph, which explains the features of the invention in conjunction with an optimisation of power. The graph lines represent the levels of electrical power during the phases of regenerative braking of the vehicle.
Six levels of power can be distinguished, which are determined by the voltage at the terminals of the super-capacitor in relation to the speed of rotation of the electrical machine 4 . It can be clearly seen that, in order to maximise the regeneratable electrical power, which in the case chosen to illustrate the invention is in the region of 10 kW, it would be useful to define a regeneration window leading to a preferred regeneration of energy at high speed with a lower degree of liberty imposed by the vehicle, although it is also clear that it would be preferable to operate at higher voltages so as to achieve more efficient regenerative braking. For example, if braking occurred at a speed of 10,000 rpm then reaching 2,000 rpm, an optimised regeneration in power is favoured by starting the regeneration of energy at the highest point of speed and as it is not possible to foresee the end of the period during which the brake in applied, even though in general, depending on the surrounding topography, it is possible to know where the vehicle is going to come to a halt, it is preferable to let the regeneration take its course. The vehicle will only stop if the super-capacitor is completely full or if the driver stops braking.
Maximising the electrical power during an energy regeneration phase means charging the super-capacitors at a high voltage regardless of the operating speed. Nevertheless, at a very low speed, the voltage that maximises the electrical power is lower than 28 V, and more particularly in the region of 24 V. A more refined strategy could integrate a mean regenerative braking voltage on which would be centred the regeneration window. If there is a need to maximise the regenerated electrical power, it is preferable to initiate the regeneration stage at the start of the braking process. This would result in the operation taking place at the highest possible speed.
FIG. 4 is a graph presenting the different levels of electrical performance during the regenerative braking stages of the vehicle. Six performance levels can be distinguished, which are determined by the voltage at the terminals of the super-capacitor in relation to the speed of rotation of the electrical machine.
To maximise the regeneratable electrical performance, which in the present case, is considered to be in the region of 10 kW, it is necessary to define a regeneration window that preferably leads to high speed regeneration. A functioning at higher voltages allows more efficient regenerative braking. The high performance points correspond to high voltages and not low voltages. Functioning at high voltages ensures more efficient regeneration braking. The high performance points are at high voltage levels and not at low voltage levels, because of the losses that are produced at the level of the electrical machine and increase with the speed of the electrical machine, while the performance is reduced in relation to the speed. A maximisation of the performance goes hand in hand with operation at high voltage, because at the same heat losses, the regenerated electrical power is increased. In this way, in order to optimise functioning in performance, regenerative braking should be carried out at low speed.
If the electrical performance is maximised, it is preferable for operation to be carried out in the upper voltage ranges of the super-capacitors. In the course of a long braking where the initial speed is high, it could be beneficial if the regeneration were only activated at the end of the braking process at low and medium speeds.
Moreover, it will be noted here that the process according to the present invention—although described here in the context of a regenerative energy operation resulting from pressure on the vehicle brake pedal—can also apply in cases where a means of transitory regenerative braking is activated, for example, by the operator of the vehicle or the heat engine, during the operation of the vehicle by the heat engine, without any pressure on the brake pedal, in such a way as to displace the torque/heat engine speed by one operating step. | Method for recovering electrical energy in a vehicle with regenerative braking is used in a vehicle equipped for this purpose with an electrical capacitance device to store electrical energy supplied by a rotary electrical machine of the vehicle during regenerative braking operation. A choice is made, on the basis of the initial rotational speed of the rotary electrical machine to apply an energy recovery stratagem from at least the following two: —a first energy recovery strategy that favors high power supplied by the rotary electrical machine; and—a second energy recovery strategy that favors high efficiency of the rotary electrical machine. | 8 |
This application claims foreign priority benefits from Canadian Patent Application 2,506,446 filed May 6, 2005.
FIELD OF THE INVENTION
The present invention relates to a counter for counting coiled tubing, and more particularly relates to a counter for counting the coiled tubing as it is inserted into an oil or gas well.
BACKGROUND
In the field of oil and gas production various activities related to wells involve the insertion of coiled tubing into the wells. Coiled tubing is typically dispended from a roll supported on a rig which inserts the tubing into the casing of the well by a coiled tubing injector head supported above the casing. When inserting the tubing, it is desirable to count the length of tubing being inserted so as to know the depth of insertion of the bottom end of the tubing.
Various types of counters are known for strand material, including cable or tubing and the like. Typical counters make use of wheels which roll along the strand material as it is dispensed. Examples of counters are found in U.S. Pat. No. 4,457,071 to Alphonso, U.S. Pat. No. 4,205,447 to Smith, U.S. Pat. No. 4,577,410 to Ritter and U.S. Pat. No. 4,481,714 to Nelson. Known systems which are suited for coiled tubing, are generally required to be installed in conjunction with the injector head or be positioned thereabove.
When counters are connected above the injector head, the counters are prone to errors due slippage on the tubing which is dirty and exposed to the environment. These counters are therefore typically unable to account for the errors due to slippage between the counting wheel and the tubing upon which the counting wheel is riding. Also, these counters are simply transported on the exterior of trucks in a manner such that they are exposed to various abuse during use and transport. Furthermore, positioning of the counter above the injector head does not take into consideration how much the tubing stretches and accordingly these types of counters are also inaccurate in addition to requiring considerable maintenance.
Counters which are supported in conjunction with the injector head typically rely on a mechanical connection to the components of the injector head which may be subject to failure due to the complexity of the mechanisms required. These types of counters are also unable to accommodate for stretch of the tubing suspended below the injector head and accordingly are also inaccurate.
SUMMARY OF THE INVENTION
According to one aspect of the invention there is provided a tubing counter for counting coiled tubing inserted into a well having an outer casing and a coiled tubing injector head connected above the outer casing, the counter comprising:
an outer housing having a through passage extending between ends of the housing for receiving the coiled tubing therethrough;
pressure rated connectors at both of the ends of the outer housing for sealably connecting the outer housing in series between the coiled tubing injector head and the outer casing of the well;
at least one counting wheel rotatably supported within the outer housing for rolling engagement along coiled tubing inserted through the outer housing; and
a counting mechanism for recording a number of rotations of said at least one counting wheel.
Use of a housing which can be connected with pressure rated connectors permits installation of the counter in series between the outer casing of the well and the injector head. The resulting counter provides a simple mechanism which is independent of the mechanisms of the injector head and which is protected within an enclosed housing. Locating the counter below the injector head and below the tubing stripper ensures that the tubing is cleaner and less likely to slip in contact with the counting wheels. Furthermore, location of the counter below the injector head accounts for stretching of the tubing for more accurate measurement of depth.
According to a further aspect of the present invention there is provided a tubing counter for counting coiled tubing inserted into a well having an outer casing and a coiled tubing injector head connected above the outer casing, the counter comprising:
an outer housing having a through passage extending between ends of the housing for receiving the coiled tubing therethrough;
connectors on the outer housing for connecting the outer housing in series with the coiled tubing injector head;
a plurality of counting wheels rotatably supported within the outer housing for rolling engagement along coiled tubing inserted through the outer housing; and
a counting mechanism for recording a number of rotations of each counting wheel independently of the other wheels.
Use of a plurality of counting wheels which independently record a number of rotations ensures that any slippage errors can be readily identified regardless of whether the counter is positioned above or below the injector head.
In preferred embodiments, the pressure rated connectors are preferably arranged for connection of the outer housing below the tubing stripper and below the BOP of the well.
The counting mechanism preferably includes a plurality of markers spaced circumferentially about each wheel and a sensor associated with each wheel which senses and records the markers being rotated past the sensor.
Preferably each wheel has a generally cylindrical outer surface for engaging the tubing in which the outer surface has a substantially constant outer diameter. The outer surface may include a gripping texture thereon.
There may be provided an upper funnel structure at one end of the outer housing and a lower funnel structure at the other end of the housing for guiding the tubing into and out of the outer housing respectively. Each funnel structure preferably includes an annular bushing for slidably receiving the tubing therethrough.
The plurality of counting wheels are preferably supported on opposing sides of the through passage in the housing for engaging opposing sides of the tubing. At least one counting wheel on one side of the through passage is preferably biased towards at least one counting wheel on the other side of the through passage.
Preferably the outer housing is pressure rated and receives an inner housing therein in which the inner housing rotatably supports the counting wheels thereon. The inner housing may be selectively supported within the outer housing by support members spanning generally radially between the inner housing and the outer housing at opposed ends of the outer housing.
There may be provided a pressure rated port in the outer housing receiving electrical connections therethrough. An epoxy material may surround the electrical connections in the pressure rated port.
According to a further aspect of the present invention there is provided a method of counting coiled tubing inserted into a well having an outer casing and a coiled tubing injector head connected above the outer casing, the method comprising:
providing a tubing counter comprising an outer housing having a through passage extending between ends of the housing and at least one counting wheel rotatably supported within the outer housing;
connecting the ends of the outer housing of the counter in series between the coiled tubing injector head and the outer casing of the well;
inserting the coiled tubing through the outer housing of the counter in rolling contact with said at least one counting wheel; and
counting a number of rotations of said at least one counting wheel.
The outer housing may be connected below the tubing stripper and the BOP of the well in one embodiment, or above the injector head in a further embodiment.
The method may include counting a number of rotations of each wheel independently of the other wheels and calculating an average number of rotations of the wheels.
The method may further include comparing the number of rotations of the wheels to one another and removing from the average, the number of rotations of any wheel which differs substantially from the other wheels.
Some embodiments of the invention will now be described in conjunction with the accompanying drawings in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevational view of the counter installed between the outer casing of the well and the coiled tubing injector head of the wellhead;
FIG. 2 is a partly sectional side elevational view of the outer housing of the counter;
FIG. 3 is a partly sectional side elevational view of the inner housing of the counter;
FIG. 4 is a top plan view of the inner housing of the housing;
FIG. 5 is a side elevational view of a pressure rated plug for receiving electrical connectors through the housing;
FIG. 6 is a partly sections plan view of one of the counting wheels;
FIG. 7 is an end view of one of the counting wheels; and
FIG. 8 is a side elevational view of the counter installed above the injector head of the wellhead.
In the drawings like characters of reference indicate corresponding parts in the different figures.
DETAILED DESCRIPTION
Referring to the accompanying Figures there is illustrated a coiled tubing counter generally indicated by reference numeral 10 . The counter 10 is particularly suited for oil or gas well operations involving coiled tubing 12 for counting the depth which the tubing is inserted into the well.
The counter 10 is typically used in an oil or gas well having an outer casing 14 terminating at a top end by a casing flange 16 which may connect a master valve 18 , a flow tee 20 having an auxiliary valve 22 and a primary well control 24 which includes a stripper 25 and a blow out preventer (BOP) as components of the wellhead. A coiled tubing injector head 30 is connected above the primary well control 24 . All of the wellhead components below the injector head, including the primary well control 24 are sealed with respect to the outer casing in such a manner so as to permit the components between the primary well control 24 and the outer casing to be pressurized.
Referring initially to FIGS. 1 through 7 , a first embodiment of the counter 10 is illustrated which is particularly suited for pressurized connection below the injector head 30 of the well.
The counter 10 includes an outer housing 32 which generally comprises a cylindrical casing forming a hollow tube having an open passage therethrough between opposing first and second ends 34 of the housing. The housing 32 is a pressure rated casing for use in the oil and gas industry.
Each end of the outer housing is threaded externally between axially spaced annular grooves 36 at an outer periphery thereof. The grooves 36 are arranged for receiving an annular sealing member therein.
Pressure rated connectors 38 are connected at each end 34 of the outer housing in sealing engagement therewith. The connectors 38 each include an inner end 40 which is cylindrical and which is internally threaded for mating with the threads at the ends 34 of the outer housing. A body of the connector 38 tapers inwardly through a central portion before joining with the outer end 42 which comprises an externally threaded collar for connection in series with the components of the well head.
The outer ends of the illustrated embodiment are designated 4 inch NPT, however any suitable connection of any size including threaded connections, flange connections, bowen unions or hammer unions could be used. The internally threaded portion of the inner end 40 of the connectors also includes annular grooves 44 therein which align with the grooves in the outer housing 34 for accommodating the sealing members received therein.
An inner housing 46 is received within the outer housing 32 for housing the working components within the counter with minimal modification being required to the outer housing during assembly to maintain the pressure rating of the outer housing. Internal shoulders 52 are formed within each connector 38 for abutting opposing ends of the outer housing when the connectors 38 are fastened thereon.
The inner housing 46 generally comprises two U-shaped channel members 48 , each having base portion 48 A and two side wall portions 48 B. The channel members 48 are mounted with the open sides confronting one another and the free ends of the side wall portions 48 B being abutted with those of the opposing channel so that the resulting assembled inner housing 46 is rectangular in cross section and elongate in the longitudinal direction of the outer housing. A mounting flange 48 C is provided along each free end of the side wall portions which is oriented perpendicular to the respective side wall portion so as to lie flat and parallel in abutment with the mounting flange of the opposing channel when mounting the channels together to assemble the inner housing. Suitable fasteners can be used to fasten the mounting flanges 48 C together.
The inner housing has open ends for receiving the tubing therethrough. Also, the inner housing is near in length to the outer housing for being retained between the connectors at opposing ends of the outer housing. A pair of mounting plates 50 are provided at opposing ends of the inner housing 46 for supporting the inner housing within the outer housing. Each mounting plate 50 is circular and spans the interior diameter of the outer housing. A central opening in each plate 50 is suitably shaped for receiving the abutted channel members 48 therethrough. The mounting plates 50 thus span radially between the inner housing and the outer housing about a full circumference at spaced apart locations at opposing ends of the housings to support the inner housing within the outer housing.
Each mounting plate 50 is divided into two halves corresponding to the two channel members forming the inner housing so that the two halves of each mounting plate can be separated when the channel members are separated for ease of access to internal components of the inner housing.
The inner housing supports a set of four counting wheels 54 therein. Each wheel is supported for rotation by bearings on a respective shaft 56 which spans between opposing side plates of a carriage 58 supporting the wheel thereon. Each carriage 58 extends inwardly from a respective base portion of one of the channel members 48 and is supported for movement in a horizontal direction which is perpendicular to the longitudinal direction between ends of the housing so that the counting wheels 54 are permitted to be displaced towards and away from the coiled tubing which extends longitudinally through the housing. A set of four springs 59 in a rectangular configuration support each carriage 58 on the respective channel member for biasing the counting wheels inwardly towards the coiled tubing and towards opposing counting wheels.
The counting wheels 54 are mounted within the inner housing in two pairs which engage opposing side of the coiled tubing and accordingly the two pairs of wheels define a channel or through passage extending therebetween through which the tubing is received. The pairs of wheels are longitudinally staggered so that one wheel of each pair is longitudinally centered between the opposing pair of wheels. The springs 59 support the wheels to be biased inwardly towards the opposing pair of wheels.
Each wheel includes a set of four markers 60 , in the form of magnets, supported at equally circumferentially spaced positions about the wheel. A corresponding sensor 62 is supported on the internal housing for alignment with the markers 60 of each wheel as the wheel is rotated. The sensor 62 detects each time the magnet passes as the wheel is rotated. The radius of the magnet and sensor from the shaft 56 is arranged to correspond to an even unit of measure for each complete rotation of the wheel.
An outer surface 64 about the periphery of each wheel 54 is generally flat and cylindrical in shape so as to have a substantially constant outer diameter. The surface 64 has a knurled gripping texture for gripping the tubing to ensure that the wheels rotate and ride along the tubing as the tubing is displaced longitudinally through the housings. The flat outer surface 64 ensures that a portion of the circumference of the coiled tubing is engaged with the tubing at all times as the wheel rides along the side of the tubing extending through the housing regardless of the size and shape of the tubing.
A funnel member 66 is provided at both top and bottom ends of the outer housing to guide the coiled tubing therethrough. Each of the funnel members 66 tapers inwardly and downwardly from top to bottom in the direction which the tubing is first inserted through the housing.
At the top end of the housing, the funnel member 66 comprises a sleeve supported within the outer end of the connector 38 . The sleeve includes a tapered shoulder 67 A which slopes downwardly and inwardly towards a central opening 67 B of reduced diameter. A bushing 67 C is supported within the central opening which has an upper end face which is similarly sloped downwardly and inwardly so as to be continuous in profile with the tapered shoulder 67 A of the funnel member. A central opening in the bushing receives the tubing therethrough.
At the bottom end of the housing, the funnel member 66 comprises a bushing 68 A which is elongate and cylindrical. A top end face 68 B at an inner end of the bushing 68 A is sloped downwardly and inwardly so as to be continuous in profile with the inner surface 68 C of the body of the connector 38 extending between the inner and outer collars of the lower connector.
A downwardly and outwardly facing shoulder is formed about the bushing 68 A for engaging a split retainer ring 69 which retains the bushing 68 A in position within the outer end of the lower connector 38 . The ring 69 is received within a mating annular groove within the internal surface of the lower connector 38 .
A split retainer ring 69 is also received within a mating annular groove in the sleeve forming the upper funnel member 66 to retain the bushing 67 C axially in position.
The bushings 68 A and 67 C comprise guide collars formed of a material having a low coefficient of friction, for example neoprene, Teflon or nylon, and have an internal diameter which is only slightly greater than the coiled tubing for receiving the tubing therethrough with minimal frictional resistance. Both of the bushings are aligned axially with one another in the longitudinal direction and with the longitudinal channel or through passage defined between the opposing pairs of rollers.
Each of the sensors 62 communicates with a computer controller 70 externally of the housing through a pressure port 72 A provided through a side wall of the outer housing. The pressure port 72 A comprises a bore formed in the outer housing which receives a pre-manufactured, internally threaded sleeve which is welded in place within the bore. The sleeve is pressure rated. One such example of a sleeve is available under the trade name Thread-a-let.
A commercially available and pressure rated plug 72 B, having external threads, is mounted within the sleeve defining the pressure port 72 A in sealing engagement therewith. The plug includes electrical connections 74 extending therethrough and in communication betweens the sensors 62 and the controller 70 . Annular grooves 72 C are formed in the internal surface of the plug 72 B for receiving epoxy which seals between the electrical connections and the plug.
The controller 70 records the signals from the sensors 62 which detect each time a magnet is rotated past it. The controller maintains a log of the total revolutions for each wheel and compares the tally or count of the revolutions of the wheels to one another. Whenever one of the wheels differs from the majority, a flag is marked on the log to indicate an error, for example due to slippage of one of the wheels 54 . The controller averages the number of revolutions counted by each wheel unless the number of revolutions of one of the wheels differs substantially from the remaining wheels. In this instance, the controller only averages the number of revolutions of wheels which are near in magnitude to one another to produce very accurate counts.
In a further embodiment shown in FIG. 8 , the counter 10 may instead be mounted above the injector head 30 . In this instance, the outer housing and connectors are not required to be pressure rated or sealably engageable with the components of the well. All of the details with regard to the mounting and configuration of the counting wheels in the second embodiment remain substantially identical to the first embodiment noted above for similarly determining when slippage errors have occurred by comparing numbers of rotations of the plurality of counting wheels. When mounting above the injector head 30 , the counter does not take into account the stretch of the tubing below the injector head, but the increased counting accuracy due to multiple counting wheels being provided remains an advantage regardless of the placement of the counter 10 .
Since various modifications can be made in my invention as herein above described, and many apparently widely different embodiments of same made within the spirit and scope of the claims without department from such spirit and scope, it is intended that all matter contained in the accompanying specification shall be interpreted as illustrative only and not in a limiting sense. | A tubing counter for counting coiled tubing inserted into a well includes an outer housing having a through passage for receiving the coiled tubing therethrough. In some embodiments, pressure rated connectors at both of the ends of the outer housing sealably connect the outer housing in series between the coiled tubing injector head and the outer casing of the well. A plurality of counting wheels are rotatably supported within the outer housing for rolling engagement along coiled tubing inserted through the outer housing while a counting mechanism records a number of rotations of each counting wheel independently of the other wheels to minimize counting errors. Locating the counter below the injector head and below the tubing stripper ensures that the tubing is cleaner and less likely to slip in contact with the counting wheels while also accounting for stretching of the tubing for more accurate measurement. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to the manufacture of containers and primarily to the preliminary assembly of a hollow sleeve preform onto an upper extremity of a container for subsequent shrinking in situ thereon. The preform is taken from a stored, flattened condition to a position immediately above the container where it is fully opened and moved into co-axial alignment with the container. The preform is transported downwardly by a pair of pivoted juxtaposed vacuum cups which move downwardly and divergently to open the preform and move it into proximity with the upper portion of the container. The two components are moved into telescopic assembly on intersecting paths of movement. The final shrinking of the preform onto the container, as may be performed by many appropriate physical conditions, is not part of this invention.
2. Description of Prior Art
This invention comprises an improvement over the methods and apparatus disclosed in issued U.S. Pat. Nos. 3,767,496, issued Oct. 23, 1973; 3,802,942 issued Apr. 9, 1974; and U.S. Pat. No. 3,959,065 issued May 25, 1976, all of which are commonly owned by the same assignee as the present application. In each of these disclosures, a tubular sleeve is formed which is telescopically assembled onto the article from below by a push-up mechanism. None of these disclosures pertain to a semi-rigid sleeve which is stored in flattened, prefabricated condition and then telescoped over the container in a telescoping operation with minimum apparatus to permit efficient and rapid assembly.
In many of the previously-disclosed processes and apparatuses for making composite containers having an integral plastic base or sleeve thereon, a manufactured glass bottle or jar is loaded onto a conveyor and preheated prior to mounting the plastic sleeve. The plastic sleeves carried on an underlying turret pass into alignment with the bottles and are moved vertically upwardly into telescopic assembly over the lower ends of the bottles. The sleeves are then carried on the bottles into a heating apparatus such as a tunnel oven wherein appropriate physical conditions shrink the sleeves into close-fitting conforming arrangement over the bottle surfaces where assembled. The heating apparatus commonly consists of a lengthwise oven through which the bottles are passed, the oven temperatures ranging from about 170° to 800° F., depending upon the plastic material selected to comprise the sleeves. U.S. Pat. No. 3,959,065, owned by the common assignee of this application, discloses method and apparatus which assure against dislocation of the sleeve on the bottle without external handling mechanism being required to hold the sleeve in place between its assembly point with the bottle and the shrinking oven.
The cap sealing of bottles has been conventionally performed in recent years to provide for reasons of sanitation, pilfer-proofing, safety and appearance, the further step of placing over and around the neck of the bottle, as well as preferably over at least part of its closure, a tubular sleeve of heat-contracting synthetic resin material, severed to a prescribed length, and then sealing the sleeve to the bottle by thermal contraction. The synthetic resin tubing is usually pressed flat and delivered in rolls in many production processes, and since the tubing may or may not stay fully flattened, particularly where it is comprised of extremely flexible and resilient material, inefficiencies can and do result when the severed lengths of tubing are fitted onto the bottle necks. In some cases, to facilitate the fitting of the short, flat, tubular sleeves onto the necks of bottles, it has been common practice to preform the sleeves such as by putting perforations or scores along their fold lines. It is also possible to apply the tubes around the bottle necks without preforming the material, as taught by U.S. Pat. No. 3,861,918 to Muto; however, such method requires the application of a bonding agent to the bottle neck for adherence of the sleeve. The method and apparatus disclosed by this patent are exceedingly more complex and prone to occasional misapplication of the tubular band or label. U.S. Pat. No. 2,852,899 to Murrell discloses a collar feeding mechanism which is designed to remove only the lowermost collar from a nested stack by frictional engagement with its inner surface. The collars are preformed and nested tightly into a stack from which they are deliverable onto the container necks.
SUMMARY OF THE INVENTION
An object of this invention is to provide apparatus and method for positively opening a flat-folded, tubular, band or sleeve of relatively-rigid material and placing the same telescopically over the top of a container while both are being continuously moved into axial alignment and subsequently moving the sleeve into further telescopic engagement over the container upper region while it is supported only by the container neck.
The present invention as disclosed hereinafter in a specific preferred embodiment provides both apparatus and method for applying a preformed, relatively-rigid tubular band or sleeve to an upper neck region of a container where it is frictionally retained prior to subsequent heat shrinking of the band onto the container into final conforming relationship. The invention permits opening and telescopic assembly of the band onto the container upper region in a single operation with the band in free-standing partial telescopic arrangement on the container neck. The band is formed of relatively-stiff material and stored in flat-folded condition in a stack with an open end lowermost adjacent a pair of vertically movable facing vacuum cups aligned in spaced-apart relation. The vacuum cups serve to remove the bands serially from the supply source and open each flat-folded band during its downward travel. During its downward travel, a leading edge of the opened band is engaged by an upper region of the container in timed relation so that the band is telescoped thereover.
A major feature of the invention is a vacuum pick-up device capable of delivery of an individual tubular preform in nearly completely opened condition from a nested stack of flattened preforms to a container upper region for disposition thereon prior to its complete opening when in telescoped vertical alignment.
A further feature of the invention is the provision of the vacuum pick-up device mounted adjacent the stack of flattened tubular preforms to assure delivery of an individual sleeve to the container neck region even at accelerated rates of operation of the combined apparatus.
A still further feature of the invention is the telescopic movement of the tubular sleeve over the container neck while supported by a pair of diverging vacuum cups for convenient and economical application thereof onto the container neck during their continuous movement at production speed prior to heat shrinkage of the sleeve onto the surrounded circumferential surface area which sleeve may also provide a pilfer-proofing feature.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevational view of a machine for applying tubular plastic sleeves onto bottles incorporating the improvements of the present invention.
FIG. 2 is a side elevational view of another version of the present invention wherein a series of cylindrical mandrels is employed intermediate one portion of the FIG. 1 machine and the containers for more fully opening the tubular plastic sleeves.
DESCRIPTION OF PREFERRED EMBODIMENT
As shown in FIG. 1 of the drawings, the apparatus for producing containers with plastic sleeves thereon consists of a banding machine 10 which is adapted to receive and downwardly convey the sleeves 11 while they are simultaneously being opened. The containers 12 preferably consist of hollow rigid, glass or plastic bottles which may or may not have a closure 13 thereon, thus being either in filled or unfilled condition, as desired.
As shown in FIG. 1, the containers 12 are delivered to the banding machine 10 serially in spaced-apart arrangement by a worm feed device 14 which is rotated in synchronism with movement of a linear conveyor 15. Conveyor 15 is of conventional construction normally adapted to convey the containers in upright contacting relation between a pair of parallel side rails. The worm feed device 14 is designed to receive a lineal alignment of upright containers in physically-contacting, close relation from the conveyor 15 and separate the same into equally-spaced arrangement for delivery to the machine 10. Normally the worm feed device 14 has either one or two continuous screw thread elements 16 with a pitch distance generally complemental to the desired spacing of the containers for their continuous delivery to the banding machine. The screw thread elements of the worm feed device 14 are aligned parallel to and above conveyor 15 to receive the lineal alignment of upright containers in physically-contacting relation and separate them into equi-spaced arrangement for passage through the banding machine 10. The axes of thread elements 16 of the worm feed device 14 extend horizontally, the thread elements replacing the conveyor side rails (not shown) for a limited distance.
A stack of folded sleeves 11 is held in a suitable holder 20 having dimensions closely complemental to the retained flattened stack of sleeves. The holder is slightly smaller at the sides of its exit area. The sleeves 11 are uniformly and tightly packed in flattened condition aligned vertically with an open end lowermost in the stack, as shown in FIG. 1. The sleeves are retained flat-folded in the holder 20 so that an individual vacuum cup 25 must exert some pulling pressure on the outermost sleeve to pull it from the sightly restricted area of the holder and in so doing partially open the sleeve. The tubular sleeves are prefabricated either seamless or having an axial fusion seal along one side. The sleeves are formed having a slightly greater diameter than the exterior diameter of the container neck area and closure, and folded flat at opposing sides so that the seal line extends along one flat side.
The sleeves 11 are preferably comprised of foamed medium impact polystyrene or foamed polyethylene having a wall thickness ranging from 0.002 to 0.030 inch. The material has a preferred density of 2 to 30 pounds per cubic foot with the primary orientation extending in a circumferential direction around the preformed sleeves. The preformed sleeves are relatively-rigid or semi-rigid having a stiffness in Taber units of 22 to 26 around the sleeve circumference, and 7 to 11 in the axial direction of the sleeve. Taber units are a well known measure of stiffness used in the paper industry. The sleeves are heat-shrinkable both circumferentially and axially due to orientation of the material as formed to facilitate shrinkage around the surrounded surfaces.
A series of equi-spaced vacuum cups 25 adapted to receive the sleeves 11 is mounted on a conveyor chain 26 which is trained around a series of rotatable sprockets 27. At least one of the sprockets is driven by a suitable power source (not shown) so that the driven chain is capable of rotating the vacuum cups 25 at a prescribed lineal speed in a vertical plane. The primary vertical reach of the chain extends from the delivery end of sleeve holder 20 to closely adjacent the upper extremity of the conveyed containers 11 so that each sleeve may be moved continuously downwardly. Each of the vacuum cups 25 is mounted on the chain 26 in pivotal relation so that the cups can move freely during pick-up and delivery of an individual sleeve 11.
A second drive chain 30 is mounted closely adjacent and parallel to chain 26 so that the facing reaches of the chains extend downwardly and divergently in a vertical direction. Second chain 30 also has a series of spaced-apart vacuum cups 31 thereon aligned having the same spacing as the cups 25 on chain 26. At least one of the sprockets 32 of chain 30 is driven by a suitable power source so that chains 26 and 30 are operated in synchronism at the same circumferential speed. Thus, while the chains are different lengths as shown in FIG. 1, i.e., with one having five vacuum cups and the other four, the chains are operated together in such manner that the two cups are moved in facing relation during the downward travel of the juxtaposed cups. Cups 25 and 31 are mounted on pivotal mounting members 28 and 33 on the respective chains so that the cups are free to move laterally.
The cups 25 and 31 are mounted on the chains so that they meet slightly off-center so that a vacuum cup is not pulled off by a facing pair in precise alignment contacting each other without a sleeve therebetween. The upper end of longer chain 26 is adapted to be moved laterally toward and away from the delivery end of sleeve holder 20 so that smooth most efficient pick-up of an individual sleeve is ensured. As a vacuum cup 25 passes over upper sprocket 27, it passes into close proximity with the outermost sleeve 12 to contact and engage the same by pressure contact. Positive vacuum is maintained on each of the cups 25 during operation of the machine through a vacuum manifold (not shown) traveling with chain 26. Similarly positive vacuum is maintained on cups 31 mounted on chain 30. The two chains 26 and 30 are mounted with their planes of rotation substantially perpendicular to the direction of travel of containers 12 on conveyor 15.
Following pick-up of an individual sleeve 11 by vacuum cup 25, the sleeve is conveyed downwardly where it is immediately engaged by second juxtaposed vacuum cup 31. The two cups thus contact and engage opposing sides of the flattened sleeve 11. As the two cups move downwardly and divergently, the sleeve is continuously moved and opened therebetween into nearly completely opened condition.
When the sleeve 11 nears the end of its continuous downward travel while retained by both cups 25 and 31, the lowermost edge is contacted by the upper extremity of the container, i.e., its closure 13 or upper surface contacting the leading edge of the sleeve 11 adjacent a fold line to assist its mounting on the container neck portion. Thus, as the sleeve continues its downward travel while held by cups 25 and 31, the container during its continuous movement helps to guide the sleeve thereon while the cups are free to turn pivotally at the sides of the moving container neck. As the cups complete their lowermost travel and are moved away as chains 26 and 30 travel arcuately around the lowermost sprockets, and the cups lose contact with the sleeve by breaking the vacuum, the sleeve is free to fall by gravity onto its desired temporary position on the container neck. The conveyor 15 is continuously operated in precisely timed sequence with the two chains bearing cups 25 and 31 in order to bring the container and sleeve into proper intersecting relation for most efficient sleeve application.
Containers 12 having sleeves 11 mounted thereon in temporary alignment are then continuously moved further by conveyor 15 to a heat-shrinking operation. Depending upon the selection of the thermoplastic material for sleeves 11, the containers bearing the sleeves are passed through a tunnel oven (not shown) having an internal temperature ranging from about 170° to 800° F. The sleeves then rapidly shrink and conform to the underlying surface areas therebeneath. The sleeves due to their extensive circumferential orientation are able to shrink tightly around the closure and neck areas thus providing a tamper-proofed structure.
An alternative form of the present invention is shown in FIG. 2. The containers 12 are continuously transported past the sleeve-applying station by worm screw elements 16 while still retained on conveyor 15. The same pair of downwardly and divergently rotatable chains 26 and 30 as shown in FIG. 1 is mounted above the containers. Intermediate the moving containers and the lower extremity of the chain sprockets 27 and 32 is located a third chain 35 bearing a spaced-apart series of cylindrical mandrels 36. The chain 35 is mounted having two horizontal reaches, the lower being parallel and adjacent the upper extremity of the conveyed containers. The upper reach extends adjacent and in the path of the two vacuum cups 25 and 31 so that an individual sleeve 11 may be deposited on an individual mandrel 36 as indicated by the arrow in FIG. 2. The sleeve in nearly fully opened condition as it nears the lower end of the two chains 26 and 30 is dropped down onto the mandrel 36 which serves to more fully open same. Chain 35 is driven by one of the two sprockets 37 being powered so that it travels in a counterclockwise direction with its lower reach continuously moving in the same direction as conveyor 15. The sleeves 11 are serially loaded onto mandrels 36 which continuously move in timed relation to delivery of the sleeves from the pair of vacuum cups. The sleeves upon entry onto the mandrels 36 fall downwardly against a stripper element 38 which surrounds each mandrel and is movable thereon. After the sleeves pass around the sprocket 37 near the incoming side of conveyor 15, the stripper element is operated downwardly by a camming mechanism to remove the sleeve from its supporting mandrel and the sleeve is placed on a container upper region moving coaxially therebelow. Once the sleeve is placed thereon, vibratory forces of the container being moved along conveyor 15 to serve to further lower the sleeve into its temporary position for heat-shrinking.
The sleeve 11 is shown below closure 13 in FIG. 2 although it may be mounted to surround both the closure and exposed container neck portion immediately below for heat-shrinking therearound.
In the modification shown in FIG. 2, mandrel chain 35 is operated in precisely timed sequence with both the vacuum cups 25 and 31 as well as conveyor 15 to ensure that the sleeves are received on each mandrel 36 and that each mandrel deposits its retained sleeve 11 on a container. Timing is capable of conventional practice where all elements are operated by a central power source.
Various modifications may be resorted to within the spirit and scope of the appended claims. | This invention relates to apparatus and method for producing a composite container having a neck label or tubular sleeve mounted temporarily thereon adapted to be shrunken into final surface covering relation. The tubular sleeve is preformed of relatively-stiff material and flat-folded until ready for use when it is fully opened and conveyed into vertical alignment with a container therebeneath. The sleeve preform comprised of heat-shrinkable plastic material is telescopically assembled onto the container while the latter is transported in spaced upright arrangement. The preform is moved downwardly by a pair of gripping vacuum cups moving downwardly and divergently to open the preform and place the same telescopically on the container upper portion. Alternately, the opened preform is placed on a cylindrical mandrel to more fully open the preform prior to its being mounted telescopically on the container neck portion. The preform on the upper portion of the container in finally-aligned relation is then adapted to heat-shrinking in place in permanent conforming arrangement. | 8 |
BACKGROUND
[0001] The present disclosure relates generally to information handling systems, and more particularly to a work content variation control system.
[0002] As the value and use of information continues to increase, individuals and businesses seek additional ways to process and store information. One option is an information handling system (IHS). An IHS generally processes, compiles, stores, and/or communicates information or data for business, personal, or other purposes. Because technology and information handling needs and requirements may vary between different applications, IHSs 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 IHSs allow for IHSs 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, IHSs 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.
[0003] IHSs are typically assembled in an assembly line where parts are added and software is installed in a process that begins with a number of part and ends with a finished product. In an effort to significantly reduce manufacturing costs in a highly configurable build to order environment (e.g., in an IHS build to order environment), a progressive assembly line (e.g., lean lines) may be implemented in the manufacturing facility. Traditionally, an assembly line works best in a low work content variation environment. This may be due to the fact that high work content variation results in assembly line inefficiencies because the slowest assembly station in the assembly line may shift each time a different configuration is assembled. In other words, the production line is as fast as the slowest station and as the configuration changes, the slowest portion of the assembly time or the bottleneck, may move from one station to another station because different parts or different numbers of parts are being assembled at a given station.
[0004] As such, what is needed is work content variation control system to develop rules that production control can use to schedule factory assembly, while minimizing work content variation in the lean lines. The system may minimize work content variation at the platform level within a setup which results in better assembly line efficiencies, improved flow throughout the manufacturing factory and a better rate predictability per setup.
[0005] Accordingly, it would be desirable to provide an improved work content variation control system absent the disadvantages discussed above.
SUMMARY
[0006] According to one embodiment, a work content variation control system includes an apparatus having a computer-readable medium encoded with a computer program. The computer program, when executed, receives order data for a family grouping of a plurality of ordered products, converts the order data to work content, groups the order data with like order data with respect to the work content, creates parsing rules with respect to the work content and defines setup rules for use to schedule assembly of the ordered products.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 illustrates a block diagram of an embodiment of an information handling system (IHS).
[0008] FIG. 2 illustrates an embodiment of a graph showing % of volume vs. configurations sorted by work content and work content time used in an embodiment of a work content variation control system.
[0009] FIG. 3 illustrates a high-level flow chart of an embodiment of a method for work content variation control.
[0010] FIG. 4 illustrates a detailed flow chart of an embodiment of a method for work content variation control.
[0011] FIG. 5 a illustrates a chart showing embodiments of different parsing rules for use in the methods provided in FIGS. 3 and 4 .
[0012] FIG. 6 illustrates embodiment of three balanced bar charts showing work content at each of a number of work stations along an assembly line.
DETAILED DESCRIPTION
[0013] For purposes of this disclosure, an IHS 100 includes 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, or other purposes. For example, an IHS 100 may be a personal computer, a network storage device, or any other suitable device and may vary in size, shape, performance, functionality, and price. The IHS 100 may include random access memory (RAM), one or more processing resources such as a central processing unit (CPU) or hardware or software control logic, read only memory (ROM), and/or other types of nonvolatile memory. Additional components of the IHS 100 may include one or more disk drives, one or more network 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 IHS 100 may also include one or more buses operable to transmit communications between the various hardware components.
[0014] FIG. 1 is a block diagram of one IHS 100 . The IHS 100 includes a processor 102 such as an Intel Pentium™ series processor or any other processor available. A memory I/O hub chipset 104 (comprising one or more integrated circuits) connects to processor 102 over a front-side bus 106 . Memory I/O hub 104 provides the processor 102 with access to a variety of resources. Main memory 108 connects to memory I/O hub 104 over a memory or data bus. A graphics processor 110 also connects to memory I/O hub 104 , allowing the graphics processor to communicate, e.g., with processor 102 and main memory 108 . Graphics processor 110 , in turn, provides display signals to a display device 112 .
[0015] Other resources can also be coupled to the system through the memory I/O hub 104 using a data bus, including an optical drive 114 or other removable-media drive, one or more hard disk drives 116 , one or more network interfaces 118 , one or more Universal Serial Bus (USB) ports 120 , and a super I/O controller 122 to provide access to user input devices 124 , etc. The IHS 100 may also include a solid state drive (SSDs) 126 in place of, or in addition to main memory 108 , the optical drive 114 , and/or a hard disk drive 116 . It is understood that any or all of the drive devices 114 , 116 , and 126 may be located locally with the IHS 100 , located remotely from the IHS 100 , and/or they may be virtual with respect to the IHS 100 .
[0016] Not all IHSs 100 include each of the components shown in FIG. 1 , and other components not shown may exist. Furthermore, some components shown as separate may exist in an integrated package or be integrated in a common integrated circuit with other components, for example, the processor 102 and the memory I/O hub 104 can be combined together. As can be appreciated, many systems are expandable, and include or can include a variety of components, including redundant or parallel resources.
[0017] In an embodiment, the present disclosure provides a work content variation control system to create rules that production control can use to schedule assembly processes for build-to-order products. One example is to use the work content variation control system of the present disclosure to plan assembly of IHSs by scheduling like systems/processes with like systems/processes on a given assembly line to create similar operation times (e.g., work content) at each of a plurality of work stations along an assembly line. In other words, if, for example, an IHS manufacturing facility has three assembly lines for assembling IHSs, the ordered IHSs that require assembly steps of similar duration in time may be assembled on the same one of the three assembly lines. Thus, the IHSs requiring the lowest operation times may be assembled on line 1 , those requiring the highest operation times may be assembled on line 3 and those in between, may be assembled on line 2 . As such, down-time at each station along the assembly line will be minimized to improve assembly line efficiencies and create an improved assembly product flow. A factor in determining scheduling may be at a platform level of an IHS family to reduce set-up for the assembly lines.
[0018] The work content variation control system of the present disclosure may be used to parse work content variation and create rules that production control can use to schedule manufacturing in an assembly line environment.
[0019] In an embodiment, the system may use historical data and/or market trends to receive order data and converts unique part numbers (PNs) to unique commodities (e.g., Hard Drives, Processors, etc.). Then, based on actual time studies (or estimates for new product platforms) the system assigns an install/assembly cycle time for each commodity at a given work station along the assembly line. At this point total work content may be calculated per system that is to be assembled. Then, based on total work content, the system may investigate what are the main commodities that drive work content cycle time variability within the platform/family. Once the commodities that drive variability are identified, the parsing rules are created and communicated to production control to schedule manufacturing for each available assembly line so that each line is assembling systems having similar work time at each operation station along the assembly line, thereby minimizing down time at any one station along the line.
[0020] It should be understood by a person having ordinary skill in the art that an embodiment of the present disclosure combines actual assembly cycle times per commodity with unique configurations to mathematically predict work content variation within a platform or product family. It should also be understood that an embodiment of the present disclosure provides a way for comparing each individual commodity versus total work content to determine which assembly processes are the main contributors to work content variation. In addition, it should be understood that an embodiment of the present disclosure provides parsing rules that are based on those commodities that drive total work content variation at a product platform level. In an embodiment, a visual system of analyzing a range of configurations within a platform is provided and thus, allows for filtering out the main commodities contributing to work content variation. In addition, once the parsing rules are setup in a factory planner/scheduling tool, the process may be automated. Using automation, minimal intervention is needed from production control.
[0021] FIG. 2 illustrates an embodiment of a graph showing % of volume vs. configurations sorted by work content and work content time (e.g., in seconds) vs. configurations sorted by work content used in an embodiment of a work content variation control system. The % volume is shown as line 136 . The work content is shown as line 138 . Using a work content variation control system, a production control planner can improve efficiency of each of a plurality of assembly lines by scheduling work on the assembly line having a high efficient use of each assembly/work station on each assembly line. Using the graphical depiction of FIG. 2 , a planner can schedule work for each assembly line based on the work content (e.g., amount of time) for each station along the assembly process for the IHS. In other words, IHSs ordered having a low work content for each assembly step are shown as low work content systems 140 . IHSs ordered having a medium work content for each assembly step are shown as medium work content systems 142 A and 142 B. And, IHSs ordered having a high work content for each assembly step are shown as high work content systems 144 . As should be understood, the system of FIG. 2 could support 4 assembly lines (e.g., 140 , 142 A, 142 B and 144 ). However, any number of assembly lines and any number of work stations on each assembly line may utilize the systems and methods of the present disclosure.
[0022] FIG. 3 illustrates a high-level flow chart of an embodiment of a method 150 for work content variation control. The method 150 starts at 152 where orders have been received. In an embodiment, the orders may be for build-to-order IHSs, such as the IHS 100 . However, the systems of the present disclosure may be utilized on assembly of any type of product. The method 150 then proceeds to block 154 where the method 150 pulls order data to determine family groupings of the orders. By grouping families of orders the method 150 may recognize families such as server IHSs, notebook IHSs, desktop IHSs, or even different product lines within each of these different types of IHSs. Other types of family groupings may be used. The method 150 then proceeds to block 156 where the method 150 reviews the orders, determines what parts or assemblies are required for each order and converts the order to a work content for a particular order. In other words, the method 150 determines how much time will be required to assemble the ordered IHS and how much time will be required at each assembly station for the particular order. The method 150 then proceeds to block 158 where the method groups similar work content orders by creating groups where the orders in each group have similar work content requirements as a whole, and/or in each work station along the assembly line. For example, the method 150 may group orders into groups for low work content systems 140 , medium work content systems 142 A, 142 B and high work content systems 144 , as seen in FIG. 1 .
[0023] The method 150 then proceeds to block 160 where the method 150 creates parsing rules with respect to work content for the orders. As such, the method 150 creates rules to parse or break-up assembly of the ordered products (e.g., IHSs) into multiple work station operations along the assembly path. For example, assembly of an IHS may be parsed into groupings for adding parts to a chassis or a mother board. The added parts may include a number of processors 102 , a number of memory modules 108 , a number of hard drives 116 , a number of expansion cards/peripherals 128 , such as the graphics processor 110 , the I/O controller 122 , and/or a variety of other devices. The method 150 then proceeds to block 162 where the method defines set-up rules for an IHS (e.g., IHS 100 ) to use to schedule assembly of a plurality of orders along a plurality of assembly lines using the rules parsed in block 160 . The rules may be defined by features such as a volume/number limits for parts to be added. For example, a rule may be that an order requiring ≦1 processors 102 , ≦4 memory modules 108 , ≦2 hard disk drives 116 and ≦5 expansion cards 128 are scheduled to be assembled on the assembly line for low work content systems 140 . See FIG. 5 . In another example, a rule may be that an order requiring ≦2 processors 102 , ≦4 memory modules 108 , ≦4 hard disk drives 116 and ≦6 expansion cards 128 are scheduled to be assembled on the assembly line for medium work content systems 142 . See FIG. 5 . In yet another example, a rule may be that an order requiring ≦2 processors 102 , ≦8 memory modules 108 , ≦4 hard disk drives 116 and ≦ 8 expansion cards 128 are scheduled to be assembled on the assembly line for high work content systems 144 . See FIG. 5 . It is to be understood that other factors may be used to create the rules and other values may be used to create the rules.
[0024] The method 150 then proceeds from block 162 to block 164 where the method 150 communicates the rules defined in block 162 to a scheduling IHS, such as the IHS 100 , so that the scheduling IHS may calculate an assembly schedule. The calculated assembly schedule may then be communicated to a production control group for setting-up the manufacturing/assembly of the ordered products along the respective assembly lines per the schedule and the products may then be assembled. The method then ends at block 166 .
[0025] FIG. 4 illustrates a detailed flow chart of an embodiment of a method 170 for work content variation control. The method 170 is similar to method 150 described above with respect to FIG. 3 . The method 170 starts at 172 where orders have been received. In an embodiment, the orders may be for build-to-order IHSs, such as the IHS 100 . However, the systems of the present disclosure may be utilized on assembly of any type of product. The method 170 then proceeds to block 174 where the method 170 pulls order data to determine family groupings of the orders. By grouping families of orders the method 170 may recognize families such as server IHSs, notebook IHSs, desktop IHSs, or even different product lines within each of these different types of IHSs. Other types of family groupings may be used. Next, the method 170 proceeds to decision block 176 to determine whether a sample size is relevant to allow for accurate validation. In an embodiment, a sample size may be relevant if it includes more than 1000 samples. However, it is to be understood that any number of samples may be used. If no, the number of samples is not relevant, the method 170 returns to block 174 . If yes, the number of samples is relevant, the method 170 proceeds to block 178 where the method 170 creates a summary of all build part numbers from the sample. The build part numbers may be the part numbers for the parts used to assemble the ordered products. The method 170 then proceeds to block 180 where the method 170 converts the build part numbers to unique commodities. The method 170 then proceeds to block 182 where the method 170 assigns work content time (e.g., the amount of time for a given operation) per commodity, where the assigned time is based on actual historical recorded times for similar work. The method 170 then proceeds to block 184 where the method 170 calculates a cumulative work content value for each of the ordered products. This calculated value may include a sum of the work content values (e.g., work times) for each step in an assembly process for each of the ordered products.
[0026] After calculating the cumulative work content per system at block 184 , the method 170 then proceeds to decision block 186 where the method determines whether the calculated work content is validated by being similar to work content values for similar products previously assembled. If no, the calculated work content is not validated, the method 170 returns to block 180 . However, if yes, the calculated work content is validated, the method 170 proceeds to block 188 where the method 170 sorts the ordered products/systems from least complex (e.g., least added parts) to most complex (e.g., most added parts). The method 170 then proceeds to block 190 where the method creates a total work content 138 and volume curve 136 , such as that shown in FIG. 2 . The method 170 then proceeds to block 192 where the method 170 determines cutoff points 192 A and 192 B along the curves (e.g., 136 , 138 ). The method 170 then proceeds to block 194 where the method 170 checks each commodity work content versus the total work content curve.
[0027] After the method 170 checks each commodity work content versus the total work content curve at block 194 , the method 170 then proceeds to decision block 196 to determine whether commodity work content follows the total work content curve. If no, the commodity work content does not follow the total work curve, the method 170 proceeds to block 198 where the method 170 does not use the commodity to define the rules. On the other hand, if yes, the commodity work contend does follow the total work curve, the method 170 proceeds to block 200 where the method 170 determines quantity rules based on cutoffs defined in the total work content curve (e.g., work content curve 138 ). The quantity rules may relate to a quantity of parts needed to complete assembly of the ordered products. The method 170 then proceeds to block 202 where the method 170 defines setups for the assembly process based on top or most common commodities. The method 170 then proceeds to block 204 where the method 170 applies the rules to historical data from similarly produced products.
[0028] After the method 170 applies the rules to historical data from similarly produced products at block 204 , the method 170 proceeds to decision block 206 to determine whether the setup rules validate the projected order groupings. If no, the setup rules do not validate the projected order groupings, the method 170 returns to block 192 . On the other hand, if yes, the setup rules do validate the projected order groupings, the method 170 proceeds to block 208 where the method 170 groups like-with-like setups and assigns these to specific assembly lines. As such, the assigned ordered products should be assigned to assembly lines where each of the different ordered products has similar assembly times or work content for similar work activities at each work station along the assembly line. The method 170 then proceeds to block 210 where the method 170 communicates the setup rules to a scheduling IHS, such as the IHS 100 . Next, the method 170 proceeds to block 212 where the method 170 applies the setup rules to a factory planner/scheduler system. After applying the setup rules to a factory planner/scheduler system, the method 170 ends at block 214 .
[0029] FIG. 5 a illustrates a chart showing embodiments of different parsing rules for use in the methods provided in FIGS. 3 and 4 . As discussed above, the rules may be defined by features such as a volume/number limits for parts to be added. For example, a rule may be that an order requiring ≦1 processors 102 , ≦4 memory modules 108 , ≦2 hard disk drives 116 and ≦5 expansion cards 128 are scheduled to be assembled on the assembly line for low work content systems 140 . In another example, a rule may be that an order requiring ≦2 processors 102 , ≦4 memory modules 108 , ≦4 hard disk drives 116 and ≦6 expansion cards 128 are scheduled to be assembled on the assembly line for medium work content systems 142 . In yet another example, a rule may be that an order requiring ≦2 processors 102 , ≦8 memory modules 108 , ≦4 hard disk drives 116 and ≦8 expansion cards 128 are scheduled to be assembled on the assembly line for high work content systems 144 . It is to be understood that other factors may be used to create the rules and other values may be used to create the rules. In an embodiment, parsing rules may vary depending on platform/family of the ordered products. Also, the rules may relate to actual product outputs as well as expected outputs. Additional features that may factor in to the rules may include software burn-in rate, traditional failure rate, custom factory integration, total work volume, highest work content, number of work stations along the assembly line, units produced per hour, number of parts in the ordered product, type of parts in the ordered product (e.g., type of chassis, and etc.), number of parts used daily, combined units per hour, labeling/packaging, order fulfillment system/factory planner used for scheduling and/or any variety of other factors.
[0030] FIG. 6 illustrates embodiment of three balanced bar charts 220 , 222 , 224 showing work content at each of a number of work stations along an assembly line. The steps at each work station K 0 -K 9 may be value added (e.g., install part) or non-value added (e.g., rotate system in conveyer). These charts 220 , 222 , 224 show an output for methods 150 and/or 170 after the rules have been created, applied and the work content balanced based on total work content, sequence restrictions and a number of work stations (e.g., K 0 -K 9 ). The X-axis represents each work station (e.g., K 0 -K 9 ) in a progressive assembly line. Any number of stations may be used with the present disclosure. The Y-axis represents the total work content (e.g., in seconds) for each station. The charts 220 , 222 , 224 show the work balance per station and as the rules change the balance per station changes due to more or less work content. As should be understood, chart 220 represents the steps of work content for workstations K 0 -K 9 along an assembly line (e.g., low work content systems 140 ) where the work is scheduled using a variation control system of the present disclosure. chart 222 represents the steps of work content for workstations K 0 -K 9 along an assembly line (e.g., low work content systems 142 ) where the work is scheduled using a variation control system of the present disclosure. chart 224 represents the steps of work content for workstations K 0 -K 9 along an assembly line (e.g., low work content systems 144 ) where the work is scheduled using a variation control system of the present disclosure. It should also be understood that the charts 220 , 222 , 224 will change with each variation in ordered product as worked through methods 150 and/or 170 .
[0031] Although illustrative embodiments have been shown and described, a wide range of modification, change and substitution is contemplated in the foregoing disclosure and in some instances, some features of the embodiments may be employed without a corresponding use of other features. Accordingly, it is appropriate that the appended claims be construed broadly and in a manner consistent with the scope of the embodiments disclosed herein. | A work content variation control system includes an apparatus having a computer-readable medium encoded with a computer program. The computer program, when executed, receives order data for a family grouping of a plurality of ordered products, converts the order data to work content, groups the order data with like order data with respect to the work content, creates parsing rules with respect to the work content and defines setup rules for use to schedule assembly of the ordered products. | 6 |
BACKGROUND OF THE INVENTION
The present invention relates to illumination of the site of the operation of knitting or crocheting.
Knitting and crocheting are old tasks that have largely been taken over by mechanized production. However, many individuals take care and pride in personally knitting and crocheting pieces by hand. These practices, although centuries old, have consistently been accompanied by the same complaint, a lack of good working light. A person working the long hours required to make substantial progress on a knitting or crocheting project typically requires somewhat better lighting than that required for viewing flat surfaces such as in reading text. A knitter's hands are constantly moving and twisting to pull yarn, move knitting needles, check finished rows for dropped stitches or improper tension, and many other small but critical jobs. As such, a person knitting or crocheting requires light from several directions to adequately illuminate the work field.
Consider the tools of the craft. The crochet hook has a notch at one end for catching loops of yarn and drawing them through stitches. Aluminum, plastic and wood crochet hooks are the most commonly used, and often use the letter system for size marking. They range in diameter from B (2.25 mm) to S (19 mm), the largest, and come in 6″ lengths. Straight knitting needles, which come in aluminum, plastic or wood, are the most commonly used. They come in varying diameter sizes, from 0 (2 mm), the smallest, to size 15 (10 mm) and larger; they are sold in pairs, and come in 10″ or 14″ lengths. There is a point at one end of the needle, and a knob at the other, which prevents stitches from slipping off. For large projects like afghans, or sweaters that can be worked in a tube without a seam, circular knitting needles can be used. These are long flexible needles with points at both ends.
Some efforts have been made to provide lighting closely associated with knitting needles. U.S. Pat. No. 2,344,370 describes a knitting needle with a plastic core and a metal sheath leaving ends of the knitting needle exposed. An enclosure is applied to the end distal to the tip so that a light bulb is directed to the top of the plastic core. Light is conducted through the plastic core to provide a low level glow from the exposed tip. The level of illumination is extremely limited and a user is required to keep the end of the device plugged in to an electrical outlet.
U.S. Pat. No. 6,325,522 describes a crochet hook inserted at its straight end into a handle assembly where illumination shines along the exposed shaft of the crochet hook. Unfortunately, this device is without beneficial effect as soon as a user grasps the exposed shaft and blocks the light. Such an action is taken often in knitting and crocheting to adjust the current row of stitches.
There is a need for a device that provides adequate lighting for a person performing hand knitting or crocheting that is closely associated with the knitting needles or crochet hooks.
SUMMARY OF THE INVENTION
The present invention comprises a plastic knitting or crocheting needle incorporating in the shaft one or more light emitting diodes powered by a battery source in a knob end of the needle. In a preferred embodiment, one or more LED's and their wiring are molded in a clear or translucent plastic shaft forming at least a front portion of the length of the needle, optionally having an LED embedded only in the tip or at a distance back from the tip equaling the typical needle crossing distance during knitting.
At least the front portion of the shaft of the invention needles are formed of a clear or translucent material such as clear or translucent polymers. It is an intent of the invention to provide light sources at critical locations along the length the knitting or crocheting needles so that the working field is primarily illuminated from the inside out. In one form, a single white or colored LED is located as near to the needle tip as practicable to preserve the required conic surface of the needle tip. Current packages of LED's will permit such a tip LED to be located very close to a knitting needle tip, i.e., within about 5 millimeters or less.
Conventional LEDs are made from a variety of inorganic minerals, producing the following colors: aluminium gallium arsenide (AlGaAs)—red and infrared; gallium aluminium phosphide (GaAIP)—green; gallium arsenide/phosphide (GaAsP)—red, orange-red, orange, and yellow; gallium nitride (GaN)—green, pure green (or emerald green), and blue; gallium phosphide (GaP)—red, yellow and green; selenide (ZnSe)—blue; indium gallium nitride (InGaN)—bluish-green and blue; indium gallium aluminium phosphide (InGaAIP)—orange-red, orange, yellow, and green; silicon carbide (SiC) as substrate—blue; diamond (C)—ultraviolet; sapphire (Al2O3) as substrate—blue.
In addition, bicolor LED's are packaged so that two colors may alternately be activated to shine from the same LED package, i.e., red and green for example. Very bright, high intensity white LED's with exceptional efficiency have been developed in recent years, and white color LED's are well known in the art.
The present invention allows a user to choose from one of many shaft locations, colors and light intensities for LED's embedded or located in the shaft of a knitting or crocheting needle. The many hours a user spends in the knitting or crocheting tasks cause a user to seek out places and devices reducing eye strain and improving comfort in viewing the work field. For example, a user may prefer a white, high intensity LED to be located in a knitting needle used to receive stitches so that the user's palm will shield the user's eyes from direct view but permit the reflected light to illuminate the background of the work field and allow the user to manipulate that same needle to temporarily brightly illuminate any surface around the user when the user's palm is removed from its covering position. A user may choose to have only a low intensity blue LED at the tip of the needle used to form the stitches so that the user can easily follow the path of the needle tip into an newly formed loop on the needle bearing the stitches.
It is an object of the present invention to essentially illuminate the work field for knitting or crocheting from the inside out so the user can move their hands, fingers, needles and yarn without blocking field illumination.
It is another object of the invention to provide point light sources within the clear or translucent shafts of knitting or crochet needles to provide illumination of the work field.
It is yet another object of the invention to provide a removable illuminated core for a range of knitting needles of multiple diameters.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a user's view of the hands of a person knitting using two knitting needles.
FIG. 2 is a side view of an embodiment of an invention knitting needle with an LED embedded or located in the tip of the needle.
FIG. 3 is a side, exploded view of the knob end of the needle of FIG. 2 .
FIG. 4 is a bottom view of the needle of FIG. 2 .
FIG. 5 is a side, cutaway view of the knob end of the needle of FIG. 2 .
FIGS. 6 , 7 and 8 are side views of alternate embodiments of the invention knitting needle of FIG. 2 .
FIG. 9 is a user's view of two invention knitting needles where one needle is initiating a stitch.
FIG. 10 is the view of FIG. 9 where the user has inserted one needle into a loop and under the other needle.
FIG. 11 is the view of FIG. 10 with a user's hands supporting the knitting needles and yarn.
FIG. 12 is a side view of the knitting needle of FIG. 2 with a clear or translucent sheath increasing the effective diameter of the invention knitting needle.
DETAILED DESCRIPTION OF THE INVENTION
The invention is now discussed with reference to the figures.
FIG. 1 shows a view of a person's hands 100 engaged in knitting, with right hand 101 grasping right needle 104 and left hand grasping left needle 103 . Loop 105 has been formed by way of insertion of the tip of right needle 104 into yarn engaged on left needle 103 . It may be easily appreciated that light must be directed from several sources to adequately light the work field for a user.
FIG. 2 shows an embodiment of the invention knitting needle 106 having a knob 108 rigidly connected to a proximal end of shaft 107 , which extends to a pointed tip. Within the section of said tip, an LED 109 is located or embedded near to said tip and oriented so that its light emissions are effectively dispersed by the clear or translucent polymer material of shaft 107 . Wires 110 connect the electrical connections of LED 109 with electrical connections for battery power and switch means for activating the battery to power LED 109 . FIG. 2 provides a single LED, which may be selected from any of several colors and lighting intensities to provide illumination to the topmost zone in a work field of a person knitting, i.e., at the top of the needles. It is an option of the invention to provide a set of knitting needles where only one of said knitting needles bears LED's or light sources in its shaft.
FIG. 3 is a side view of knob 108 which comprises a threaded cap that is adapted to engage threaded battery housing 113 , which cooperate to securely hold battery 112 . FIG. 4 is a bottom view of needle of FIG. 2 showing shaft 107 and an underside of battery housing 113 . FIG. 5 shows one form of the switching means for the LED's of the invention where wires 110 extend to positive and negative terminals of battery 112 . Broken lines 114 indicate the location of an optional, cylindrical bore in shaft 107 which will allow the LED's of the invention and wires therefor to be inserted to a distance desired for the objects of the invention.
FIG. 6 shows an alternate embodiment of the invention needle 115 wherein LED's 116 through 117 are fixed at intervals along the length of shaft 107 . LED 116 is located at the tip of shaft 107 . LED 117 is located at a distance away from the tip so that it will most likely not pass under the other knitting needle in the knitting operation. More specifically, one knitting needle is typically moved under one that bears a row of stitches. In this example, the needle moved under the other is more efficiently deployed if a user can see LED 117 as an indication of when to stop moving that needle in a forward direction under the other knitting needle. LED's 118 , 119 and 120 provide additional illumination for counting stitches in a row of stitches on a shaft 107 . Wires 121 connect LED's 116 through 118 to battery power and switching means in knob 108 . Switch means include switches capable of causing any one, two, three, four or five of the LED's to become lighted.
FIG. 7 shows an alternate embodiment of the invention needle 122 wherein an LED 123 is located along the length of shaft 107 alone in about the location of LED 117 of the knitting needle of FIG. 6 . Wires 124 connect LED 123 with battery power and switch means.
FIG. 8 shows an alternate embodiment of the invention needle 125 wherein a group of LED's 126 are located close together to provide a relatively unified illumination source for greater light levels and even lighting of a work field.
FIG. 9 shows left needle 115 a bearing a number of stitches 129 and a loop 128 being initiated by a tip of right needle 115 b . LED's 117 a and 116 b illuminate virtually all of the required work field for a user to see the yarn and needle surfaces needed for forming the loop 128 . LED 116 a provides an “umbrella” lighting generally downward from a highest point in the work field. In FIG. 10 , right needle 115 b has been moved under left needle 115 a and through loop 129 just before the location of LED 117 b . FIGS. 9 and 10 illustrate two of the most important and basic motions taken during knitting, i.e., forming a loop and completing a stitch. LED's 116 a , 116 b , 117 a and 117 b cooperate to make these basic tasks fully and internally illuminated.
FIG. 11 shows how a user's hands 101 and 102 in the action of FIG. 10 appear engaged with the invention knitting needles 115 a and 115 b . A user's thumb and inner palm cover LED 118 a (not shown). LED's in that location will not shine into a user's eyes but instead provide indirect, reflected light if so desired by a user.
FIG. 12 shows the knitting needle 106 of FIG. 2 with a clear or translucent cylindrical sleeve or sheath 131 having a cylindrical bore 133 with a diameter just larger than that of shaft 107 , an opening at a lower end and ending just before the tip 132 . The outer diameter of sheath 131 is one or more standard diameters of knitting needles above that of shaft 107 . Said opening of bore 133 is adapted to receive the tip of shaft 107 and to be fully inserted therein. A user may then purchase only a single needle 106 with additional sheaths 131 to be provided with all standard sizes of knitting needles.
The above design options will sometimes present the skilled designer with considerable and wide ranges from which to choose appropriate apparatus and method modifications for the above examples. However, the objects of the present invention will still be obtained by that skilled designer applying such design options in an appropriate manner. | The present invention is a plastic knitting or crocheting needle incorporating in the shaft one or more light emitting diodes powered by a battery source in a knob end of the needle. In a preferred embodiment, one or more LED's and their wiring are molded in a clear or translucent plastic shaft forming at least a front portion of the length of the needle, optionally having an LED embedded only in the tip or at a distance back from the tip equaling the typical needle crossing distance during knitting. | 3 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a self adjusting toilet bolt assembly for connecting a toilet bowl to a closet flange and, more particularly to such an assembly wherein a tightening stud or bolt assembly component can adjust downwardly in length when the assembly is tightened. Beneficially, the proposed invention allows unencumbered placement of a covering cap over the connecting hardware extending above the top surface of the toilet bowl base and eliminates the need to cut a bolt member.
2. Description of the Related Art
In the past, the most commonly used closet bolt employed for connecting a toilet bowl to a closet flange was a fixed length component having a diameter of either ¼″ or 5/16″. The closet bolt was conveniently made longer than necessary to accommodate floor, flange and toilet height variation during installation. For that reason and following connection, it was necessary to cut off an excess top length portion of the threaded stud or bolt or rod member extending above the tightened hold down nut so that the connection hardware could be hidden with an attractive covering cap. If the excess top length portion was not removed, the cap piece could not be seated properly in hardware concealment position. Additionally, it was also recognized that an uncovered hardware assembly provided a debris gathering area in the bathroom and that the covering cap enabled easy cleaning for a beneficial health benefit.
U.S. Pat. No. 6,254,141 to Piper, the entire contents of which are herein incorporated herein by reference, discloses an adjustable length closet fastener in which a length adjustment bolt can be adjusted downwardly by rotating it in a length adjustment sleeve, which length adjustment sleeve passes through an arcuate flange slot in a mounting ring part of the closet flange. The width of the arcuate flange slot is essentially of a standard diameter being fractionally or slightly wider than 5/16″. A shortcoming of the patented Piper fastener is that it cannot be used with a 5/16″ bolt since an internally threaded sleeve receptive of a 5/16″ bolt must include an outer member mandating an outer dimension in excess of 5/16″, such excess providing that the internally threaded sleeve cannot fit into the standard arcuate flange slot. Accordingly, the patented fastener is useable only with a ¼″ bolt.
It is therefore desirable that a self adjusting toilet bolt assembly useable with both ¼″ and 5/16″ diameter threaded studs or bolts be provided.
It is additionally recognized, that conventional use of steel assembly members promotes rust development in the moist bathroom environment and that brass and stainless steal bolts have been used as substitutes to overcome this corrosion detriment. Unfortunately, this use of stainless steal contrasts with the need to adjust the bolt length by cutting to fit each installation. Thus, since stainless steal bolts are much harder and are impossible or highly difficult to cut with a conventional hand-held metal saw brass bolts may be readily cut with a conventional hand-held metal saw and have become the standard material in use. Ultimately, while the strength and corrosion resistance of stainless steal makes it a more desirable metal, the use of brass has been widely adopted because of the need to cut bolts to length after installation due to the non-adjustability of the standard assembly configuration.
SUMMARY OF THE INVENTION
It is an object of the invention to provide a self adjusting toilet bolt assembly which overcomes at least one of the drawbacks of the related art.
Another object is to provide a self adjusting toilet bolt assembly that can be used with both ¼″ and 5/16″ diameter studs and bolts, and which enables the use of full 5/16″ studs and bolts without compromising attachment or positioning strength.
Another object is to provide a self adjusting toilet bolt assembly which makes it unnecessary to cut off any length portion of the bolt once tightening with the hold down nut has been completed.
Another object of the present invention is to provide a self adjusting toilet bolt assembly that enables self driving of a 5/16″ stud with a separable head nut that also adjusts the ultimate assembly length to the minimum necessary to affix the toilet to a closet mounting flange.
The present invention provides a self adjusting toilet bolt assembly provides an anchor member for connecting a toilet bowl to a closet flange which allows use of downward 5/16″ stainless steal or brass stud travel through a standard width dimension slotted opening in the closet flange incident making connection of a toilet bowl to the closet flange. This result is made possible by use of apertures in an anchor member body lower body portion extending between two lower body portion wall parts providing clearance for the stud to pass unobstructedly in the flange slotted opening and connected with a bottom web member.
In accordance with the invention, the bolt assembly includes a threaded stud and an anchor member in which the stud is received. The anchor member includes an upper body portion and a lower body portion, the upper body portion having an internally threaded bore, the lower body portion comprising two spaced apart wall parts which extend down from the upper body portion. A retainer web is carried fixedly at a lower terminus of the wall parts. The closet flange has arcuate course slotted openings to which the anchor member lower body portion is slidably mounted, the mounting being one wherein the retainer web locates at an underside of the closet flange and disposes laterally of the slotted opening to capture the anchor member on the closet flange. The wall parts locate in the flange slotted opening and a first washer encircling the spaced wall parts and retain-ably positioned proximate the point where the wall parts have juncture with the upper body part is set on a top surface of the closet flange. The threaded stud is threaded into the upper body portion and an opening in a toilet bowl base is received over the threaded stud where the stud extends up from the closet flange. Optionally, a second washer encircling the stud is set on top of the toilet bowl opening. A hold down nut threaded onto an upper end of the stud is rotated down on the stud until the nut encounters an interference on the stud that produces unitary rotation of the stud and hold down nut along the threads into the anchor member. The stud thus is moved down to thereby reduce the length of the stud extending above the top surface of the toilet bowl base and eliminating any interference the upstanding stud and hold down nut would present to securement of a decorative concealment cover over the connection hardware
The interference producing unitary rotation of the stud with the hold down nut can be effected by engagement of the hold down nut with any suitable system known to those of skill in the assembly arts, including the use of an unthreaded or narrowed-thread segment on the stud, or with a deposit of a self hardening material such as LOCTITE® applied on the a segment of the threads.
The spacing of the wall parts of the anchor member lower body part portion provides apertures in the lower body portion. With the wall parts disposed in the closet flange slotted opening, the apertures provide a clearance space presence allowing the stud to move down between these wall parts. It is this arrangement that allows presence of a 5/16″ stud in the closet flange slotted opening which opening is only slightly larger than 5/16″. Prior art closet bolt types employing an internal threaded sleeve in which a stud is received and which sleeve extends down through the closet flange slotted opening, is limited in use to a maximum stud diameter of ¼″. A prior art sleeve companion to a 5/16″ stud has an external sleeve diameter too large to pass through the slotted opening. Thus, a 5/16″ stud cannot be used with the prior referenced Piper patent.
The above, and other objects, features and advantages of the present invention will become apparent from the following description read in conduction with the accompanying drawings, in which like reference numerals designate the same elements.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a bottom front perspective depicting the toilet bolt assembly disposition when it is anchored in place to a closet flange extension ring, the flange extension ring being a metal type, a portion of a toilet bowl base part which has been connected to the closet flange being shown in phantom depiction.
FIG. 2 is top perspective view of the bolt assembly shown in FIG. 1 except the assembly tightening bolt is disposed in bolt assembly untightened disposition without the top washer.
FIG. 3 is a top perspective view similar to FIG. 1 except the closet flange extension ring is a plastic type.
FIG. 4 is a view similar to FIG. 3 except the assembly tightening bolt is disposed in bolt assembly untightened disposition.
FIG. 5 is an exploded perspective view of the bolt assembly.
FIG. 6 is a partly exploded perspective view of the bolt assembly illustrating the tightening direction in which the bolt will be rotated on insertion thereof into the anchor member component of the assembly to initiate tightening as well as moving the stud downwardly in the anchor member.
FIG. 7 is a partial cutaway perspective section view of the anchor member component illustrating the upper internal threaded bore passage of the anchor member upper body portion, the threaded stud of the assembly not being shown, the anchor member integral lower body portion wall parts optionally being devoid of threads.
FIG. 8 is a view of the anchor member but with the stud being threaded in the receiver body portion, the stud extending downwardly in the boss portion in disposition thereof when bolt assembly is tightened.
FIG. 9 is a perspective view of the anchor member with a first assembly washer positioned above the anchor member preliminary to the forced passage of the first washer over the skirted structure at the juncture of the upper and lower body portions to capture said first washer encircling the wall parts.
FIG. 10 is a perspective view depiction the arrangement after the washer has been pressed down past the skirted structure with the first washer now being captively slidably mounted but slidably moveable of the wall parts between the underface of the skirted structure and the top face of anchor member base.
FIG. 11 is a plan view of the assembly first washer depicting in dashed lines the stress distortion of the washer imposed in consequence of forcing it past the skirted structure.
FIG. 12 is a fragmentary plan view partly in section showing how a 5/16″ diameter stud large size stud is slidably accommodated in a clearance area defined by apertures in the oppositely facing wall parts in an anchor member as a result of cutting opposite side aperture openings in the anchor member lower body boss portion for sliding access.
FIG. 13 is a perspective showing of an assembled toilet bolt provided in ready-to-use condition in a kit form package, the package including a receptacle receiving a pair of bolt assemblies and a transparent wrapper enclosing the receptacle.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Reference will now be made in detail to several embodiments of the invention that are illustrated in the accompanying drawings. Wherever possible, same or similar reference numerals are used in the drawings and the description to refer to the same or like parts or steps. The drawings are in simplified form and are not to precise scale. For purposes of convenience and clarity only, directional terms, such as top, bottom, up, down, over, above, and below may be used with respect to the drawings. These and similar directional terms should not be construed to limit the scope of the invention in any manner. The words “connect,” “couple,” and similar terms with their inflectional morphemes do not necessarily denote direct and immediate connections, but also include connections through mediate elements or devices.
Referring to FIGS. 1 through 4 , the self adjusting toilet bolt assembly 100 comprises as components, a hold down nut 200 , a threaded stud 300 , an anchor member 400 , a first washer 500 made of nylon, and a second metal washer 550 . Assembly 100 is interfitted with optional plastic closet flanges 600 A or metal closet flanges 600 B having assembly entry openings 800 with opposing side walls 802 , 802 for sliding access along a sliding direction B.
Referring additionally to FIGS. 5-8 , anchor member 400 includes an upper body portion 415 and a lower body portion 420 . Upper body portion 415 comprises a cylindrical part 416 and a lower frusto-conical part 408 includes defining a skirted structure. Upper body portion 415 includes a bore passage extending there through, the bore passage being internally threaded as at 401 . Lower body portion 420 comprises a pair of spaced apart wall parts 405 A and 405 B, these extending downwardly from the skirted structure part 408 , the wall parts 405 A, 405 B being arranged at reciprocal locations on the anchor member and having opposing cut-away wall faces 406 A, 406 B respectively. A retainer web part 403 includes a bottom opening 402 and is carried at the bottom of the wall parts 405 A and 405 B, this web structure being provided to be received under a lower face 601 B of flange 600 B ( FIG. 2 ). Spaces on the anchor member intermediate the wall parts 405 A, 405 B, define apertures 417 , 417 in the lower body portion 420 , these apertures being disposed at oppositely located sides of the lower body portion on cut away wall faces 406 A, 406 B respectively. The inner surfaces of the depicted wall parts are devoid of any threaded formation, although threads on these surfaces can be optionally provided for additional strength, the threads being identical with threads 401 .
Stud 300 receives on a top end thereof, the hold down nut 200 , while at an opposite or bottom stud end 418 ( FIG. 5 ) is the end inserted into the top of the threaded bore of the upper body portion 415 . The stud 300 can be threaded into the bore passage threads 401 and down below that passage such as to locate a lower tip end segment of the stud slightly below the retainer web parts 402 , 403 , the wall part lengths immediately above the retainer web parts 402 , 403 when the stud lower tip end segment is so situated, are disposed between oppositely facing slot walls 802 , 802 which define arcuate course slotted openings 810 in the closet flange, the said slotted openings 810 each having an enlarged entry opening as at 800 ( FIG. 3 ).
When hold down nut 200 is mounted at a top end segment of stud 300 , the hold down nut can be freely rotated on the stud in up or down directions without rotating the stud, the extent of free downward hold down nut independent of any rotation of the stud being limited. An optional and advantageous limitation is effected by presence of a resistance means on the stud provided to produce a unitary rotation of the hold down nut and the stud. This means can comprise a deformed or narrowed thread segment 305 formed on the stud ( FIG. 4 ). When the hold down nut 200 is being freely rotated on the stud 300 in the rotation direction R show by arrow in FIG. 6 and moving downwardly on the stud reaches the deformed thread segment 305 , the hold down nut threads bind with the stud threads produce unitary rotary movement of the hold down nut and the stud. The result is the stud concurrent with rotation thereof moves downwardly into the anchor member in the direction of the vertical arrow in FIG. 6 . The means to bind the hold down nut to the stud could be any means known to those of skill in the art and in a preferable embodiment may be an application of a self-hardening agent polymeric material such as a deposit 700 of LOCTITE® applied to a thread segment on the stud ( FIG. 5 ).
Referring now to FIGS. 9-11 , when nylon washer 500 is subjected to forced passage over the skirted structure 408 having an outer diameter X and slid down to an encircling of the wall parts 405 A and 405 B, the washer becomes elastically deformed with the result that it cannot be again forced over the skirted structure 407 A, 407 B to remove it from the anchor member. FIG. 11 depicts the elastic deformation impart to the washer 500 . The force passage of the washer over the skirted structure 408 results in a deformation of the normal circular inner diameter Y of the washer in a first outer direction X′ to accommodate the outer diameter X of skirted structure 408 a certain distance, the diameter differences being on the order of a few thousandths to several millimeter (mm). Also following such forced passage of the washer, the inner diameter of washer 500 elastically deforms in a direction D, a second inwardly distance X-Y′ to accommodate the opposing stretch in outer direction X′ and balance the elastic energies related thereto. Consequently, washer 500 shortens its inner dimension to a dimension Z from its original inner dimension Y, or an amount Z 2 on each side proximate each side wall region 406 A, 406 B, as shown. It will be recognized that this Z 2 deformation of washer 500 on the wall parts impedes removal relative to cut in lips 407 A, 407 B but does not completely stop sliding or rotation of the washer up and down of the wall parts 405 A, 405 B.
As noted earlier herein, and as can be seen from FIG. 12 , a particular advantage of the invention is that the presence of apertures 417 between the wall parts 405 A, 405 B in the anchor member 400 provides an enabling clearance area accommodating presence of the anchor member lower body portion in the closet flange arcuate course anchoring slotted openings 801 . In contrast to the present invention, where a 5/16″ diameter threaded bolt is received in a fully cylindrical length adjustment sleeve as in the Piper patent, such sleeve outside surface cannot enter slotted openings 801 being too wide for entering in between the walls 802 , 802 of the slotted openings 801 . As FIG. 12 depicts, the threads of the stud 300 of the present invention just fits between walls 802 , 802 and side walls 406 A, 406 B prevent relative rotation to the slot side walls enabling an easy installation and operating as rotational resistant surfaces contacting respective side walls 802 during installation.
The invention also provides as shown in FIG. 13 , a kit of components parts for connecting a toilet to a connecting closet flange. The kit includes at least one components parts assembly 100 , the assembly including an anchor member 400 having an upper body portion and a lower body portion. The upper body portion has a threaded through bore passing from an upper body portion top end to a location where the upper and lower body portions have a joinder juncture.
The lower body portion 420 comprises two spaced apart wall parts extending downwardly of the upper body portion, there a retainer web 403 is carried fixedly to a lower terminus of each wall part. A threaded stud 300 , a hold down nut 200 and a first washer 500 are included in the assembly as is a second washer 550 . The components are arranged in an assembly with a lower length portion of the stud threaded into an upper body bore passage with the first washer encircling the lower body wall parts, as shown although each member may be provided separately in wrapper 88 without departing from the spirit and scope of the present invention.
The hold down nut is threaded to an upper length part of the stud and the second washer is mounted on the stud intermediate the anchor member upper body portion intermediate a top end the anchor member upper body portion and a lower face of the hold down nut. The component parts assembly in wrapper 88 may be optionally received in a flexible side-walled container such as a open top box 77 , there being a transparent wrapper 88 encasing said container. It is advantageous that two assemblies be packaged in a container for sale since a bowl installation will require use of two assemblies.
In addition to the description above, it is noted that FIG. 1 depicts (in phantom outline) how a toilet bowl base 150 is positionally connected to the closet flange 600 B when the assembly has been tightened with hold down nut. It is seen that the bottom face of the bowl base sits on top of the upper face of closet flange 600 B, and the base upper face is engaged under a the lower face of a washer received on stud 300 next below the bottom of the hold down nut 200 .
Referring again to FIG. 12 , it is seen that the retainer webs carried on wall parts 405 A and 405 B mount the anchor member to the flange 600 B, this mounting being effected by inserting the retainer web parts 403 into enlarged entry end 800 of the arcuate course slotted openings 802 in the closet flange and at the underface of the flange. The web parts 403 are widened and extend under the structure of the closet flange, and need not be a continuous structure despite preference for same for strength reasons.
Referring again to the description of the FIGS. 1 and 2 , the structure and function is replicated with respect to FIGS. 3 and 4 , the these embodiments being identical except for the material from which the closet flange extension rings are made. One is made of metal while the other is plastic.
In the claims, means- or step-plus-function clauses are intended to cover the structures described or suggested herein as performing the recited function and not only structural equivalents but also equivalent structures. Thus, for example, although a nail, a screw, and a bolt may not be structural equivalents in that a nail relies on friction between a wooden part and a cylindrical surface, a screw's helical surface positively engages the wooden part, and a bolt's head and nut compress opposite sides of a wooden part, in the environment of fastening wooden parts, a nail, a screw, and a bolt may be readily understood by those skilled in the art as equivalent structures.
Having described at least one of the preferred embodiments of the present invention with reference to the accompanying drawings, it is to be understood that the invention is not limited to those precise embodiments, and that various changes, modifications, and adaptations may be effected therein by one skilled in the art without departing from the scope or spirit of the invention as defined in the appended claims. | A self adjusting toilet bolt assembly provides an anchor member for connecting a toilet bowl to a closet flange which allows use of downward 5/16″ stud travel through a standard width dimension slotted opening in the closet flange incident making connection of a toilet bowl to the closet flange. This result is made possible by use of apertures in an anchor member body lower body portion extending between two lower body portion wall parts providing clearance for the stud to pass unobstructedly in the flange slotted opening. | 4 |
TECHNICAL FIELD
[0001] This disclosure relates to structures for helping to fix an implantable device into an implant pocket. More specifically, the disclosure relates to suture bars for fixing an implantable device into a body.
BACKGROUND
[0002] A variety of medical devices are used for chronic, i.e., long-term, delivery of therapy to patients suffering from a variety of conditions, such as chronic pain, tremor, Parkinson's disease, epilepsy, urinary or fecal incontinence, sexual dysfunction, obesity, spasticity, or gastroparesis. As examples, electrical stimulation generators are used for chronic delivery of electrical stimulation therapies such as cardiac pacing, neurostimulation, muscle stimulation, or the like. Pumps or other fluid delivery devices may be used for chronic delivery of therapeutic agents, such as drugs. Typically, such devices provide therapy continuously or periodically according to parameters contained within a program. A program may comprise respective values for each of a plurality of parameters, specified by a clinician. The devices may be implantable medical devices that receive the program from a programmer controlled by the clinician.
[0003] Examples of such implantable medical devices include implantable fluid delivery devices, implantable neurostimulators, implantable cardioverters, implantable cardiac pacemakers, implantable defibrillators, cochlear implants, and others that now exist or may exist in the future. These devices are intended to provide a patient with a therapeutic output to alleviate or assist with a variety of conditions. Typically, such devices are implanted in a patient and provide a therapeutic output under specified conditions on a recurring basis.
[0004] One type of implantable medical device (IMD) is an implantable fluid delivery device that delivers a drug, medication or other substance, typically in fluid form, to a patient at a selected therapy site. An implantable fluid delivery device may be implanted at a location in the body of a patient and deliver a fluid through a catheter to a selected delivery site in the body. Drug IMDs, such as implantable fluid delivery pumps, typically include fluid reservoirs that may be self-sealing and may be percutaneously accessible through ports. A fluid delivery device may be configured to deliver a therapeutic agent, such as a drug, from the fluid reservoir to a patient according to a therapy program. The therapy program may specify, for example, the size of a fluid bolus of the therapeutic agent delivered to the patient, the concentration of the therapeutic agent, and/or the delivery rate of the therapeutic agent.
[0005] Implantable medical devices are normally sutured into the body of the patient using sutures and suture loops located on the outside of the housing of the medical device. Typically, four suture loops may be positioned on the housing to secure the implantable medical device. However, depending on how the implantable medical device is positioned in the implant pocket, the surgeon implanting the device may not be able to utilize all of the suture loops to secure the medical device. Improvements in structures and methods for securing implantable medical devices are therefore useful.
SUMMARY
[0006] The present description includes a flexible, adaptable suturing aid for securing an implantable medical device into a body.
[0007] A suture bar for facilitating the securing of an implantable medical device in a body including a body member having a length disposed between a first and a second end, the body member being formed of a generally elongate tube that is piercable by a suture needle, a first and second connector fixedly attached on the first and second end of the body member, the first and second connector operable to connect the body member to the implantable medical device.
[0008] Another aspect is a kit for securing an implantable medical device into a body wherein the kit includes a plurality of suture bars of varying lengths, the suture bars including a body member having a length disposed between a first and a second end, the body member being formed of a generally elongate tube that is piercable by a suture needle, and a plurality of connectors that can be fixedly attached to the first and second end of the body member.
[0009] Another aspect is a method of securing an implantable medical device into a body including the steps of providing an implantable medical device, the implantable medical device including at least two suture loops disposed on an outside surface, creating a pocket in a body, securing one or more suture bars to the at least two suture loops of the implantable medical device, and securing the implantable medical device into the pocket in a desired position by suturing the suture bars to the pocket.
BRIEF DESCRIPTION OF DRAWINGS
[0010] FIG. 1 is a conceptual diagram illustrating an example of a fluid delivery system, which includes an implantable medical device that is configured to deliver a therapeutic agent to a patient via a catheter.
[0011] FIG. 2 is a conceptual diagram illustrating the placement of an implantable medical device of the present invention.
[0012] FIG. 3 is functional block diagram illustrating an example of an implantable fluid delivery device.
[0013] FIG. 4 is a functional block diagram illustrating example components of an external programmer for an implantable medical device.
[0014] FIG. 5 is a functional block diagram illustrating an implantable medical device with suture bars.
[0015] FIG. 6 is a suture bar of the present invention.
DETAILED DESCRIPTION
[0016] Medical devices are useful for treating, managing or otherwise controlling various patient conditions or disorders, such as, but not limited to, pain (e.g., chronic pain, post-operative pain or peripheral and localized pain), tremor, movement disorders (e.g., Parkinson's disease), diabetes, epilepsy, neuralgia, chronic migraines, urinary or fecal incontinence, sexual dysfunction, obesity, gastroparesis, mood disorders, or other disorders. Some medical devices may be configured to deliver one or more therapeutic agents, alone or in combination with other therapies, such as electrical stimulation, to one or more target sites within a patient. For example, in some cases, a medical device may deliver one or more pain-relieving drugs to patients with chronic pain, insulin to a patient with diabetes, or other fluids to patients with different disorders. The medical device may be implanted in the patient for chronic therapy delivery (e.g., longer than a temporary, trial basis) or temporary delivery.
[0017] The following detailed description is of the presently contemplated mode of implementing the invention. The embodiment herein is described in terms of an implantable medical device (IMD) that could be any type of device implanted into a body, including, for example, a drug pump, a stimulator, a monitor, a catheter, etc. This description is not to be taken in a limiting sense, but is merely for the purpose of illustrating the general principles of embodiments of the invention. Furthermore, there is no intention to be bound by any theory presented in the preceding background of the invention or the following detailed description of the invention. The scope of the invention is defined by the appended claims.
[0018] FIG. 1 shows an IMD 10 . The illustrated IMD 10 is configured to be surgically implanted into a patient, for example, in the abdominal region, between the skin and the abdominal wall, and is part of a therapy system that may include a catheter connected to the IMD 10 . The catheter may deliver infusion medium to the patient, for example, but not limited to, by feeding infusion medium to a particular location in the venous system, within the spinal column, or in the peritoneal cavity of the patient. The therapy system may also include a programmer or other device for controlling the functions of the IMD. For purposes of simplifying the present disclosure, the term “patient” is used herein to refer to any environment in which an implantable device is implanted, whether or not the implant or connection is carried out for medical purposes. The patient may also be referred to by the term “body” to refer to the patient's body. Also, the term “infusion medium” is used herein to refer to any suitable medium delivered by the IMD 10 .
[0019] The IMD 10 may include a generally disc-shaped housing 14 . While a generally circular disc-shaped embodiment is illustrated in FIG. 1 , it will be understood that further embodiments of the IMD 10 may employ housing of other shapes, including, but not limited to, oval, oblong, rectangular, or other curved or polygonal shapes. Generally, the housing 14 is made of a biocompatible material and most often has a relatively small diameter and thickness to reduce patient trauma during implant surgery and after implantation. Generally, IMD 10 has an outer housing that is constructed of a biocompatible material that resists corrosion and degradation from bodily fluids, such as titanium or biologically inert polymers.
[0020] The housing 14 includes a reservoir 16 for holding a volume of infusion medium, such as, but not limited to, a liquid medication to be administered to the patient. Housing 14 may also contain a drive mechanism 18 (e.g. a pump), a power source 13 , and control electronics 20 . Pump 18 may be configured to receive infusion media from reservoir 16 via a pump inlet 22 . Inlet structure 22 may provide a closeable and sealable fluid flow path to the reservoir in the reservoir portion of the housing. The inlet structure may include a port for receiving a needle through which fluid may be transferred to the IMD, for example, to fill or re-fill the reservoir of the device with the infusion media or a rinsing fluid as will be more fully discussed below. In particular embodiments, the inlet structure may be configured to re-seal after a fill or re-fill operation, and to allow multiple re-fill and re-seal operations. One example of an inlet structure is described in U.S. Pat. No. 6,652,510, titled “Implantable Medical Device and Reservoir for Same,” which is incorporated by reference herein in its entirety and for everything it teaches and discloses. However, further embodiments may employ other suitable inlet structures, including, but not limited to, those described in U.S. Pat. Nos. 5,514,103 and 5,176,644, each to Srisathapat et al.; U.S. Pat. No. 5,167,633 to Mann et al.; U.S. Pat. No. 4,697,622 to Swift; and U.S. Pat. No. 4,573,994 to Fischell et al., also incorporated by reference. Representative examples of reservoir housing portions and reservoirs which may be employed in embodiments of the invention are described in the above referred to U.S. Pat. No. 6,652,510, and further embodiments may employ other suitable reservoir configurations, including, but not limited to, those described in the above referred to U.S. Pat. Nos. 5,514,103; 5,176,644; 5,167,633; 4,697,622; and 4,573,994. The IMD 10 may further include an outlet 12 . The outlet 12 illustrated is sized and shaped to connect to a catheter 22 (see below) and to operably attach the catheter 22 to the IMD 10 to receive the therapeutic agent as further discussed below.
[0021] FIG. 2 is a conceptual diagram illustrating an example of a therapy system, which includes IMD 10 configured to deliver at least one therapeutic agent, such as a pharmaceutical agent, insulin, pain relieving agent, anti-inflammatory agent, gene therapy agent, or the like, to a target site within patient 23 via catheter 22 , which is coupled to IMD 10 . In one example, catheter 22 may comprise a plurality of catheter segments. In the example of FIG. 2 , the therapeutic agent is a therapeutic fluid. IMD 10 may be, for example, an implantable fluid delivery device that delivers therapeutic agents in fluid form to patient 23 . In the example shown in FIG. 2 , the target site is proximate to spinal cord 19 of patient 23 . A proximal end of catheter 22 is coupled to IMD 10 , while a distal end of catheter 22 is located proximate to the target site. In the present embodiment, therapy system 10 may also include an external programmer 80 , which wirelessly communicates with IMD 10 as needed, such as to provide or retrieve therapy information or control aspects of therapy delivery (e.g., modify the therapy parameters, turn IMD 10 on or off, and so forth). Programmer 80 may include a user interface that may display a representation of a portion of an implantable fluid delivery device and simultaneously display an indication of a location of fluid within the implantable fluid delivery device during a delivery phase, as discussed in greater detail below. While patient 23 is generally referred to as a human patient, other mammalian or non-mammalian patients are also contemplated. In other examples, IMD 10 may be implanted within other suitable sites within patient 23 , which may depend, for example, on the target site within patient 23 for the delivery of the therapeutic agent.
[0022] The IMD 10 and catheter 22 are typically implanted by a clinician (e.g., surgeon) within the body 23 during a surgical procedure. A proximal end of the catheter 22 may be tunneled through the tissue to the IMD 10 location and coupled to a catheter port of the IMD 10 . If implanted, the medical device 10 is typically positioned subcutaneously, e.g., from 1 centimeter (0.4 inches) to 2.5 centimeters (1 inch) beneath the skin, where there is sufficient tissue for supporting the IMD 10 , e.g., with sutures or the like.
[0023] Therapy system may be used, for example, to reduce pain experienced by patient 23 . IMD 10 may deliver one or more therapeutic agents to patient 23 according to one or more therapy programs that set forth different therapy parameters, such as bolus size, frequency of bolus delivery, time during which a bolus is to be delivered, and so forth. In some examples, the therapeutic agent may be a liquid. The therapy programs may be may be a part of a program group for therapy, where the group includes a plurality of therapy programs. In some examples, IMD 10 may be configured to deliver a therapeutic agent to patient 23 according to different therapy programs on a selective basis. IMD 10 may include a memory to store one or more therapy programs, instructions defining the extent to which patient 23 may adjust therapy parameters, switch between programs, or undertake other therapy adjustments. Patient 23 may select and/or generate additional therapy programs for use by IMD 10 via external programmer 80 at any time during therapy or as designated by the clinician.
[0024] In some examples, multiple catheters 22 may be coupled to IMD 10 to target the same or different tissue or nerve sites within. Thus, although a single catheter 22 is shown in FIG. 1 , in other examples, system 12 may include multiple catheters or catheter 22 may define multiple lumens for delivering different therapeutic agents to patient 23 or for delivering a therapeutic agent to different tissue sites within patient 23 . Accordingly, in some examples, IMD 10 may include a plurality of reservoirs for storing more than one type of therapeutic agent. In some examples, IMD 10 may include a single long tube that contains the therapeutic agent in place of a reservoir. However, for ease of description, an IMD 10 including a single reservoir is primarily discussed herein with reference to the example of FIG. 1 .
[0025] FIG. 3 is a functional block diagram illustrating components of an example of IMD 10 , which includes refill port 22 , reservoir 16 , processor 20 , memory 40 , telemetry module 42 , power source 13 , fluid delivery pump 18 , internal tubing 32 , and catheter access port 36 . Fluid delivery pump 18 may be a mechanism that delivers a therapeutic agent in a metered or desired flow rate to the therapy site within patient 23 from reservoir 16 via the catheter 22 . Refill port 22 may comprise a self-sealing membrane to prevent loss of therapeutic agent delivered to reservoir 16 via refill port 22 . After a delivery system, e.g., a hypodermic needle, penetrates the membrane of refill port 22 , the membrane may seal shut when the needle is removed from refill port 22 .
[0026] Internal tubing 32 is a segment of tubing that runs from reservoir 16 , around or through fluid delivery pump 18 , to catheter access port 36 . In one example, fluid delivery pump 18 may be a squeeze pump that squeezes internal tubing 32 in a controlled manner, e.g., such as a peristaltic pump, to progressively move fluid from reservoir 16 to the distal end of catheter 22 and then into the patient 23 according to parameters specified by a set of program information. Fluid delivery pump 18 may, in other examples, comprise an axial pump, a centrifugal pump, a pusher plate, a piston-driven pump, or other means for moving fluid through internal tubing 32 and catheter 22 .
[0027] Processor 20 controls the operation of fluid delivery pump 18 with the aid of program information stored in memory 40 . For example, the program information may include instructions that define therapy programs to specify the amount of a therapeutic agent that is delivered to a target tissue site within patient 23 from reservoir 16 via catheter 22 . The instructions may further specify the time at which a bolus will be delivered and the time interval over which the bolus will be delivered, e.g., as defined by a start and an end time. The therapy programs may also include other therapy parameters, such as the frequency of bolus delivery, the type of therapeutic agent delivered (if IMD 10 is configured to deliver more than one type of therapeutic agent), and so forth. Components described as processors within IMD 10 , external programmer 80 , or any other device described in this disclosure may each comprise one or more processors, such as one or more microprocessors, digital signal processors (DSPs), application specific integrated circuits (ASICs), field programmable gate arrays (FPGAs), programmable logic circuitry, or the like, either alone or in any suitable combination.
[0028] Memory 40 may include any volatile or non-volatile media, such as a random access memory (RAM), read only memory (ROM), non-volatile RAM (NVRAM), electrically erasable programmable ROM (EEPROM), flash memory, and the like. As mentioned above, memory 40 may store program information including instructions for execution by processor 20 , such as, but not limited to, therapy programs, historical therapy programs, timing programs for delivery of fluid from reservoir 16 to catheter 22 , and any other information regarding therapy of patient 23 . A program may indicate the bolus size or flow rate of the drug, and processor 20 may accordingly deliver therapy. Memory 40 may include separate memories for storing instructions, patient information, therapy parameters (e.g., grouped into sets referred to as “therapy programs”), therapy adjustment information, program histories, and other categories of information such as any other data that may benefit from separate physical memory modules. Therapy adjustment information may include information relating to timing, frequency, rates and amounts of patient boluses or other permitted patient modifications to therapy. In some examples, memory 40 stores program instructions that, when executed by processor 20 , cause IMD 10 and processor 20 to perform the functions attributed to them in this disclosure.
[0029] Telemetry module 42 in IMD 10 , as well as telemetry modules in other devices described herein, such as programmer 80 , may accomplish communication by RF communication techniques. In other embodiments, telemetry module 42 may communicate with the programmer 80 in other methods, such as, for instance, telemetry module 42 may communicate with programmer 80 via proximal inductive interaction. Accordingly, telemetry module 42 may send information to external programmer 80 on a continuous basis, at periodic intervals, or upon request from the programmer. Processor 20 controls telemetry module 42 to send and receive information.
[0030] Power source 13 delivers operating power to various components of IMD 10 (connection lines not shown). Power source 13 may include a small rechargeable or non-rechargeable battery and a power generation circuit to produce the operating power. In the case of a rechargeable battery, recharging may be accomplished through proximal inductive interaction between an external charger and an inductive charging coil within IMD 10 . In other embodiments, power requirements may be small enough to allow IMD 10 to utilize patient motion and implement a kinetic energy-scavenging device to trickle charge a rechargeable battery. In other examples, traditional batteries may be used for a limited period of time. As a further alternative, an external inductive power supply could transcutaneously power IMD 10 whenever measurements are needed or desired.
[0031] Programmer 80 , as further discussed and detailed herein, may be an external computing device that is configured to wirelessly communicate with IMD 10 . For example, programmer 80 may be a clinician programmer that the clinician uses to communicate with IMD 10 . Alternatively, programmer 80 may be a patient programmer that allows patient 23 to view and modify therapy parameters. The clinician programmer may include additional or alternative programming features than the patient programmer. For example, more complex or sensitive tasks may only be allowed by the clinician programmer to prevent patient 23 from making undesired changes to the operation of IMD 10 .
[0032] Programmer 80 may be a hand-held computing device that includes a display viewable by the user and a user input mechanism that can be used to provide input to programmer 80 . For example, programmer 80 may include a small display screen (e.g., a liquid crystal display or a light emitting diode display) that presents information to the user. In addition, programmer 80 may include a keypad, buttons, a peripheral pointing device, touch screen or another input mechanism that allows the user to navigate though the user interface of programmer 80 and provide input.
[0033] If programmer 80 includes buttons and a keypad, the buttons may be dedicated to performing a certain function, i.e., a power button, or the buttons and the keypad may be soft keys that change in function depending upon the section of the user interface currently viewed by the user. Alternatively, the screen (not shown) of programmer 80 may be a touch screen that allows the user to provide input directly to the user interface shown on the display. The user may use a stylus or their finger to provide input to the display.
[0034] In other examples, rather than being a handheld computing device or a dedicated computing device, programmer 80 may be a larger workstation or a separate application within another multi-function device. For example, the multi-function device may be a cellular phone, personal computer, laptop, workstation computer, or personal digital assistant that can be configured to an application to simulate programmer 80 . Alternatively, a notebook computer, tablet computer, or other personal computer may enter an application to become programmer 80 with a wireless adapter connected to the personal computer for communicating with IMD 10 .
[0035] When programmer 80 is configured for use by the clinician, programmer 80 may be used to transmit initial programming information to IMD 10 . This initial information may include hardware information for system 10 such as the type of catheter 22 , the position of catheter 22 within patient 23 , the type of therapeutic agent(s) delivered by IMD 10 , a baseline orientation of at least a portion of IMD 10 relative to a reference point, therapy parameters of therapy programs stored within IMD 10 or within programmer 80 , and any other information the clinician desires to program into IMD 10 .
[0036] Whether programmer 80 is configured for clinician or patient use, programmer 80 may communicate to IMD 10 or any other computing device via wireless communication. Programmer 80 , for example, may communicate via wireless communication with IMD 10 using radio frequency (RF) telemetry techniques known in the art. Programmer 80 may also communicate with another programmer or computing device via a wired or wireless connection using any of a variety of local wireless communication techniques, such as RF communication according to the 802.11 or Bluetooth specification sets, infrared (IR) communication according to the IRDA specification set, or other standard or proprietary telemetry protocols. Programmer 80 may also communicate with another programming or computing device via exchange of removable media, such as magnetic or optical disks, or memory cards or sticks. Further, programmer 80 may communicate with IMD 10 and another programmer via remote telemetry techniques known in the art, communicating via a local area network (LAN), wide area network (WAN), public switched telephone network (PSTN), or cellular telephone network, for example.
[0037] In other applications of therapy system 10 , the target therapy delivery site within patient 23 may be a location proximate to sacral nerves (e.g., the S2, S3, or S4 sacral nerves) in patient 23 or any other suitable nerve, organ, muscle or muscle group in patient 23 , which may be selected based on, for example, a patient condition. For example, therapy system 10 may be used to deliver a therapeutic agent to tissue proximate to a pudendal nerve, a perineal nerve or other areas of the nervous system. In some instances catheter 22 may be implanted and substantially fixed proximate to the respective nerve. As further examples, catheter 22 may be positioned to deliver a therapeutic agent to help manage peripheral neuropathy or post-operative pain mitigation, ilioinguinal nerve therapy, intercostal nerve therapy, gastric stimulation for the treatment of gastric motility disorders and/or obesity, muscle stimulation, for mitigation of other peripheral and localized pain (e.g., leg pain or back pain). As another example, catheter 22 may be positioned to deliver a therapeutic agent to a deep brain site or within the heart (e.g., intraventricular delivery of the agent). Delivery of a therapeutic agent within the brain may help manage any number of disorders or diseases. Example disorders may include depression or other mood disorders, dementia, obsessive-compulsive disorder, migraines, obesity, and movement disorders, such as Parkinson's disease, spasticity, and epilepsy. Catheter 22 may also be positioned to deliver insulin to a patient with diabetes.
[0038] Examples of therapeutic agents that IMD 10 may be configured to deliver include, but are not limited to, insulin, morphine, hydromorphone, bupivacaine, clonidine, other analgesics, genetic agents, antibiotics, nutritional fluids, analgesics, hormones or hormonal drugs, gene therapy drugs, anticoagulants, cardiovascular medications or chemotherapeutics. Various embodiments of the present invention may be utilized with any type of medical device that is to be implanted into the body to aid in securing the medical device into the desired position.
[0039] FIG. 4 is a functional block diagram illustrating various components of one example external programmer 80 for IMD 10 . As shown in FIG. 4 , external programmer 80 includes processor 84 , memory 86 , telemetry module 88 , user interface 82 , and power source 90 . A clinician or patient 23 interacts with user interface 82 in order to manually change the parameters of a program, change programs within a group of programs, view therapy information, view historical therapy regimens, establish new therapy regimens, or otherwise communicate with IMD 10 or view programming information.
[0040] User interface 82 may include a screen and one or more input buttons, as discussed in greater detail below, that allow external programmer 80 to receive input from a user. Alternatively, user interface 82 may additionally or only utilize a touch screen display, as in the example of clinician programmer 60 . The screen may be a liquid crystal display (LCD), dot matrix display, organic light-emitting diode (OLED) display, touch screen, or any other device capable of delivering and/or accepting information. For visible indications of therapy program parameters or operational status, a display screen may suffice. For audible and/or tactile indications of therapy program parameters or operational status, programmer 80 may further include one or more audio speakers, voice synthesizer chips, piezoelectric buzzers, or the like.
[0041] Input buttons for user interface 82 may include a touch pad, increase and decrease buttons, emergency shut off button, and other buttons needed to control the therapy, as described above with regard to patient programmer 80 . Processor 84 controls user interface 82 , retrieves data from memory 86 and stores data within memory 86 . Processor 84 also controls the transmission of data through telemetry module 88 to IMD 10 . The transmitted data may include therapy program information specifying various drug delivery program parameters. Memory 86 may include operational instructions for processor 84 and data related to therapy for patient 23 . User interface 82 may be configured to present therapy program information to the user. User interface 82 enables a user to program IMD 10 in accordance with one or more therapy delivery programs, schedules, or the like. The therapy program information may also be stored within memory 86 periodically during therapy, whenever external programmer 80 communicates within IMD 10 , or only when the user desires to use or update the therapy program information.
[0042] Telemetry module 88 allows the transfer of data to and from IMD 10 . Telemetry module 88 may communicate automatically with IMD 10 at a scheduled time or when the telemetry module detects the proximity of IMD 10 . Alternatively, telemetry module 88 may communicate with IMD 10 when signaled by a user through user interface 82 . To support RF communication, telemetry module 88 may include appropriate electronic components, such as amplifiers, filters, mixers, encoders, decoders, and the like. Power source 90 may be a rechargeable battery, such as a lithium ion or nickel metal hydride battery. Other rechargeable or conventional batteries may also be used. In some cases, external programmer 80 may be used when coupled to an alternating current (AC) outlet, i.e., AC line power, either directly or via an AC/DC adapter.
[0043] In some examples, external programmer 80 may be configured to recharge IMD 10 in addition to programming IMD 10 . Alternatively, a recharging device may be capable of communication with IMD 10 . Then, the recharging device may be able to transfer programming information, data, or any other information described herein to IMD 10 . In this manner, the recharging device may be able to act as an intermediary communication device between external programmer 80 and IMD 10 . The techniques described in this disclosure may be communicated between IMD 10 via any type of external device capable of communication with IMD 10 .
[0044] FIG. 5 illustrates an IMD 10 with suture bars 100 for securing the IMD 10 into a patient 23 . The suture bar 100 may include a generally elongate body 106 and at least one suture bar connector 104 attached at the ends of the body 106 . In the illustrated embodiment, the suture bar 100 is secured to the IMD 10 by attaching the suture bar connectors 104 to existing suture loops 102 . As illustrated, the suture bar connector 104 is shown as a generic attachment device and is further described in detail below.
[0045] The body 106 of the suture bar 100 may be made of any biocompatible polymer material that is known to those of skill in the art such as, for example, polyethylene terephthalate (PET). The biocompatible polymer may be molded or extruded. Other suitable material may be material that is used in making suture materials, such as polypropylene, polyester, or nylon. Other materials may have various properties as desired, such as being elastic. Elastic materials may include copolymers of styrene-butadiene, polybutadiene, polymers formed from ethylene-propylene diene monomers, polychloroprene, polyisoprene, copolymers of acrylonitrile and butadiene, copolymers of isobutyldiene and isoprene, polyurethanes and the like. In further embodiments, as discussed below, absorbable suture material may also be used.
[0046] In the embodiment shown in FIG. 6 , the body 106 of the suture bar 100 is constructed as a mesh formed into a hollow tube. The body 106 may have a cross sectional area that allows for sutures to be placed there through. The sutures placed through the body 106 of the suture bar 100 allow for the IMD 10 to be secured into the desired location using a series of spaced apart sutures, or sutures in a line, rather than sutures at specific points as required by utilization of the suture loops 102 .
[0047] As illustrated, the body 106 of the suture bar 100 is generally a hollow elongate cylindrical shape. In various embodiments, the suture bar 100 may be of a uniform thickness or may have varying thicknesses along its length. For example, the middle of the body 106 may have a slightly thicker width so as to facilitate easy piercing during implantation. The ends of the body 106 may be slightly narrower to reduce overall volume of the suture bar 100 . In still further embodiments the body 106 of the suture bar 106 can have several variations in width along its length in order to reduce size, weight, or to provide easier suturing. In still further embodiments the suture bar may be solid or comprised of a tightly woven three dimensional mesh. As may be appreciated, the body 106 of the suture bar may have a generally open structure (a loosely woven mesh) or a generally closed structure (tightly woven mesh) as is desired. In still further embodiments the body 106 may be braided.
[0048] The suture bar 100 may be of a length designed to fit along the IMD 10 between successive suture loops 102 or may connect to three or more suture loops. The length of the body 106 of the suture bar 100 and the distance between the suture loops 102 may be balanced to provide a desired tension in the body 106 of the suture bar 100 after it is connected to the suture loops 102 . If the suture bar 100 is too short, attaching the suture bar to the suture loops 102 may be difficult.
[0049] As may be appreciated, the suture bar 100 provides improved implantation stability for the IMD 10 . The suture bar 100 may provide an increased suture area for the clinician (surgeon) to attach the IMD 10 to the implant pocket. The suture bar 100 may free the clinician from only having four distinct points in which to place sutures to secure the IMD 10 . In further embodiments, the suture bar 100 may also be designed to promote tissue in-growth after implantation of the IMD 10 . Tissue in-growth may further secure the IMD 10 in the implant pocket and reduce surgical revisions that may be necessary to correct a flipped or migrated IMD 10 .
[0050] The suture bar connector 104 may be a molded clip such as is illustrated in FIG. 6 . Such a clip may be made out of a plastic, metal, silicon or any other material that is compatible with medical devices and the implantation of medical devices. It may be desirable to minimize sharp points, edges, or surfaces that can cause irritation. The suture bar connector 104 may be attached to the suture bar 100 by weaving, tying, welding, sonic welding, or by any other attachment method compatible with the material of the suture bar connector 104 and the suture bar 100 .
[0051] In further embodiments the suture bar connector 104 may be any type of clip or connector known to those of skill in the art that can be secured to or through the suture loop 102 , such as, for example a snap clip, a spring clip, a single-sided arrowhead, a flexible wedge, a flexible tie or twist tie, etc. In other embodiments, the suture loop 102 may be replaced by another structure that corresponds to the suture bar connector 104 whereby the suture loop 102 and the suture bar connector 102 are any corresponding connectors for creating a link. In still further embodiments the suture bar 100 may be directly sewn or sutured to the suture loop 102 before the IMD 10 is placed into the desired position, wherein afterwards the suture bar 100 is utilized to fix the IMD 10 in place. In such an embodiment each end of the suture body 106 may be reinforced so as to provide the necessary strength to secure the suture bar 100 and the IMD 10 after implantation.
[0052] In still further embodiments the body 106 of the suture bar 100 may be made of a substantially inelastic or elastic cord that can be penetrated by a suture needle. In still further embodiments that body 106 may be made of an extruded plastic material such that the body 106 is a relatively solid piece that is of a desired durometer and that can both be pierced by a suture needle and retain the suture thread. In still further embodiments the suture bar 100 may be constructed of material that is completely or substantially resorbable. Such suture bars 100 may be constructed such that long term tissue in-growth keeps the IMD 10 secured after the suture bar 100 is eroded. In further embodiments the suture bar 100 may be made of materials that are not resorbable.
[0053] In further embodiments the suture bar 100 may incorporate radiopaque materials in order to be visible through standard imaging methods.
[0054] In further embodiments, the suture bar 100 may also provide a location for dispensing a therapeutic agent. Such materials may include antibiotic, antiviral, antiseptic, anti-infective, or other therapeutic agents or pharmaceuticals that can be eluted from a polymer or other material incorporated into the suture bar 100 . Such materials may help to reduce infections or other physiological reactions after the IMD 10 is implanted. In further embodiments, the suture bar 100 may incorporate a pouch or other pocket that allows for a desired material to be loaded into the suture bar 100 before placement by the clinician. As may be appreciated, the location of the pocket should not interfere with the primary purpose of providing an area to secure the IMD 10 during implantation. Further, the therapeutic agent should be selected to be compatible with the material forming the suture bar 100 and the suture bar connector 104 .
[0055] In still further embodiments the length of the suture bar 100 may be adjusted by the clinician during the implantation procedure. The length may be adjusted by stretching, uncoiling, or cutting the suture bar 100 . In further embodiments the body 106 may be a woven or braided mesh that includes a pre-tied sliding knot that can be secured in a manner to result in a desired final length of the body 106 . In such embodiments the suture bar connector 104 may be attached to the suture bar 100 after the suture bar is trimmed to the desired length. In still further embodiments, the connector 104 may be utilized to adjust the overall length of suture bar 100 to provide the desired tension between the suture loops 102 .
[0056] While at least one exemplary embodiment has been presented in the foregoing detailed description of the invention, it should be appreciated that a vast number of variations exist. It should also be appreciated that the exemplary embodiment or exemplary embodiments are only examples and are not intended to limit the scope, applicability, or configuration of the invention in any way. Rather, the foregoing detailed description will provide those skilled in the art with a convenient road map for implementing exemplary embodiments of the invention, it being understood that various changes may be made in the function and arrangement of elements described in an exemplary embodiment without departing from the scope of the invention as set forth in the appended claims and their legal equivalents. | A suture bar for facilitating the securing of an implantable medical device in a body. The suture bar including a body member having a length disposed between a first and a second end, the body member being formed of a generally elongate tube that is piercable by a suture needle. The suture bar also including a first and second connector fixedly attached on the first and second end of the body member, the first and second connector operable to connect the implantable medical device to a pocket in a body. | 0 |
BACKGROUND OF THE INVENTION
The present invention concerns a composite sheet.
Various methods of manufacturing composite sheets are known in the art. All have various drawbacks.
SUMMARY OF THE INVENTION
The principal object of the present invention is to provide a novel method of manufacturing a composite sheet, and a composite sheet produced by the method, which overcomes the drawbacks of the prior art.
The composite sheet according to the invention comprises a supporting sheet bonded to a “hetero sheet” consisting of (1) a heterogeneous blend of an elastic thermoplastic matrix that cures semicrystalline or amorphous subsequent to processing, and (2) particles of added material distributed therein. The particles can be mixed and extruded along with the matrix although they are heterogeneously bound therein. In the hetero sheet the particles of added material heterogeneously distributed therein are detached from the surrounding matrix at their interfaces therewith and the material of the hetero sheet stands up at the many areas of detachment to create a fleecy surface.
Such a composite sheet can be produced from many different fundamental materials. The fundamental material of the hetero sheet can be a polymer in the form of a polyolefin, a polyamide, a polycarbonate, or a polyester or a copolymer thereof. The particles must be of a material that cannot be processed adhesively with the fundamental material. Appropriate added materials are, for example, such inorganic fillers as titanium dioxide, lampblack, kaolin, ground quartz, silicic acid, chalk, and lithopone.
It is, however, also possible, and indeed recommended to pair off the polymers in the hetero sheet, with each member being an organic substance, polystyrene or polyamide particles with a matrix in the form of a polyolefin, especially polyethylene or polypropylene, or other pairs of polymers that cannot be processed mutually adhesively, for example.
The supporting sheet will preferably be of elastomer, thermoplastic rubber for example, a copolymer of styrene, butadiene, and styrene, an SBR elastomer, or EPDM (ethylene-propylene rubber).
The hetero sheet can be bonded to one or to both sides of the supporting sheet, with various types of material added. The hetero sheet can be bonded to the supporting sheet with a thermoplastic adhesive. The supporting sheet can consist of several layers.
Methods of manufacturing such composite sheets can be based on different principles.
One such method comprises the steps that will now be described. As this term is used herein, the “hetero sheet” comprises a heterogenous blend of an elastic thermoplastic matrix that cures semicrystalline or amorphous with, distributed therein, one or more particles of an added material that can be mixed and extruded with the matrix but are heterogeneously bound therein. The hetero sheet is bonded to a supporting sheet consisting of an elastomer that can be stretched to a considerable extent and can return to its original or optionally to a slightly lower order of magnitude. The composite sheet is stretched to an extent below the maximal extent that the supporting sheet can be stretched to. The hetero sheet is likewise stretched and the distributed particles of added material simultaneously detach from the thermoplastic matrix enclosing them at the interfaces therewith in such a way that, as the stretched supporting sheet is released, it either returns to its original configuration or remains extensively stretched, whereas the material of the hetero sheet stands up at the many ripped interfaces and generates a fleecy surface.
The supporting sheet can be extruded along with the hetero sheet. On the other hand, it is also possible, for example, to extrude the melt from slotted dies and produce a stack of sheets. In this event the supporting sheet will either have been coated with a thermoplastic adhesive or be coated with such an adhesive on-line.
It should be noted, in particular, that the sheet can be stretched not only longitudinally and transversely but also in superimposed directions. This will provide the fleece with a “nap” and render it particularly dense.
The composite sheet should be stretched by as much as 300% of its original area. It is also possible to use a low-elasticity supporting sheet that will remain extensively stretched. The result will be less volume and larger area.
Fleeciness and elasticity can be increased if the composite sheet is embossed before being stretched. The composite sheet can be mechanically stretched longitudinally and transversely in a tenter. The composite sheet can also be co-extruded as a tube and the tube sealed and inflated in order to attain the desired fleeciness.
It is also possible to employ a stretchable woven or knit instead of a polymeric sheet.
Another object of the present invention is to employ the aforesaid method not to produce fleeciness for the purpose of improving feel, but to increase the volume of a composite sheet, whether smooth or rough.
This object is achieved by sandwiching between two supporting sheets a hetero sheet that has been rendered fleecy.
The standing up and detachment of the heterogeneous particles is in this event exploited inside the composite sheet to increase its volume.
Particularly recommended is a volume-increased composite sheet comprising five sheets, specifically a supporting sheet against a hetero sheet against another supporting sheet against another hetero sheet against another supporting sheet.
One particular embodiment of the method comprises the steps that will now be described. A composite sheet comprising a hetero sheet between two supporting sheets is extruded. The composite sheet is mechanically stressed, by wrapping it around a short radius for example, detaching the particles of added material distributed within the hetero sheet from the surrounding thermoplastic at their interfaces therewith, such that the material of the hetero sheet stands up at the many ripped sites of detachment, increasing the volume of the composite sheet.
A composite sheet comprising five sheets, specifically a supporting sheet against a hetero sheet against another supporting sheet against another hetero sheet against another supporting sheet can be co-extruded, for example, and then volume-increased.
For a full 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
FIGS. 1 a, 1 b, and 1 c are sections through a two-layer composite sheet before, during, and after tentering.
FIG. 2 illustrates a composite sheet like that illustrated in FIG. 1 a being tentered around a short radius.
FIG. 3 illustrates a composite sheet being brushed.
FIGS. 4 a, 4 b, and 4 c are sections through a three-layer composite sheet before, during, and after tentering.
FIG. 5 illustrates a five-layer composite sheet after tentering.
FIG. 6 illustrates a composite sheet like that illustrated in FIG. 4 a being tentered around a short radius.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The preferred embodiments of the present invention will now be described with reference to FIGS. 1-6 of the drawings. Identical elements in the various figures are designated with the same reference numerals.
EXAMPLE 1
A composition of 25% by weight of polystyrene particles with a density of 1.05 and 75% by weight of a homopolymerized polypropylene with a density of 0.91 is mixed and plasticized in a plasticizer. The plasticized blend is heated above its melting point and extruded through a slot by a screw. The slot deposits a composition sheet 200 μm thick onto a rolled-out sheet of ethylene propylene diene monomer 150 μm thick with an adhesive surface, producing a composite sheet (FIG. 1 a ).
The composite sheet is allowed to cool and then stretched to 150% of its original area (FIG. 1 b ). The polystyrene particles 1 simultaneously detach from the surrounding polypropylene 2 . Rubber sheet 3 is released, and the ripped edges of the interfaces stand up and create a fleecy surface (FIG. 1 c ).
EXAMPLE 2
The hetero sheet is made of a compositon mixed and plasticized from 30% by weight of titanium dioxide particles and 70% by weight of low density polyethylene. The blend is heated and plasticized and extruded by compressed air through a slot with a filled styrene-and-butadiene rubber. The hetero sheet obtained from the first composition is 80 μm thick and the elastomer sheet 70 μm thick.
The mutually adhering sheets are stretched 120% of their original length. The inorganic particles of titanium dioxide detach from the surrounding low density polyethylene. Once the elastomer sheet returns to size, the ripped edges of the interfaces stand up and create a fleecy surface.
EXAMPLES 3
The hetero sheet is mixed and plasticized from a composition consisting of 25% by weight of a PA6 polyamide particles of density 1.13 and 75% by weight of polypropylene (PP-H) of density 0.91. The supporting sheet is a sheet of styrene-butadiene-styrene elastomer (SBS).
The co-extruded and cool composite sheet is stretched to 125% of its original length both along the direction of flow and perpendicular thereto and allowed to return to its original dimensions. The result is a particularly fleecy feel.
EXAMPLE 4
A preliminary-stage composite sheet produced as described in Examples 1 through 3 is fed through a creping machine with two powered cogwheels, resulting in a corrugating embossment. The sheet of elastomer is stretched and allowed to return to its corrugated state. The result is considerable fleeciness.
EXAMPLE 5
A sheet of elastomer is covered on both sides with a hetero sheet and stretched, producing an area of fleece on each side.
EXAMPLE 6
A stretchable fabric woven or knit from threads of elastomer is employed instead of the sheet of elastomer. This supporting sheet is covered in accordance with the aforesaid method with a hetero sheet and converted to a composite sheet with a fleecy surface.
EXAMPLE 7
A thermoplastic rubber (PUR elastomer) is extruded in a tube extruder along with a compositon consisting of 30% by weight polystyrene particles with a density of 1.05 and 70% by weight of a homopolymeric polypropylene with a density of 0.91. The resulting tube is sealed at one end with a roller. Air is pumped in from below, subjecting the cold or tempered tube to bi-axial inflation tentering. The inflation is terminated and the sheet of elastomer allowed to return to its original state, upon which the sheet of copolymerized composition stands up fleecy.
EXAMPLE 8
The supporting sheet 3 illustrated in FIG. 2 with a hetero sheet is drawn over a rod of relatively short diameter D, approximately 2 mm, and accordingly mechanically stressed. The bending detaches the added particles from the plastic surrounding them. The material of hetero sheet 5 stands up.
EXAMPLE 9
A supporting sheet 3 with a hetero sheet is surface-roughened by brushing it with a brush B as shown in FIG. 3 . The mechanical stress detaches the added particles from the plastic supporting sheet that surrounds them. The material of hetero sheet 5 stands up.
EXAMPLE 10
A hetero sheet is obtained by mixing and plasticizing in a plasticizer a composition consisting of 25% by weight of polystyrene particles of density 1.05 and 75% by weight of a homopolymerized polypropylene of weight 0.91. The plasticized blend is forwarded above its melting point to an annular cavity in a tube extruder. Extruded along with the aforesaid hetero sheet through two annular cavities concentric with the first is a supporting sheet in the form of a molten composition of ethylene propylene diene monomer with a tacky surface. The result is a co-extruded tube of composite sheet in the state illustrated in FIG. 4 a. This composite sheet consists of a supporting sheet 10 , a hetero sheet 20 , and another supporting sheet 30 . The unstretched hetero sheet is 200 μm thick and the unstretched supporting sheet 100 μm thick.
The tube is then slit and laid out in two separate layers. The composite sheet is allowed to cool (FIG. 4 a ) and stretched to 150% of its original length (illustrated in FIG. 4 b ). The heterogeneous polystyrene particles 1 in the middle layer simultaneously detach from the surrounding polypropylene 2 . The sheet is tentered and the composite sheet allowed to return to its original dimensions subject to the recovery force exerted by the ethylene propylene diene monomer rubber sheet. The ripped edges of the interfaces simultaneously stand up and create, in conjunction with the now more randomly erect polystyrene particles 1 , a larger-volume middle layer (illustrated in FIG. 4 c ).
EXAMPLE 11
It is also possible to produce a five-layer composite sheet as illustrated in FIG. 5 by stacking flat and blocking two of the tubes discussed in Example 1 , resulting in a simple supporting sheet 10 against a hetero sheet 20 against a double supporting sheet 30 + 30 against another hetero sheet 20 against another simple supporting sheet 10 . Stretching such a five-layer composite sheet will in principle have the effect with respect to increased volume represented in FIG. 1 c.
EXAMPLE 12
A composition comprising 30% by weight of titanium dioxide particles and 70% by weight of low density polyethylene is manufactured and plasticized. The heated and plasticized blend is extruded through a die along with a filled styrene-butadiene rubber. The hetero sheet from the first composition will accordingly be 80 μm thick and the elastomer sheet 70 μm thick. The still hot tube is laid flat against itself and blocked, resulting in a supporting sheet 10 against a double hetero sheet 20 + 20 against another supporting sheet 10 .
The three mutually adhering sheets are stretched 120% of their original length, the inorganic titanium-dioxide particles detaching from the surrounding low density polyethylene. The elastomer sheets are allowed to return to their original dimensions, and the ripped edges of the interfaces stand up and constitute, in conjunction with the inorganic titanium-dioxide particles, a milky inner layer with an increased volume.
EXAMPLE 13
The hetero sheet is mixed and plasticized from a composition comprising 25% by weight PA6 polyamide particles of density 1.13 and 75% by weight polypropylene H of density 0.91. The supporting sheet is a sheet of styrene-butadiene-styrene elastomer. The two substances are co-extruded in a tube extruder. The still hot tube is folded over itself and blocked, resulting in a composite sheet comprising a supporting sheet against a double hetero sheet against another supporting sheet.
The composite sheet is allowed to cool, stretched to 125% of its original length along the direction of flow and at a right angle thereto, and allowed to return to its original dimensions. The result is a particularly fleecy feel.
EXAMPLE 14
A composite sheet manufactured as described in one of Examples 1 through 3 is fed through a creping machine with two powered cogwheels, producing a corrugated embossment. The material is then stretched and the elastomer sheet allowed to return to its corrugated state. The volume is simultaneously increased considerably.
EXAMPLE 15
A hetero sheet is sandwiched between two elastomer sheets and another hetero sheet co-extruded onto each side. The composite sheet is allowed to cool and stretched, resulting in a fleecy surface on each side and an increased volume inside.
EXAMPLE 16
A thermoplastic rubber (PUR elastomer) is extruded in a tube extruder along with a composition of 30% by weight of polystyrene particles of density 1.05 and 70% by weight of a homopolymeric polypropylene of density 0.91. The tube is sealed at one end with a roller. Air is pumped in from below, subjecting the cool or tempered tube to biaxial tentering. The elastomer tube is allowed to return to its original dimensions, upon which the co-polymerized composition sheet will stand up and create a fleece. The fleecy surfaces are laid together, heated with infrared radiation, and accordingly blocked with no sacrifice in volume.
EXAMPLE 17
A co-extruded composite sheet comprising two supporting sheets 10 and 30 and a hetero sheet 20 between them, as illustrated FIG. 6, is drawn over a rod 5 with a relatively short diameter D, say 2 mm, and accordingly mechanically stressed. The bending causes the added particles to detach from the surrounding plastic supporting sheet. The material in the hetero sheet stands up and increases the volume.
There has thus been shown and described a novel composite sheet and method of manufacture thereof which fulfills all the objects and advantages sought therefor. Many changes, modifications, variations 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. | The invention concerns a multiple-layer composite sheet and a method of manufacturing such a sheet. The composite sheet comprises a supporting sheet bonded to a “hetero sheet”. The hetero sheet consists of a heterogeneous blend of an elastic thermoplastic fundamental substance that cures semicrystalline or amorphous subsequent to processing and particles of added material distributed therein. The particles can be mixed and extruded along with the fundamental substance although they are heterogeneously bound therein. In the hetero sheet the particles of added material heterogeneously distributed therein are detached, by stretching for example, from the surrounding fundamental substance ( 2 ) and the material of the hetero sheet stands up at the many areas of detachment to create a fleecy surface. At least one hetero sheet ( 20 ) is enclosed in at least one supporting sheet ( 10 & 30 ). | 1 |
TECHNICAL FIELD OF THE INVENTION
The present invention generally relates to a fast looping-up and releasing rope loop assembly, which eliminates jamming problem of a rope loop that is operated with a one-way locking device to facilitate efficient release of the rope loop applicable to loop up an opening of a sack or the likes, and is particularly applicable to a covering sack for a yacht or a jet ski.
DESCRIPTION OF THE PRIOR ART
When a motorized vehicle, such as a yacht or a jet ski, is to be stowed for not use for a long while, it is often to cover to vehicle with a dust-proof cover to protect the vehicle from being contaminated by dust or other debris and also to protect the vehicle against aging and surface cracking caused by sun light.
The dust-proof cover is set over the yacht or the jet ski. When the yacht or the jet ski is transported to a marine area through road transportation, the dust-proof cover that covers the yacht or jet ski may be blown away by the high speed air flow caused during the road transportation through for example a high way. Thus, a rope is often used to loop up the cover around the yacht or jet ski for securing the cover. This is proven to be not working effectively in securing the cover and the cover may still be blown away once it is acted upon by strong blows. Another way is to use a sufficient length of rope, which can be for example as long as 80 feet, to entangle around fixation bars set around a yacht carrier platform to secure the cover on the yacht or jet ski. However, this is an elaborate and time-consuming job for entangling the rope around the yacht carrier platform, and the entangling rope is susceptible to over-tightening after being acted upon by strong blows during the road transportation, making it difficult to release subsequently.
It is thus desired to provide a rope loop assembly that can efficiently tightened and released and is applicable to cover an article without the risk of being blown away when undergoing high way transportation and without the risk of jamming of the rope so as to facilitate efficient release of the rope loop assembly.
SUMMARY OF THE INVENTION
The primary objective of the present invention is to provide a fast looping-up and releasing rope loop assembly that can be efficiently tightened and released so that a cover to which a one-way locking device and a rope of the rope loop assembly are attached can be effectively looped up without being blown off during high speed transpiration through for example a high way.
Another objective of the present invention is to provide a fast looping-up and releasing rope loop assembly, wherein in case a one-way locking device that selectively fixes the rope get jammed, a presser of a buckle can be simply depressed in a one-step operation to release the rope for a given distance that serves as a buffering space for actually releasing the rope so that convenience of efficient loop-up and release of the rope loop assembly can be realized.
To achieve the above objectives, the present invention provides a fast looping-up and releasing rope loop assembly comprising two one-way locking devices, at least one band, and a buckle. The one-way locking device has a configuration that allows a rope extending therethrough to be pulled in a single direction and prevents movement of the rope in an opposite direction. The one-way locking device is provided at one side thereof with a metal slotted plate through which the band extends. An end of the band is coupled to the buckle. The rope is set to extend along an opening of a covering sack, whereby the opening of the sack can be looped up by pulling the rope to cause the rope to be withdrawn in a single direction to loop up the sack opening. To release the sack opening, a presser of the buckle is depressed to provide an initial release of the sack opening and an operation arm of the one-way locking device is actuated to completely release the rope of the sack opening. Thus, efficient loop-up and release of the rope loop assembly can be realized.
The foregoing objective and summary provide only a brief introduction to the present invention. To fully appreciate these and other objects of the present invention as well as the invention itself, all of which will become apparent to those skilled in the art, the following detailed description of the invention and the claims should be read in conjunction with the accompanying drawings. Throughout the specification and drawings identical reference numerals refer to identical or similar parts.
Many other advantages and features of the present invention will become manifest to those versed in the art upon making reference to the detailed description and the accompanying sheets of drawings in which a preferred structural embodiment incorporating the principles of the present invention is shown by way of illustrative example.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a first embodiment of the present invention.
FIG. 2 is a schematic view illustrating the present invention loops up a covering sack.
FIG. 3 is a perspective view of a second embodiment of the present invention.
FIG. 4 is an exploded view of a one-way locking device of the present invention.
FIG. 5 is a perspective view illustrating a pull rope inserting into the one-way locking device in accordance with the present invention.
FIG. 6 is a perspective view illustrating a band inserting into a buckle in accordance with the present invention.
FIG. 7 is a cross-sectional view illustrating the band received in the buckle in accordance with the present invention.
FIG. 8 is a plan view, partially broken, illustrating the operation of the one-way locking device in looping up, wherein a block is caused to resiliently leap between adjacent teeth by the movement of the pull rope.
FIG. 9 is a plan view, partially broken, illustrating the operation of the one-way locking device in releasing the pull rope.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The following descriptions are exemplary embodiments only, and are not intended to limit the scope, applicability or configuration of the invention in any way. Rather, the following description provides a convenient illustration for implementing exemplary embodiments of the invention. Various changes to the described embodiments may be made in the function and arrangement of the elements described without departing from the scope of the invention as set forth in the appended claims.
Referring to FIGS. 1 and 2 , a rope loop assembly in accordance with the present invention comprises two one-way locking devices 1 , 1 a , a length of pull rope 80 , a length of a band 63 , and a buckle 70 . As shown, the band 63 has an end fixed to the buckle 70 and an opposite end extending through a slot 61 formed in a metal plate 60 of the first one-way locking device 1 , further extending through a slot 61 formed in a metal plate 60 of the second locking device 1 a , and eventually extending through a slot formed in front of a presser 76 of the buckle 70 , whereby the band 63 is connected between the two one-way locking devices 1 , 1 a . The pull rope 80 , which is connected to the locking devices 1 , 1 a , is looped around an opening rim 91 of a cover 90 (see FIG. 2 ) to effect fast looping-up and releasing.
To loop up the opening 91 of the cover 90 , the end of the band 63 is inserted into the buckle 70 and the presser 76 is operated to effect engagement and securely fixing (see FIG. 7 ). Afterwards, an operator may use both hands to simultaneously pull the pull rope 80 from both one-way locking devices 1 , 1 a whereby the rope 80 fast reduces the diameter looped in a one-way ratcheted condition for looping up and the opening 91 is thus tightened to the extreme by the pull rope. Due to the two one-way locking devices 1 , 1 a that provide an effect against backward movement of the pull rope 80 , the pull rope 80 is maintained in a gradually tightened condition during the looping up process and can be secured in the extremely tightened condition after the looping up of the rope.
Referring to FIG. 6 , to release the opening 91 of the cover for removing the cover, a release knob 53 that is provided in each one-way locking device 1 , 1 a can be operated to allow clockwise movement of the pull rope 80 for releasing. However, the pull rope 80 may get over-tightened, which causes the release knob 53 to be jammed by ratcheting teeth 33 . In accordance with the present invention, a one-step operation of depressing the presser 76 of the buckle 70 can be done to release the band 63 for a given distance and by doing so, the release knobs 53 of the two one-way locking devices 1 , 1 a are released from jamming caused by over-tightening and can be operated to allow clockwise releasing movement of the pull rope 80 (see FIG. 9 ). Afterwards, the opening 91 of the cover that is looped up by the rope can be easily expanded to remove the cover 90 . Fast looping up and releasing can be realized.
Referring to FIG. 3 , another embodiment of the present invention is illustrated, the rope loop assembly comprises a one-way locking device 1 to which a length of a band 63 a is attached. An opposite end of the band 63 a is attached to a buckle 70 . Another one-way locking device 1 a is fixed to an extended length of band 63 b . The rope loop assembly further comprises a pull rope 80 that extends in and along an opening rim 91 of a cover 90 (see FIG. 2 ). To loop up, an end of the band 63 b is inserted into the buckle 70 and engagement and fixing thereof is effected by the presser 76 . A similar function of fast looping up and releasing can be realized.
Referring to FIG. 4 , the one-way locking device 1 (the one-way locking device 1 a as well) is constructed in such a way that the one-way locking device 1 comprises a base 10 , a cover 20 , a rotary disk 30 , a rotary wheel 35 , and a locker 50 . The base 10 forms at one side thereof a rope entry opening 11 opposite sides of which form holes 18 . Two roller 13 are arranged above the holes 18 respectively and two bolts 19 extend in a down-to-up direction through the holes 18 and the rollers 13 to engage the cover 20 thereby rotatably holding the rollers 13 on the opposite sides of the opening 11 for protection of the pull rope 80 against abrasion and rubbing during the pulling operation of the rope. A recess 12 is centrally formed in the base 10 and a hole 16 is defined at a center of the recess 12 . One side of the base 10 is extended to form an extension plate 15 that forms on left and right side portions thereof two holes 14 . The cover 20 forms a positioning hole 21 , a positioning post 22 , and a slot 23 , and is extended at one side thereof to form an extension plate 25 . The rotary disk 30 forms a central bore 31 . The rotary disk 30 has a top face, which forms a cavity 32 that has a circumference forming the ratcheting teeth 33 . The rotary disk 30 has a bottom that has a configuration having a protruding central portion and a reduced circumferential portion and also forming raised ribs 34 that radially extend from a center defined by the bore 31 and an engagement peg (not shown) corresponding in shape to an engagement bore. The ribs 34 are arranged to respectively correspond to raised ribs 37 formed in the rotary wheel 35 . The rotary wheel 35 comprises a body that has a center-protruding and circumference-reduced configuration and forms the engagement bore 36 (which is octagonal in the drawings) at a center thereof around which radially extending ribs 37 are set. In the embodiment illustrated, the engagement peg formed on the bottom face of the rotary disk 30 is fit into and engages the engagement bore 36 of the rotary wheel 35 . However, the rotary disk 30 and the rotary wheel 35 can be integrally formed together, namely the engagement peg that is formed in the bottom of the rotary disk and is shaped corresponding to the engagement bore and the engagement bore defined in the center of the rotary wheel can be integrated together to provide an equivalent result.
Referring to FIGS. 3 and 4 , the pull rope 80 is inserted into the rope entry opening 11 through the right hand side portion thereof, extending between the ribs of the rotary disk 30 and the rotary wheel 35 and then projecting outward through the left hand side portion of the rope entry opening 11 . In this way of arrangement, the pull rope 80 can be withdrawn out of the locking device 1 by a counterclockwise movement or retracted back into the locking device 1 in a clockwise movement. The locker 50 comprises a bar 51 from which an operation arm 53 transversely extends. A tongue 56 also transversely extends from the bar 51 and is substantially opposite to the operation arm 53 . The tongue 56 forms a through hole 54 . A block 52 is formed on a bottom of the operation arm 53 .
Referring to FIG. 4 , the metal plate 60 that forms the slot 61 also forms holes 62 . A high-tension band 63 a is received through the slot 61 . To assemble, bolts 24 are respectively and sequentially set through the holes 14 defined in the extension plate 15 of the base 10 , the holes 62 defined in the metal plate 60 and then engage threaded holes defined in the extension plate 25 of the cover 20 so as to secure the metal plate 60 between the base 10 and the cover 20 . An end of the band 63 a extending through the slot 61 (see FIG. 3 ) is folded over and is fixed to the band 63 a by sewing. An opposite end of the band 63 a extends through the buckle 70 and is also folded over and sewn to the band 63 a itself. Thus, the band 63 a connects between the one-way locking device 1 and the buckle 70 .
To assemble the one-way locking device 1 , a central shaft 17 is first fit into the hole 61 defined in the recess 12 of the base 10 . Alternatively, the central shaft is integrally formed with the hole. The engagement bore 36 of the rotary wheel 35 is then fit over the central shaft 17 to allow the rotary wheel 35 to be positioned in the recess 12 of the base 10 . The rotary disk 30 is set to have the ribs 34 thereof opposing the rotary wheel 35 and the central bore 31 of the rotary disk 30 is fit over the central shaft 17 with the ribs 34 , 37 of the rotary disk 30 and the rotary wheel 35 facing each other. The engagement peg formed on the bottom of the rotary disk and corresponding in shape to the engagement bore 36 is then fit into the engagement bore 36 of the rotary wheel 35 . The bar 51 of the locker 50 is fit into the positioning hole 21 of the cover 20 and the block 52 of the locker 50 is received in the cavity 32 defined in the top face of the rotary disk 30 . An end of a spring 55 is coupled to the through hole 54 of the tongue 56 , while an opposite end of the spring 55 is attached to the positioning post 22 of the cover 20 to provide a returning biasing force to the block 52 when the block 52 is forced aside by the ratcheting teeth 33 during the rotation thereof.
Referring to FIG. 4 , the band 63 a extends between the metal plate 60 and the buckle 70 . The buckle 70 comprises a chassis 71 of which one end is coupled to the band and an opposite end supporting a stop tab 72 , a retention bar 73 , a pivot 77 , a spring 75 , and the presser 76 . The presser 76 forms a through hole 78 . The pivot 77 sequentially extends through a hole 79 defined in one sidewall of the buckle 70 , the through hole 78 of the presser 76 , and the spring 75 , and is fit into a hole defined in an opposite sidewall of the buckle 70 and fixed thereto by means of for example riveting, whereby the presser 76 is retained on the buckle 70 . The spring 75 is rotatably and deformably arranged on the back side of the presser 76 . The retention bar 73 forms a retention notch 74 .
Referring to FIG. 8 , to insert the pull rope 80 in a counterclockwise direction into the one-way locking device 1 by inserting the pull rope 80 through one side portion of the rope entry opening 11 , the pull rope 80 is caused to extend over outer surfaces of the ribs 34 , 37 of the rotary disk 30 and the rotary wheel 35 . The forward insertion of the pull rope 80 induces a dragging force to cause the rotary disk 30 and the rotary wheel 35 to rotate. The pull rope 80 projects outward through the opposite side portion of the rope entry opening 11 to complete the assembling of the one-way locking device. When the pull rope 80 is pulled by an external force, the pull rope 80 is only allowed to move in a single direction, namely a direction that causes counterclockwise rotation of the rotary disk 30 (and the rotary wheel 35 ). Under this condition, the block 52 of the locker 50 is resiliently leaping between adjacent teeth 33 under a biased condition with the spring 55 that is coupled to the through hole 54 of the tongue 56 of the block 52 . Thus, each time the block 52 is put aside by one of the teeth 33 , the spring 55 drives the tongue 56 back to the original position, and the pull rope can thus be smoothly pulled outward.
Referring to FIG. 9 , on the other hand, when the pull rope 80 is pulled in a clockwise direction, the teeth 33 engages and blocks the block 52 , preventing the rotary disk 30 from rotation. Thus, the pull rope 80 is constrained from moving outward. In this way, a one way locking function can be realized.
Referring to FIGS. 6 , 7 , and 9 , due to the spring 75 arranged below the presser 76 of the buckle 70 , the presser 76 is biased by the spring 75 , which is held in the retention notch 74 to generate an upward spring force, to tightly engage and thus fix the band. The rope loop assembly in accordance with the present invention can be tightly looped up by continuously pulling the pull rope 80 that is allowed to do one-way movement. In case that an attempt to release the pull rope 80 when the pull rope 80 is in a tightened condition is made and the actuation of the operation arm 53 is jammed by the over-tight engagement between the block 52 and the teeth 53 , slight relief of the pull rope tension is needed to remove the jamming. However, the over-tightened condition makes it difficult to release the rope. In accordance with the present invention, a one-stop operation of depressing the presser 76 , which releases the band 63 coupled thereto for a distance, can effectively release the tension of the pull rope through the releasing of the band 63 through such a distance, making the rotary disk 30 no longer jammed and a buffering space for retraction of the pull rope 80 is provided. The block 52 can thus be disengaged from the teeth 53 by the operation of the operation arm 53 . Consequently, fast clockwise retraction of the pull rope 80 can be carried out to release the rope loop assembly (see FIG. 9 ).
While certain novel features of this invention have been shown and described and are pointed out in the annexed claim, it is not intended to be limited to the details above, since it will be understood that various omissions, modifications, substitutions and changes in the forms and details of the device illustrated and in its operation can be made by those skilled in the art without departing in any way from the spirit of the present invention. | A fast looping-up and releasing rope loop assembly includes two one-way locking devices, at least one band, and a buckle. The one-way locking device includes a body constituted by a base and a cover. The one-way locking device allows the pull rope to extend therethrough and to move with respect thereto along a single direction. By inserting the pull rope through a rope entry opening of the base of the one-way locking device and further extending the rope around a rotary disk and a rotary wheel arranged inside the locking device and extending out of the locking device, the one-way locking device that locks the movement of the rope in an opposite direction is completed. When the rope is jammed due to excessive tightening, a presser of the buckle is depressed to release the one-way locking device from the jamming condition so that efficient loop-up and release can be realized. | 5 |
BACKGROUND OF THE INVENTION
[0001] The present invention relates to a novel method of dry cleaning of fabric materials and a dry cleaning solvent used therefor. More particularly, the invention relates to a dry cleaning method of fabric materials having advantages of, besides the high cleansing effect exhibited to an oily or greasy dirt deposited on the fabric material and pleasant touch feeling of the fabric material finiashed by the dry cleaning method, absence of unpleasant smell therefrom, little problems against environmental pollution possibly leading to destruction of the ozone layer in the aerosphere and safety against workers' health by virtue of the use of a unique dry cleaning solvent which has never been employed for this purpose of dry cleaning.
[0002] Needless to explain, dry cleaning is a process for cleaning a fabric material such as clothes in which the fabric material is immersed in or soaked with a non-aqueous organic solvent capable of dissolving oily or greasy dirt materials deposited on the fabric material so as to dissolve the dirt material out of the fabric material into the solvent followed by removal of the solvent from the cleaned fabric material and drying thereof.
[0003] A great variety of organic solvents have been proposed as the dry cleaning solvent and are actually employed for the purpose, of which the solvents currently under wide applications include halogenated hydrocarbon solvents, such as chlorofluorinated hydrocarbons and chlorinated hydrocarbons such as perchloroethylene, trichloroethylene and trichloroethane, and petroleum-based hydrocarbon solvents which are mainly paraffinic or naphthenic.
[0004] While advantageous in respects of non-inflammability and rapid drying, the above mentioned halogenated hydrocarbon solvents as a dry cleaning solvent have serious problems because vapors of such a halogenated hydrocarbon solvent emitted to the atmosphere are suspected to be liable for destruction of the ozone layer in the aerosphere in addition to the problem against public and workers' health due to contamination of the underground wate by discarded dry cleaning solvents and environmental pollution by the solvent vapor.
[0005] Accordingly, it is now a world-wide trend that use of halogenated hydrocarbon solvents is going to be banned not only as a dry cleaning solvent but also in any other applications. Petroleum-based hydrocarbon solvents are also noxious as an environmental pollutant against workers' health. For example, regulations in many countries prescribe the maximum permissible concentration of vapors of petroleum-based hydrocarbon solvents in the working environment at a very low level in order to ensure workers' health against toxication by the solvents. Among various proposals to solve this problem, Japanese Patent No. 1502875 proposes use of a cyclic organopolysiloxane oligomer or a mixture thereof with a petroleum-based hydrocarbon solvent as a dry cleaning solvent. Japanese Patent Kokai 6-327888 further discloses a method of dry cleaning by using a volatilizable organopolysiloxane having a straightly linear molecular structure as the dry cleaning solvent.
[0006] The above mentioned cyclic organopolysiloxane oligomer, however, has a disadvantage, when used as a dry cleaning solvent, that the cyclic organopolysiloxane oligomer is susceptible to ring-opening polymerization by the catalytic activity of the acidic or basic compound contained in the contaminant dirt material deposited on the fabric material for cleaning to produce a non-volatile organopolysiloxane of an increased degree of polymerization which in turn is deposited on the fabric material sometimes adversely affecting the touch feeling of the finished fabric material.
[0007] Japanese Patent Kokai 11-214587 teaches that organopolysiloxane oligomers are useful as a washing solvent of articles of a metal, ceramic, glass and plastic as well as semiconductor materials. It is unclear there, however, whether or not the organopolysiloxane oligomer be effective as a dry cleaning solvent for fabric materials or, in particular, clothes.
SUMMARY OF THE INVENTION
[0008] In view of the above described problems in the prior art method of dry cleaning, the present invention has an object to provide a novel method for dry cleaning of a fabric material by using a unique volatilizable organopolysiloxane compound as the dry cleaning solvent having advantages, in addition to the excellent cleansing effect on not only oily or greasy dirt materials but also some water-soluble dirt materials and very pleasant touch feeling of the fabric material finished by the method, that the dry cleaning solvent is not toxic against human body to ensure safety to the public and workers' health and that the solvent is not liable for the destruction of the ozone layer in the aerosphere due to emission of the vapor thereof to the atmosphere. The invention also has an object to provide a dry cleaning solvent used in the dry cleaning method.
[0009] Thus, the method of the present invention for dry cleaning of a fabric material comprises the steps of:
[0010] (a) immersing the fabric material in or soaking the fabric material with a dry cleaning solvent which is a tris(trimethylsiloxy) silane compound represented by the general formula
RSi(—O—SiMe 3 ) 3 , (I)
[0011] In which Me is a methyl group and R is a monovalent hydrocarbon group having 1 to 6 carbon atoms, or a mixture thereof with a petroleum-based hydrocarbon solvent so as to dissolve dirt materials on the fabric material into the solvent;
[0012] (b) removing the dry cleaning solvent containing the dirt materials dissolved therein from the fabric material by solid-liquid separation; and
[0013] (c) drying the fabric material wet with the dry cleaning solvent.
[0014] The invention also provides a dry cleaning solvent used in the above defined method of dry cleaning which comprises:, as a uniform mixture:
[0015] (A) at least 30% by weight of the tris(trimethylsiloxy) silane compound represented by the above given general formula (I); and
[0016] (B) a petroleum-based hydrocarbon solvent in an amount not exceeding 70% by weight.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0017] As is described above, the dry cleaning method of the present invention is characterized by the use of, as the dry cleaning solvent, the tris(trimethylsiloxy) silane compound, referred to as the silicone solvent hereinafter, represented by the general formula (I) or a mixture thereof with a petroleum hydrocarbon solvent.
[0018] In the general formula (I) representing the silicone solvent, the group denoted by R is a monovalent hydrocarbon group having 1 to 6 carbon atoms exemplified by alkyl groups such as methyl, ethyl, propyl, butyl, pentyl and hexyl groups, cycloalkyl groups such as cyclopropyl, cyclobutyl, cyclopentyl and cyclohexyl groups and phenyl group, of which alkyl groups having 1 to 3 carbon atoms, i.e. methyl, ethyl and propyl groups, are preferable and methyl group is more preferable as R in respects of the low boiling point to ensure good volatilizability and inexpensiveness of methyl tris(trimethylsiloxy) silane.
[0019] Particular examples of the tris(trimethylsiloxy) silane compounds as the silicone solvent include: methyl, ethyl, propyl, butyl, pentyl and hexyl tris(trimethylsiloxy) silanes of the formulas MeSi(—O—SiMe 3 ) 3 , C 2 H 5 Si(—O—SiMe 3 ) 3 , C 3 H 7 Si(—O—SiMe 3 ) 3 , C 4 H 9 Si(—O—SiMe 3 ) 3 , C 5 H 11 Si(—O—SiMe 3 ) 3 and C 6 H 13 Si(—O—SiMe 3 ) 3 , respectively, when R is an alkyl group, cyclopropyl, cyclobutyl, cyclopentyl and cyclohexyl tris(trimethylsiloxy) silanes expressed by the formulas C 3 H 5 Si(—O—SiMe 3 ) 3 , C 4 H 7 Si(—O—SiMe 3 ) 3 , C 5 H 9 Si(—O—SiMe 3 ) 3 and C 6 H 11 Si(—O—SiMe 3 ) 3 , respectively, when R is a cycloalkyl group, and phenyl tris(trimethylsiloxy) silane of the formula C 6 H 5 Si(—O—SiMe 3 ) 3 , when R is a phenyl group, in which Me is a methyl group. These silicone solvents can be used either singly or as a mixture of two kinds or more.
[0020] The above described tris(trimethylsiloxy) silane compound as the silicone solvent can be prepared by several different synthetic routes including, for example, the dehydrochlorination reaction between trimethyl silanol Me 3 SiOH and a trichlorosilane compound RSiCl 3 , a co-hydrolysis/co-condensation reaction between a trichlorosilane compound RSiCl 3 and trimethyl chlorosilane Me 3 SiCl and a rearrangement reaction between hexamethyldisiloxane and a chlorosilane compound or an alkoxysilane compound.
[0021] The dry cleaning solvent used in the inventive dry cleaning method of fabric materials can be a mixture of the above described tris(trimethylsiloxy) silane compound and a petroleum-based hydrocarbon solvent which can be any of those used in the conventional dry cleaning processes and specified in JIS K2201-5 and ASTM D235. The petroleum-based hydrocarbon solvent can be paraffinic or naphthenic including benzines and solvent naphthas as well as isoparaffins. These petroleum-based hydrocarbon solvents can be used either singly or as a combination of two kinds or more.
[0022] The above described silicone solvent and the petroleum-based hydrocarbon solvent are freely miscible in any desired mixing proportions to give a uniform solvent mixture. When the dry cleaning solvent used in the inventive dry cleaning method is a mixture of the silicone solvent and the petroleum-based hydrocarbon solvent, it is preferable that the solvent mixture contains at least 30% by weight of the silicone solvent, the proportion of the hydrocarbon solvent not exceeding 70% by weight, in order to obtain the advantages to be accomplished by the inventive method. When the weight proportion of the silicone solvent in the solvent mixture is too small, the fabric material finished by dry cleaning by using the mixed solvent cannot be imparted with fully improved touch feeling in addition to the disadvantages inherent in the use of a petroleum-based hydrocarbon solvent.
[0023] The procedure of dry cleaning of fabric materials according to the invention is not particularly different from that in the conventional dry cleaning processes using a halogenated hydrocarbon solvent or a petroleum-based hydrocarbon solvent as the dry cleaning solvent excepting for the replacement of the conventional dry cleaning solvent with the silicone solvent or a mixture thereof with a petroleum-based hydrocarbon solvent so that the facilities for dry cleaning ready installed can be used as such in the inventive method. In step (a) of the inventive method, namely, the fabric material for cleaning is immersed in a sufficiently large volume of the dry cleaning solvent so as to dissolve out the dirt materials adhering to the fabric material into the solvent. Instead of immersion in the dry cleaning solvent, the fabric material can be soaked with a limited volume of the solvent, for example, by spraying the solvent. Application of ultrasonic waves to the fabric material or increase of the temperature up to 60° C. or in the range from 10 to 60° C. is sometimes effective to promote dissolution of the dirt materials in the solvent. In step (b) of the inventive method, the fabric material is separated from the solvent containing the dirt material dissolved therein in a solid-liquid separating method such as centrifugation and roller squeezing as completely as possible and, in step (c), the fabric material still wet with the solvent is dried by air drying, hot-air circulation drying or drying under reduced pressure.
[0024] In the following, the present invention is described in more detail by way of Examples, which, however, never limit the scope of the invention in any way. The Examples are preceded by the description of the synthetic preparation of the tris(trimethylsiloxy) silane compounds.
SYNTHESIS EXAMPLE 1
[0025] Methyl tris(trimethylsiloxy) silane was prepared in the following manner. Thus, 1296 g (8 moles) of hexamethyl disiloxane, 100 g of concentrated hydrochloric acid and 30 g of water were introduced into a four-necked flask of 2 liter capacity to form a reaction mixture which was chilled by immersing the flask in an ice water bath. Thereafter, 359 g (2.4 moles) of methyl trichlorosilane were added dropwise into the reaction mixture under agitation and chilling and agitation of the reaction mixture was continued for further 1 hour to complete the reaction between hexamethyl disiloxane and methyl trichlorosilane. The reaction mixture was then neutralized with a 10% by weight aqueous solution of sodium hydrogencarbonate followed by washing with water and distillation under reduced pressure to give a colorless, clear liquid product having physical properties including: boiling point of 86° C. under 20 Torr, viscosity of 1.4 mm 2 /s at 25° C., density of 0.848 g/cm 3 at 25° C., refractive index of 1.386 at 25° C. and surface tension of 16.6 mN/m at 25° C., from which the liquid product could be identified to be methyl tris(trimethylsiloxy) silane. The yield of the product was 65% of the theoretical value.
SYNTHESIS EXAMPLE 2
[0026] Propyl tris(trimethylsiloxy) silane was prepared in the following manner. Thus, 303 g (3 moles) of triethylamine and 300 g of toluene were introduced into a four-necked flask of 2 liter capacity to give a solution which was chilled by immersing the flask in an ice water bath. Thereafter, 177.5 g (1 mole) of propyl trichlorosilane and 297 g (3.3 moles) of trimethyl silanol were added separately but concurrently each dropwise into the solution in the flask under agitation followed by washing with water and distillation under reduced pressure to give a colorless, clear liquid product having physical properties including: boiling point of 78° C. under 12 Torr, viscosity of 2.2 mm 2 /s at 25° C., density of 0.852 g/cm 3 at 25° C., refractive index of 1.395 at 25° C. and surface tension of 17.1 mN/m at 25° C., from which the liquid product could be identified to be propyl tris(trimethylsiloxy) silane. The yield of the product was 55% of the theoretical value.
EXAMPLE 1
[0027] Three 15 cm by 15 cm square pieces of plain-woven cloths of polyester, nylon and cotton fibers were each smeared with 1 g of a motorcar oil on the respective center areas to serve as the oil-stained fabric specimens for the dry cleaning test. The thus stained test specimens were put together into 1 liter of methyl tris(trimethylsiloxy) silane prepared in Synthesis Example 1 held in the 3-liter washing vessel of a test washer machine and agitated therein for 15 minutes at 40° C. followed by roller squeezing and drying in a hot-air drying oven at 60° C. taking 60 minutes.
[0028] The conditions of each of the test specimens after the above described dry-cleaning run were examined by subjecting the specimens to organoleptic tests for the items of: (Evaluation Item I) cleansing effect on the oil-stained areas; (Evaluation Item II) touch feeling of the finished cloths; and (Evaluation Item III) smell due to remaining solvent. The results of each evaluation item were rated in two ratings of A (no trace of oil stain) and B (trace of oil stain recognizable) for the Evaluation Item I, in two ratings of A (good) and B (poor) for the Evaluation Item II and in three ratings of A (no smell), B (slight but noticeable smell) and C (noticeable smell) for the Evaluation Item III as shown in Table 1 below. Discoloration or denaturation was noted in none of the test specimens after the dry cleaning test.
EXAMPLE 2
[0029] The experimental procedure was substantially the same as in Example 1 described above excepting for the replacement of the methyl tris(trimethylsiloxy) silane as the dry cleaning solvent with the same volume of propyl tris(trimethylsiloxy) silane prepared in Synthesis Example 2. The results of the test cleaning are shown in Table 1. Discoloration or denaturation was noted in none of the test specimens after the dry cleaning test.
EXAMPLE 3
[0030] The experimental procedure was substantially the same as in Example 1 described above excepting for the replacement of the methyl tris(trimethylsiloxy) silane as the dry cleaning solvent with the same volume of a 50:50 by weight mixture of methyl tris(trimethylsiloxy) silane and a petroleum-based hydrocarbon solvent (Brightsol, a product by Shell Japan Co.). The results of the test cleaning are shown in Table 1. Discoloration or denaturation was noted in none of the test specimens after the dry cleaning test.
COMPARATIVE EXAMPLE 1
[0031] The experimental procedure was substantially the same as in Example 1 described above excepting for the replacement of the methyl tris(trimethylsiloxy) silane as the dry cleaning solvent with the same volume of the petroleum-based hydrocarbon solvent (Brightsol, supra) alone. The results of the test cleaning were clearly inferior for the Evaluation Items II and III as shown in Table 1 although no discoloration nor denaturation was noted in any of the test specimens after the dry cleaning test.
TABLE 1 Fiber Evaluation Polyester Nylon Cotton Item I II III I II III I II III Example 1 A A A A A A A A A Example 2 A A A A A A A A A Example 3 A A B A A B A A B Comparative A B C A B C A B C Example 1 | The invention discloses a novel method for dry cleaning of a fabric material characterized by the use of a unique dry cleaning solvent which is a tris(trimethylsiloxy) silane compound represented by the general formula of RSi(—O—SiMe 3 ) 3 , in which Me is a methyl group and R is a monovalent hydrocarbon group of 1 to 6 carbon atoms or, preferably, a methyl group, or a mixture thereof with a petroleum-based hydrocarbon solvent in a limited proportion. In addition to the excellent effect of dry cleaning equivalent to that of conventional dry cleaning solvents and little unpleasant smell remaining on the fabric material, the solvent used in the inventive method is little liable for the problems of environmental pollution against public and workers' health and the problem of ozone layer destruction in the aerosphere due to emission of vapors of halogenated hydrocarbon solvents can be solved by the inventive method. | 3 |
BACKGROUND OF THE INVENTION
The present invention relates to arrays for performing logic functions and more particularly it is related to the manufacture of PLA chips with different circuit configurations.
The performing of logic in an array of identical circuit elements each located at a unique intersection of an input and output line in a grid of intersecting input and output lines is well known. It is also well known to perform logic in a compound arrangement of these arrays called a programmable logic array chip (PLA) by using the outputs of one array as the inputs to another array. Co-pending application Ser. No. 537,219 filed on Dec. 30, 1974 describes such a PLA on which a number of decoders feed inputs to a first array called a product term generator or an AND array which in turn supplies outputs to a second array called a sum of product term generator or an OR array. The outputs of the OR array are then used to control the setting and resetting of a string of latches so that both combinatorial and sequential logic functions can be performed by the PLA. The particular logic functions actually performed by the given PLA are controlled by the locations and number of the active logic circuits in the AND and OR arrays of the PLA and also by how inputs are supplied to the decoders either from off the chip or from the latches. Furthermore, the type of latch used determines the logic functions performed on the PLA chip. Therefore, it is important that a number of different types of latches be available on the PLA chip each in the quantities needed to permit the efficient use of the chip.
THE INVENTION
Therefore, in accordance with the present invention the functions performed by the latch circuits of a PLA and other circuits in the PLA are changeable. These changes can be provided merely by changing the metallization pattern of the PLA chip so that changes can be made at the same time and in the same manner that the arrays of the PLA are personalized in the above mentioned application Ser. No. 537,219.
Therefore it is an object of the present invention to provide a programmable logic array with latches and other circuits that can be personalized to perform specific purposes.
It is another object of the present invention to provide a scheme in which circuits on a logic array can be personalized by the selection of the metallization pattern of the chip.
A further object of the invention is to provide a programmable logic array with latches that can function as either JKs or polarity hold latches depending on the metallization pattern of the chip.
THE DRAWINGS
These and other objects, features and advantages of the invention will be apparent from the following more particular description of the preferred embodiments of the invention of which:
FIGS. 1A and 1B are a circuit diagram showing the circuits to perform logic on a typical pair of inputs to the array of the above mentioned patent application.
FIG. 2 is a logic block diagram of a JK latch.
FIG. 3 is a logic block diagram of a polarity hold latch.
FIG. 4 is a logic block diagram of a gated polarity hold latch.
FIG. 5 is a circuit diagram of a JK latch.
FIG. 6 is a circuit diagram of a polarity hold latch.
FIG. 7 is a circuit diagram of a gated polarity hold latch.
FIG. 8 is a chip layout for common portions of the circuits in FIGS. 1 to 5.
FIG. 9 is the metallization pattern peculiar to the circuit of FIG. 5.
FIG. 10 is the metallization pattern peculiar to the circuit of FIG. 6, and
FIG. 11 is the metallization pattern peculiar to the circuit of FIG. 7.
DETAILED DESCRIPTION
Referring now to FIG. 1 two inputs A and B to the chip are fed to a decoder 10 which in response to the input signals supplies an output on one of four outputs 12. When input A is up and input B is down an up signal is placed on line 12 and fed into the search or AND array. For other combinations of A and B one of the other output lines of the decoder 10 contains the up signal. When the up signal is placed in line 12 any transistor 16 along line 12 in the array is rendered conductive discharging the output line 18 of the array that are coupled to the transistor 16. The line 18 had previously been charged to plus 5 volts through device 20 coupling the line 18 to a 5 volt source. The output line 18 therefore goes down when device 16 conducts and discharges it. When the output line is down, any device 22 arranged along it in the Read OR array 24 is turned off providing an up output on the output line 26 of the OR array 24 coupled by device 22 to line 18. If the device 16 is left non-conducting, line 18 will be down biasing device 22 off. With device 22 off the potential on line 26 will be up providing an up output on the output line of the array. Potential on line 26 is maintained through FETs 28 and 30 which has their bias connected so that they act like resistive elements.
The signals on the output lines 26 of the OR array 24 are fed into one of a number of latches 32. For purposes understood by those skilled in the art it is desireable that a number of different types of latches be available to perform logic. One type of latch is the JK latch. As shown in FIG. 2, in this type of latch one input J or K to the latch 50 disabled by feeding both of the outputs Q or Q into an AND gate 52 or 54 along with one of the inputs. The following logic table contains the possible logic states for a JK latch.
______________________________________J K Q______________________________________0 0 hold0 1 S1 0 R1 1 T______________________________________
Another type of latch that is useful in performing logic is an AND polarity hold latch shown in FIG. 3. When both the inputs A and B of this type of latch are up you obtain a one signal on the Q output otherwise the Q output line is down. This is shown in the following table.
______________________________________A B Q______________________________________0 0 hold0 1 01 0 11 1 X______________________________________
A third type of circuit that could be desireable is shown in FIG. 4. This latch is referred to as a gated polarity hold. The gated polarity hold latch prevents the data signal DATA from entering the latch when the gate signal GATE is not up.
It is desirable that all three of the above type latches be available at any of the outputs of the array shown in the above mentioned patent application. In accordance with the present invention, a latch circuit is provided that can be transferred into any of the three types of latches with a minimum number of changes in the chip making process. FIG. 5 shows the JK configuration for this latch. The basic latching circuit 34 comprises two cross connected devices J1 and J2 each connected to a 5-volt source by a load device I1 or I2. When J1 is conducting the flip flop is in one of its operating states, the binary 1 state. When J2 is conducting flip flop is in its other operating state or the binary 0 state. The state of the latch can be changed by making the devices H1 and H2 conductive while the devices G1 and G2 are conductive. Devices G1 and G2 are conductive when the MS signal is up so while the MS signal is up an input to line 40 or 42 can cause device J1 or J2 to be rendered non-conductive by biasing the gate of device J1 or J2 below the threshold level.
The inputs to lines 40 or 42 are controlled by AND circuits 44 and 46. During MS time device D1 is conductive to charge line 40 through device C1 while device G1 is maintained off to prevent the shunting of the gate to drain voltage of device J2 by the H1, G1 combination. If MS time J is up it shunts this charge to ground so that there will not be any potential on line 40 when G1 is activated at the MS time. However if J is down all during MS time device B1 will not be rendered conductive and potential at point 40 will shunt the gate to drain of J2 to ground when device G1 is biased conductive MS time. During MS time the gate of B1 is isolated from the J input signal by device A1 which is biased conductive during the period when the MS signal is up.
Thus it can be seen that the state of the latch 34 can be changed through AND gate 44 by the J signal from the Q state to the Q state by turning device J2 off. In the same manner the K signal can change the state of the latch 34 from the Q state to the Q state by turning J1 off when a down K signal to AND gate 46 during MS times. Thus inputs applied to J and K will change the states of the latch 34 when they are applied to J during MS time and otherwise will be ineffective at changing the state of the latch.
The gate of device E1 is the input to AND gate 44 that receives the feedback signal from the output 38 of the latch. If Q is up during MS time the signal is transferred to the gate of E1 biasing E1 conductive thereby disabling the J input. Likewise device E2 is the input device of AND gate 46 that receives the Q signal during MS time through device K2 disabling the K input.
As explained in the above mentioned patent application the latches are connected together to form a shift register so that the state of one latch can be transferred to another latch. This is the purpose of devices F1, F2. When such a transfer from flip flop to flip flop is to occur devices F1, F2 are activated by signal A during MS time allowing the signals on the output lines 38 and 36 of one flip flop to be transferred through devices F1 and F2 into the AND gates 44 and 46 so that AND gates can provide a signal on lines 40 or 42 to change the state of the latch 34.
The circuit in FIG. 6 can be modified as shown in FIG. 7 to obtain the AND polarity hold latch shown schematically in FIG. 4. As can be seen in FIG. 6 the modification involves feeding both inputs from the OR array into the AND gate 44, taking the output of AND gate 44 and feeding it to the gate of device B2 in the other AND gate 46, grounding the gate of device E2, and breaking the feedback loops coupling the outputs 38 and 36 to the devices E1 and E2. Also, the circuit can be used as the gated polarity hold latch shown in FIG. 7 by coupling the gate of E2 to the same input as E1 instead of grounding the gate of E2.
Therefore it can be seen that the circuit is adaptable to at least three different types of latching arrangements. These latching arrangements can all be obtained with the same physical layout by merely changing the metallization pattern of connections shown.
FIG. 8 is a physical layout of the devices B1, E1, E2 and B2 in the latch circuit of FIGS. 5, 6 and 7 on the chip containing the PLA. The speckled lines represent diffusions made into the substrate of silicon chip containing the logic array while the hatched lines represent metallization patterns on an oxide layer on top of the silicon. The rectangular areas with a smaller rectangle in them are holes through the oxide layer for connections through the insulating layer between the diffusions and the metallization pattern.
FIG. 9 shows metallization peculiar to a JK trigger. The position of this additional metallization on the layout of FIG. 8 can be seen by aligning the coordinates arranged around the edges of the two figures. FIG. 10 shows the additional metallization needed to obtain the polarity hold latch and FIG. 11 shows the additional metallization needed to obtain the gated polarity hold latch. Thus it can be seen that the latches can be modified quite simply in the same steps that the arrays are personalized to permit a more flexible application of the array chip.
Although we have shown in detail only the modification of the latches of the gated polarity hold circuit other circuits may also be modified in the array in the same manner. For instance, the array chip drivers 48 which receive their inputs from the outputs of the latches 32 can be modified by enabling and disabling the connection between the gate of device 49 so that the off chip driver 49 can be changed from a single stage driver to a multi stage driver.
Obviously other changes can be made in the scope of the invention. Therefore it should be obvious to those skilled in the art that many changes can be made in the above embodiment of the invention without departing from the spirit and scope of the invention. | This specification describes means that permit the variation of circuits, particularly latch circuits, used in programmable logic array chips (PLAs). The latch circuits are changeable to enable the selection of one of three different latch configurations to be used or in combination on the same PLA chip. The differences in the circuit configurations of the different types of latches occur only in metallization pattern of the chip so that chips with different latch configurations can be manufactured with a minimum of different processing steps. | 7 |
CROSS REFERENCE TO RELATED APPLICATIONS
This claims priority of Japanese Patent Application No. 2013-164837, filed on Aug. 8, 2013, the disclosure of which is incorporated by reference in its entirety.
TECHNICAL FIELD
The present invention relates to a novel cultured cell line adapted to a medium substantially free of proteins or lipids, a method for producing the cell line, a medium for culturing the cell line, and a use of the cell line for producing a recombinant protein.
BACKGROUND ART
The share of biopharmaceuticals has been rapidly increasing in a medicinal market. Among biopharmaceuticals, remarkably increasing have been recombinant protein formulations such as enzymes, hormones, antibodies, growth factors, and blood coagulation factors. For stable supplies of these pharmaceuticals, establishment of a system for producing a recombinant protein, which is safe, low-cost and efficient, is desired.
Recombinant proteins have been conventionally expressed using Escherichia coli , etc. because of the productivity and efficiency. However, the expression systems of E. coli have problems that it is difficult to reproduce the conformation of a protein and that a post-translational modification such as glycosylation modification cannot be achieved. Thus, many of those recombinant protein formulations each comprising a cytokine, an enzyme, an antibody drug, or the like, which involves its conformation or the post-translational modification for its activity, are produced using Chinese Hamster Ovary (CHO) cells.
The expression systems using CHO cells also involve problems. Until recent years, a serum or a biological material derived from a heterologous animal has been used for culturing CHO cells. However, the use of the serum or the biological material derived from the heterologous animal causes problems about safety such as a risk of infection of a virus originated from an animal and an allergy due to a heterologous animal antigen. Further, a problem concerning stability, such as a lot-to-lot variability, is also caused by using biological materials. Therefore, chemically defined media (synthetic media) have been developed, in which media components produced by chemical syntheses or recombinant techniques are used instead of biological materials such as a serum (Non-patent Literature 1: Sunstrom, et al., 2000). However, those components produced by chemical syntheses or recombinant techniques, especially growth factors, are expensive and unstable. Thus, it is desirable for industrial production to conduct culture without adding such substances or growth factors.
An adapted culture method, in which cells are gradually adapted to an environment which is free of materials derived from biologics or growth factors, is an approach to eliminate those factors from CHO cell culture. It has been reported for a long time that cells have an ability to adapt to an environment and can be adapted to an environment with only minimum essential nutrients by spending time on adaptation (Non-patent Literature 2: Kagawa, et al., 1969; Non-patent Literature 3: Kagawa, et al., 1970). In a protein expression system, when a protein of interest is expressed by transfecting the CHO cells with a vector carrying cDNA of the protein, a drug resistant gene is used in the transfection in order to select cells carrying the gene of interest. If any transfection is carried out in addition to transfection for introducing the gene for the protein of interest, a selection method comes to be limited. Thus, it is desirable not to carry out additional transfection. In the adapted culture method, it is unnecessary to perform an additional manipulation for gene modification such as gene introduction, because cells themselves are being adapted to the environment. In this meaning, the adapted culture method has a high flexibility in terms of introduction of the gene of interest. However, the adapted culture method is time-consuming and labor-intensive, and has a low success rate. Thus, this method has not been tried in order to obtain adapted cells derived from the CHO cells having high productivity.
Further, the CHO cells also involve other problems. The CHO cells are inherently adherent cells and therefore they are not suitable for tank culture by using, e.g., a bioreactor, which is used in large-scale productions of materials for industrial use. Adherent cells require a large cell-adhering surface area because they propagate while adhering to a vessel wall. To ensure such large adhering area, a high-density culture apparatus of a layered or hollow fiber type, or an adherent carrier such as a micro-carrier, is used, which causes problems such as complication of the culture apparatus and increase in production costs. Furthermore, to suspend the cells, a carrier or a flotation agent such as a surfactant may be used. Such carrier increases the costs for production. On the other hand, surfactants are cytotoxic and often exert toxicity to cells. Further, those surfactants must be removed as impurities upon purification of the product, and may also inhibit the purification. Therefore, it has been desired to suspend the CHO cells without using such flotation agents.
PRIOR-ART LITERATURES
Non-Patent Literatures
[Non-patent Literature 1] Sunstrom N A, Gay R D, Wong D C, Kitchen N A, DeBoer L, Gray P P. Insulin-Like Growth Factor-I and Transferrin Mediate Growth and Survival of Chinese Hamster Ovary Cells. Biotechnol Prog., 2000; 16: 698-702.
[Non-patent Literature 2] Kagawa Y, Takaoka T, Katsuta H. Mitochondria of mouse fibroblasts, L-929, cultured in a lipid- and protein-free chemically defined medium. J. Biochem., 1969; 65: 799-808.
[Non-patent Literature 3] Kagawa Y, Takaoka T, Katsuta H. Absence of essential fatty acids in mammalian cell strains cultured in lipid- and protein-free chemically defined synthetic media. J. Biochem., 1970; 68: 133-6.
SUMMARY OF INVENTION
Problem to be Solved by Invention
The present invention has been attained in view of the above circumstances, and aims to provide a CHO-derived cell line which is free of safety concerns, can be stably used for production of recombinant proteins, can proliferate in a suspended state, and can be cultured at low costs. In other words, the invention aims to provide a CHO cell line adapted to a protein-free and lipid-free medium, which cell line highly proliferates independent of materials derived from biologics or expensive and unstable factors. The present invention further aims to provide a method for adapting CHO cells by using a protein-free and lipid-free medium, a medium to be used for the method, and so on.
Means for Solving Problems
The present inventor has successfully established a CHO cell line that has adapted to a protein-free and lipid-free medium, which is free of proteinaceous biological materials or growth factors, lipids, or the like, by using an adapted culture method. Accordingly, the present invention provides followings:
[1] A method for producing a recombinant protein comprising steps of:
(a) culturing a transformed cell in a protein-free and lipid-free medium comprising no exogenous growth factors, wherein the transformed cell was produced by transfecting a cell of a cell line derived from Chinese Hamster Ovary (CHO) cells, the cell line being adapted to a protein-free and lipid-free medium, and the cell being able to proliferate in a suspended state in a protein-free and lipid-free medium comprising no exogenous growth factors, with a vector comprising a gene coding for the protein to be produced under the control of a promoter operable in the cell, and
(b) recovering the protein produced by the transformed cell;
[2] The method as described in said item [1], wherein the cell line has been deposited under Accession number NITE P-01641;
[3] The method as described in said item [1] or [2], wherein the protein-free and lipid-free medium used in the step (a) of culturing the transformed cell is a medium characterized by comprising putrescine, thymidine, hypoxanthine, and monoethanolamine, in a DMEM medium modified so as to contain glucose in an amount of 3 to 5 times of the usual amount, and by comprising no exogenous growth factors;
[4] The method as described in said items [3], wherein the protein-free and lipid-free medium used in the step (a) of culturing the transformed cell is a protein-free and lipid-free medium comprising 2000 to 5000 mg/L of glucose, 0.001 to 2 mg/L of putrescine, 0.01 to 1 mg/L of thymidine, 0.1 to 10 mg/L of hypoxanthine, and 0.1 to 5 mg/L of monoethanolamine;
[5] The method as described in any one of said items [1] to [4], wherein the protein-free and lipid-free medium used in the step (a) of culturing the transformed cell is a protein-free and lipid-free medium further comprising 1 to 20 mg/L of insulin and/or 0.1 to 10 mg/L of ganglioside GM3;
[6] The method as described in any one of said items [1] to [5], wherein the transformed cell had been cultured in a protein-free and lipid-free medium comprising insulin and ganglioside GM3 before it was subjected to the transformation; and
[7] The method as described in any one of said items [1] to [6], wherein the transformed cell had been cultured in a protein-free and lipid-free medium comprising insulin and ganglioside GM3, and thereafter subjected to the transfection in a protein-free and lipid-free medium comprising no GM3.
Effects of Invention
The present invention provides a CHO cell line adapted to a protein-free and lipid-free medium, which can proliferate in a suspended state independent of materials derived from biologics or expensive and unstable factors. The cell line adapted to a protein-free and lipid-free medium according to the present invention can be cultured in a suspended state by using a common culture apparatus for floating cells, e.g., one for spin culture or another one for high-density culture of a bioreactor type, without use of a flotation agent such as a surfactant. Further, it has been demonstrated that the suspended form of cells is not due to a deficiency of their extracellular matrix (ECMs) or is not due to irreversible morphological change associated with genetic mutation. Therefore, the adapted cell line of the present invention has morphology which enables a large-scale production by a tank culture. Further, the present cell line is a stable one without any mutation and is a safe and stable cell line desirable for production systems for biopharmaceuticals.
The cells of the adapted cell line of the present invention show a proliferative property that depends on epidermal growth factor (EGF), which is produced by the cells themselves, i.e., by an autocrine action, but not on the addition of exogenous growth factors. By inducing a lipid raft formation in a cell membrane by supplying insulin and/or GM3 ganglioside to a medium, the cells of the adapted cell line of the present invention show a proliferative property that is the same or more than the proliferative property of the original CHO cells.
Also, the cells of the adapted cell line of the present invention show a production efficiency of a recombinant protein, which is more excellent than that of the original CHO cells. Therefore, by using the adapted cell line of the present invention, it is possible to produce a desired recombinant protein efficiently, thereby the productivities of biopharmaceuticals can be increased. By using the adapted cell line of the present invention, biopharmaceuticals can be produced in a safer, less expensive, and more stable manner.
The process for producing the adapted cells of the present invention does not require any special apparatus, and it enables production of the adapted cells that can be cultured in a suspended state with a high reproducibility. Further, the medium of the present invention is advantageous because it is substantially free of proteins or lipids, inexpensive, stably available at low cost, and free of unnecessary materials that are obstacles in the purification of a recombinant protein.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a diagram illustrating a protocol of the method for preparing the adapted cell line of the present invention. Panels A and B show methods for preparing a cell line adapted to a DMEM medium and another cell line adapted to an NPL medium, respectively.
FIG. 2 is an inverted phase-contrast microphotograph (100 magnifications) that shows cellular morphology of the cells adapted to a protein-free and lipid-free medium according to the present invention. Panel A: NPLAd CHO cells; Panel B: DMAd CHO cells; and Panel C: Original CHO-K1 cell line.
FIG. 3 is an inverted phase-contrast microphotograph (40 magnifications) which shows influences of ECMs to the cellular morphology of the cells adapted to a protein-free and lipid-free medium according to the present invention (NPLAd CHO cells). Panel A: No treatment plate; Panel B: fibronectin-coated plate; Panel C: Type 1 collagen-coated plate; and Panel D: albumin-coated plate.
FIG. 4 is an inverted phase-contrast microphotograph (40 magnifications) which shows influences of the addition of a serum to the cellular morphology of the cells adapted to a protein-free and lipid-free medium according to the present invention. Panel A: DMAd CHO cells; Panel B: Reverse-adapted DMAd CHO cells (the third passage); Panel C: Reverse-adapted DMAd CHO cells (the twentieth passage); Panel D: NPLAd CHO cells; Panel E: Reverse-adapted NPLAd CHO cells (the second passage); Panel F: Reverse-adapted NPLAd CHO cells (the ninth passage); and Panel G: Original CHO cells.
FIG. 5 is a figure that shows reversion of the cell growth rates by a reverse-adapting culture method. -◯-: Original CHO cells; -X-: DMAd CHO cells; and -●-: Reverse-adapted DMAd CHO cells (the twenty-fifth passage). The numerical values are shown as an average (of three wells for each group)±SD.
FIG. 6 is a figure that shows influences of an anti-EGF neutralizing antibody on the proliferation of the NPLAd CHO cells and the induction of cell proliferation by insulin. -●-: insulin was added; -◯-: insulin and an anti-EGF neutralizing antibody (5 mg/mL) were added. The numerical values are shown as an average (of three wells for each group)±SD.
FIG. 7 is a figure that shows a comparison of cell proliferations between insulin-added NPLAd CHO cells and the original CHO cells. □: Original CHO cells; and ▪: insulin-added (10 mg/L) NPLAd CHO cells. The numerical values are shown as an average (of three wells for each group)±SD.
FIG. 8 is a schematic representation that shows the EGF/EGFR autocrine loop and inhibition of cell proliferation by an anti-EGF antibody.
FIG. 9 is a schematic representation that shows the structure of cell membrane and lipid rafts.
FIG. 10 is an inverted phase-contrast microphotograph (40 magnifications) which shows influences of the addition of ganglioside GM3 to the cellular morphologies. Panel A: 0 ng/mL GM3; Panel B: 250 ng/mL GM3; Panel C: 1,250 ng/mL GM3; and Panel D: 2,500 ng/mL GM3.
FIG. 11 is a figure that shows influences of the amount of added ganglioside GM3 on cell proliferation. The numerical values are shown as an average (of three wells for each group)±SD.
FIG. 12 is a figure that shows a comparison of cell proliferations between NPLAd CHO cells that have been cultured in an insulin- and GM3-added NPL medium, and the original CHO cells that have been cultured in a serum-added medium. -◯-: NPLAd CHO cells that have been cultured in an insulin- and GM3-added NPL medium; and -●-: original CHO cells that have been cultured in a serum-added medium. The numerical values are shown as an average (of three wells for each group)±SD.
FIG. 13 is a schematic representation of a concept of induction of lipid raft formation by the addition of GM3.
FIG. 14 is a schematic representation that shows a flow of an experiment for comparing productivities of a recombinant protein by a transient assay of the original CHO cells and of cells of an adapted cell line.
FIG. 15 is a vector map of NanoLuc reporter vector pNL1.3.CMV.
FIG. 16 is a figure that shows a comparison among specific activities of luciferase of the DMAd CHO cells, the GM3-added NPLAd CHO cells, and the NPLAd CHO cells with no added GM3, based on the luciferase activity of the original CHO cells. -▴-: DMAd CHO cells; -◯-: NPLAd CHO cells with no added GM3; and -●-: GM3-added NPLAd CHO cells. The numerical values are shown as an average (of specific activities of luciferase of three experiments for each experiment group)±SD.
FIG. 17 is a figure that shows a comparison among estimated values of the luciferase activities per cell of the GM3-added. NPLAd CHO cells, the NPLAd CHO cells with no added GM3, the DMAd CHO cells, and the original CHO cells. -●-: GM3-added NPLAd CHO cells; -◯-: NPLAd CHO cells with no added GM3; -Δ-: DMAd CHO cells; and -X-: the original CHO cells. The numerical values are the total luminescence of each cell group determined in FIG. 16 divided by the number of cells in the cell group with time, wherein the number of cells are determined by culturing the cells in the same medium under the same culturing conditions, and are shown as an average±SD.
DETAILED DESCRIPTION OF THE INVENTION
As used in the present description and claims, the following terms have meanings as respectively defined below. An “established cell line” is defined as a cell line that has been confirmed to present no change in the growth rate or cellular morphology for three or more passages when the cells are plated at the same cell density upon passage. A “protein-free and lipid-free medium” means a medium that is substantially free of proteins or lipids, namely, a medium to which composition one or both of a protein and a lipid, or an additive comprising one or both of them (for example, a serum or a tissue extract) is not intentionally added. In this case, it may be allowed the presence of a small amount of a protein or a lipid, which is introduced into the medium as an impurity or a contaminant of an added component. A “growth factor” means a cytokine having a molecular weight of more than 810, which promotes proliferation of a specified cell. Examples of the growth factors include epidermal growth factor (EGF), insulin like growth factor (IGF), transforming growth factor (TGF), nerve growth factor (NGF), brain-derived neurotrophic factor (BDNF), vesicular endothelial growth factor (VEGF), granulocyte-colony stimulating factor (G-CSF), granulocyte-macrophage-colony stimulating factor (GM-CSF), platelet-derived growth factor (PDGF), erythropoietin (EPO), thrombopoietin (TPO), basic fibroblast growth factor (bFGF, or FGF2), and hepatocyte growth factor (HGF).
The “DMEM medium (Dulbecco's modified Eagle's medium)” is a synthetic medium for mammal cells having a composition that has been obtained by Dulbecco (Dulbecco, Virology 1959 July; 8(3): 396-7) by modifying the Eagle's minimum essential medium (Eagle, Science 1959 Aug. 21; 130(3373): 432-7). The DMEM medium may contain components such as HEPES, phenol red, pyruvic acid and the like in varied amounts, as long as it is based on the Dulbecco's composition. However, DMEM media, to which a protein or a lipid has been added, are not included within the scope of the present invention.
1. A Protein-Free and Lipid-Free Medium
The protein-free and lipid-free medium according to the present invention has been obtained by modifying the DMEM medium. The original CHO cells have been continuously cultured for a long period of time in DMEM medium supplemented with serum. Therefore, the original CHO cells have been adapted to the composition of the DMEM medium. Thus, the DMEM medium was selected as the base medium in expectation that the CHO cells would readily be adapted to a modified DMEM medium.
The protein-free and lipid-free medium (hereafter, this may be called as an NPL medium) of the present invention was designed by using the DMEM medium as a base in order to improve the proliferation and the like of the cells. Decreased nutrient components caused by not adding a serum, especially decreased nonessential components, are compensated by syntheses of them through metabolism. However, the cell growth rate may decrease because of, e.g., the time lag until the completion of the syntheses of those components. Therefore, the composition of the NPL medium has been formulated by adding to the DMEM composition the following components that are not contained in the DMEM medium:
(1) Nonessential Amino Acids
1 to 100 mg/L, preferably 1 to 50 mg/L, and most preferably 10 mg/L of alanine; 5 to 100 mg/L, preferably 20 to 80 mg/L, and most preferably 50 mg/L of asparagine; 5 to 100 mg/L, preferably 5 to 50 mg/L, and most preferably 25 mg/L of asparagine acid; 5 to 100 mg/L, preferably 5 to 50 mg/L, and most preferably 20 mg/L of cysteine; 1 to 250 mg/L, preferably 100 to 250 mg/L, and most preferably 200 mg/L of glutamic acid; 1 to 100 mg/L, preferably 40 to 100 mg/L, and most preferably 70 mg/L of phenylalanine; and 10 to 100 mg/L, preferably 50 to 100 mg/L, and most preferably 100 mg/L of proline;
(2) Inorganic Salts
0.1 to 10 mg/L, preferably 0.5 to 5 mg/L, and most preferably 2 mg/L of zinc sulfate heptahydrate; 0.001 to 0.01 mg/L, preferably 0.001 to 0.008 mg/L, and most preferably 0.004 mg/L of sodium selenite; and 0.0001 to 0.005 mg/L, preferably 0.0001 to 0.003 mg/L, and most preferably 0.002 mg/L of copper (II) sulfate pentahydrate;
(3) Vitamins
0.001 to 1 mg/L, preferably 0.005 to 0.5 mg/L, and most preferably 0.01 mg/L of biotin; and 0.01 to 2 mg/L, preferably 0.01 to 1 mg/L, and most preferably 0.1 mg/L of vitamin B12;
(4) Precursors of Nucleic Acids
0.01 to 1 mg/L, preferably 0.05 to 0.8 mg/L, and most preferably 0.7 mg/L of thymidine; and 0.1 to 10 mg/L, preferably 0.5 to 7 mg/L, and most preferably 4 mg/L of hypoxanthine;
(5) Others
0.0001 to 2 mg/L, preferably 0.001 to 1 mg/L, and most preferably 0.2 mg/L of putrescine; and 0.1 to 5 mg/L, preferably 0.5 to 3 mg/L, and most preferably 1.5 mg/L of monoethanolamine.
Further, the amount of glucose is increased to 2000 to 5000 mg/L, i.e., 2 to 5 times of the usual amount in the DMEM medium.
To the NPL medium a low-molecular compound may be added as long as it is not a protein or a lipid. The medium is adjusted so that the final osmic pressure during use comes to be within the range of 200 to 400 mOsml/kg, preferably 250 to 350 mOsml/kg.
Further, to the NFL medium according to the present invention, 1 to 20 mg/L (preferably 1 to 15 mg/L) of insulin and/or 0.1 to 10 mg/L (preferably 1 to 5 mg/L) of ganglioside GM3 (1-O-[4-O-(3-O-α-neuraminosyl-β-D-galactopyranosyl)-β-D-gluco pyranosyl]ceramide) (Chemical Formula 1):
By adding one or both of them, the growth rate of the cells is increased, or the term for adaptation can be shortened.
The NPL medium according to the present invention can be prepared as a dry composition or a concentrate comprising a part or entire set of the above constituents. By dissolving the dry composition or by diluting the concentrate before use, an aqueous solution comprising a composition of the NPL medium according to the present invention can be obtained. By using the dry composition or the concentrate, the NPL medium according to the present invention can be readily prepared just before its use.
2. A Method for Establishing an Adapted CHO Cell Line
As the original CHO cells, commercially available cells can be used. CHO cells that have been usually maintained in a medium supplemented with serum are passaged while gradually decreasing the serum concentration, and are adapted until they finally come to stably proliferate in a serum- and growth factor-free medium. As the medium that is used in the adaptation process, a standard medium such as the DMEM medium can be used. However, to attain a stable proliferation property in a serum-free medium, it is preferable to use the NPL medium according to the present invention. Further, an NPL medium supplemented with insulin and/or GM3 is preferred because the cells can be adapted in a shorter period of time by using the medium.
The adapted cell line thus established has acquired such ability that the cells stably proliferate in a suspended state in a static culture. Therefore, the cells of the adapted cell line of the present invention can be readily cultured in a suspended state in large quantity in a spinner or a tank without using a carrier or an agent for suspension.
The adapted CHO cell line that had been established by using the NPL medium was deposited in the National Institute of Technology and Evaluation Patent Microorganisms Depository (NPMD), Kamatari 2-5-8, Kazusa, Kisarazu, Chiba, Japan, on Jun. 28, 2013, as Identification reference “NPLAd001,” and Accession number of NITE BP-01641 was assigned.
3. A Process for Producing a Recombinant Protein
The cell line adapted to a protein-free and lipid-free medium according to the present invention can be used for the production of a recombinant protein by transfecting the cell with a gene that encodes a desirable protein. The method for producing a vector that carries the gene to be transfected and the method for transfection are not specifically restricted as long as those methods can be applied for the CHO cells. Methods that are used in this technical field can be used. The cells of the cell line adapted to a protein-free and lipid-free medium according to the present invention can be cultured in a suspended state in large quantity. Further, the cells of the present invention have a protein-productivity that is several times higher than that of the original CHO cells. Therefore, when the cells of the present invention are used, sufficient yields can be secured even by the transient method. In the production of a recombinant protein, any protein-free and lipid-free media such as DMEM and NPL can be used. However, by culturing cells in a medium supplemented with GM3 and/or insulin before transfection and conducting the transfection in another medium comprising no GM3, the recombinant protein can be efficiently produced.
The protein to be produced by the method of the present invention is not particularly limited as long as it can be produced in CHO cells, and includes tissue plasminogen activator, enzymes (exemplary enzymes include glucocerebrosidase, alpha-L-iduronidse, acidic alpha-glucosidase, human N-acetyl galactosamine-4-sulfatases, urate oxidase, DNases, and the like), blood coagulation factor IX, thrombomodulin, follicle-stimulating hormone, interferons, erythropoietin, antibodies (as examples, anti-CD20 antibody, anti-IL6 receptor antibody, anti-VEGF antibody, TNF-alpha antibody, anti-IgE antibody, anti-RANKL antibody, anti-CCR4 antibody, and the like) and so on. The recombinant protein produced can be recovered and purified from the cells according to the present invention or the medium by using any methods that are used in this technical field depending on the feature of the protein.
EXAMPLES
1. Establishment of a CHO Cell Line Adapted to a Protein-Free and Lipid-Free Medium by a Method for Adaption to a Medium
By using a method for adaption to a medium, two types of CHO cell lines were established as follows.
(1) Cells
The original CHO-K1 cells that were used in the method for adaption to a medium were purchased from the European Collection of Cell Cultures (ECACC). These cells were maintained in a Dulbecco's Modified Eagle's MEM (DMEM) medium (Kyokuto Pharmaceutical Industry) supplemented with 10% fetal bovine serum (FBS).
(2) Media
To apply the method for adaption to a medium to the original CHO cells, the DMEM medium (Kyokuto Pharmaceutical Industry) and an NPL medium, which are shown in Table 1, were used.
Each medium was prepared by dissolving prescribed constituents in distilled water to obtain the predetermined final concentrations of the constituents, followed by sterilization by filtration.
TABLE 1 (Unit: mg/L) INGREDIENTS DMEM NPL INGREDIENTS DMEM NPL NaCl 6,400 6,400 L-Leucine 105 105 KCl 400 400 L-Lysine•HCl 146 146 CaCl 2 (anhyd.) 200 200 L-Methionine 30 30 MgSO 4 (anhyd.) 98 98 L-Phenylalanine 66 NaH 2 PO 4 (anhyd.) 109 109 L-Proline 100 Fe(NO 3 ) 3 •9H 2 O 0.1 0.2 L-Serine 42 42 ZnSO 4 •7H 2 O 2.0 L-Threonine 95 95 Na 2 SeO 3 0.0043 L-Tryptophan 16 16 CuSO 4 •5H 2 O 0.002 L-Tyrosine•HCl 72 72 HEPES 4,000 L-Valine 94 94 Glucose (anhyd.) 1,000 4,000 Biotin 0.01 Sodium Pyruvate 110 110 D-Ca Pantothenate 4.0 4.0 Phenol Red 15 15 Choline Chloride 4.0 4.0 L-Alanine 10 Vitamin B12 0.1 L-Arginine•HCl 84 164 Folic Acid 4.0 4.0 L-Aspragine•H 2 O 50 myo-Inositol 7.2 7.2 L-Aspartic Acid 25 Niacineamide 4.0 4.0 L-Cystein HCl•H 2 O 20 Pyridoxal HCl 4.0 4.0 L-Cystine•2HCl 63 63 Riboflavin 0.4 0.4 L-Glutamic Acid 200 Thiamine HCl 4.0 4.0 L-Glutamine 584 584 Putrescine 2HCl 0.2 Glycine 30 30 Thymidine 0.7 L-Histidine HCl•H 2 O 42 42 Hypoxanthine Na 4.0 L-Isoleucine 105 105 Monoethanolamine 1.53
(3) a Method for Adaption to a Medium
(3-1) Adaptation by Using a DMEM Medium
The adaptation by using a DMEM medium was carried out according to the following procedure ( FIG. 1 , Panel A). First, starting from the DMEM medium supplemented with 10% FBS, i.e., the medium that was used for maintaining the cells of the original CHO cell line, the cells were incubated for about one week while sequentially lowering the serum concentration to 3%. Further, incubation of the cells was continued in a DMEM medium supplemented with 1% FBS for one month. Until the cell proliferation property became stable, the cells were incubated in a DMEM medium supplemented with 1% FBS medium. When the cell proliferation property became stable, the supplementation of the serum was stopped. The incubation of the cells was continued thereafter.
When the cell growth rate markedly lowered by culturing in a serum-free DMEM medium, the cells were returned to a medium comprising 1% of a serum, and cultured until the proliferation property was restored. When the proliferation property became stable, culturing of the cells in a serum-free medium was resumed. These operations were repeated until the cells were able to be stably cultured in the serum-free medium. The culture was carried out under conditions of 37 degrees Celsius and 5% CO 2 .
The cell line that had been adapted to the serum-free medium by using a DMEM medium was named as “DMAd CHO cells.” For the following experimentations, DMAd CHO cells that had experienced at least thirty passages after adaptation were used.
The definition of the adapted cell line is as follows: When the growth rate becomes stable, cells having a viability of at least 90% are seeded in a culture flask (25 cm 2 -size) at a cell density of 100,000 cells/mL, and then continuously cultured. When the growth rate and the cell morphologies are not altered for at least three passages, the cells are established as an adapted cell line.
(3-2) Adaptation by Using an NPL Medium
The adaptation by using an NPL medium was carried out according to the following procedure ( FIG. 1 , Panel B). First, starting from the DMEM medium supplemented with 10% FBS, i.e., the medium that was used for maintaining the cells of the original CHO cell line, the cells were incubated for about one week while sequentially lowering the serum concentration to 3%. Further, incubation of the cells was continued in an NPL medium supplemented with 1% FBS for two weeks. Until the cell proliferation property became stable, the cells were incubated in an NPL medium supplemented with 1% FBS medium. When the cell proliferation property became stable, the supplementation of the serum was stopped. The incubation of the cells was continued thereafter.
When the cell growth rate markedly lowered by culturing in a serum-free NPL medium, the cells were returned to a medium comprising 1% of a serum, and incubated until the proliferation property was restored. When the proliferation property became stable, culturing of the cells in a serum-free medium was resumed. These operations were repeated until the cells were able to be stably cultured in the serum-free medium. The culture was carried out under conditions of 37 degrees Celsius and 5% CO 2 . The cell line that had been adapted to the serum-free medium by using an NFL medium was named as “NPLAd CHO cells.” For the following experimentations, NPLAd CHO cells that had experienced at least two-hundred passages after adaptation were used.
(4) Results
In the two cases in which the DMEM medium and the NPL medium were respectively used, adapted cell lines were able to be established. The morphologies of the cells of the established adapted cell lines and the cells of the original cell line are shown in FIG. 2 . During their subcultures, the NPLAd CHO cells (Panel A), the DMAd CHO cells (Panel B), and the cells of the original CHO-K1 cell line were observed by using an inverted phase-contrast microscope (100 magnifications). The CHO cells of the original cell line showed cobblestone-like proliferation (Panel C). In contrast, the DMAd CHO cells (Panel B) and the NPLAd CHO cells (Panel A), which had been adapted to a protein-free and lipid-free medium, were in a suspended state as single cells or aggregates. Usually, to suspend the CHO cells, shaking or addition of a flotation agent such as a surfactant is required. However, without these operations, the cells of the adapted cell lines were able to be suspension-cultured as aggregates.
It has been said that the CHO cells require lipids and growth factors, which are supplied from a serum, for proliferation. It is thought that the adapted cells came to be able to produce these substances by themselves during the adaptation process. Further, in contrast to the CHO cells of the original cell line, the two adapted cell lines were both acquired altered phenotypes that allow the cells to be suspension-cultured as aggregates without any treatment for realizing the suspended state. Namely, the cells came to be able to proliferate in a suspended state without a flotation agent or the like.
The growth rates of the adapted cell lines according to the present invention were slightly inferior to that of the original CHO cell line when cells were in static cultures using culture flasks as described above. The DMAd CHO cells reached confluency in one week to ten days. In contrast, the NPLAd CHO cells reached confluency five days after the start of the culture and required to be subcultured. Thus, the growth rate of the NPLAd CHO cells was faster than that of the DMAd CHO cells. The interval between subcultures is 3 to 4 days for the original CHO cells. Thus, the growth rates of the NPLAd CHO cell line and the DMAd CHO cell line were slightly slower as compared to that of the original cell line.
The cell lines adapted to a protein-free and lipid-free medium depend on only autologous growth factors for cell proliferation. Thus, the slower growth rates may be attributable to several causes such as deficiency of factors other than autologous growth factors and functional deterioration of the cells because of deficiency of proteins and/or lipids for a long period of time. However, it is accepted that the use of a spinner or a culturing apparatus of a bioreactor-type allows efficient exchange of nutrient components and oxygen supply, and thus allows cultures at a more rapid growth rate and at a higher cell density, as compared to the static culture. Thus, it is likely that such a difference of the cell growth rates of this level can be adequately compensated by the selection or improvement of the culturing method.
The adapted NPLAd CHO cell line that had been established was deposited in the National Institute of Technology and Evaluation Patent Microorganisms Depository (NPMD), Kamatari 2-5-8, Kazusa, Kisarazu, Chiba, Japan, on Jun. 28, 2013, as Identification reference of “NPLAd001,” and Accession number of NITE P-01641 was assigned
2. Study of Adherence Property of the CHO Cells Adapted to a Protein-Free and Lipid-Free Medium
Adherent cells, which are usually cultured by using a serum, adhere to a wall of a culture vessel by binding a cell-adhesion factor such as integrin, which is secreted by the cells themselves, through an ECM contained in the serum, such as fibronectin. The reason that the adapted cells can be cultured in a suspended state, unlike its original cells that are cultured in an adhesion state, may be because an ECM is not supplied from the protein-free and lipid-free medium. Therefore, whether the NPLAd CHO cells become adherent was studied by seeding and culturing the NPLAd CHO cells using plates, which had been coated with an ECM (such as fibronectin or type-I collagen) or albumin.
(1) Culture Substrate
The following culture substrates were used: (1) a fibronectin-coated 24-well plate (manufactured by Japan Becton, Dickinson and Company; “Fibronectin-coated 24-well plate”), (2) a type I collagen-coated 24-well plate (manufactured by Japan Becton, Dickinson and Company; “Type I collagen-coated 24-well plate”), (3) an albumin-coated 24-well plate (produced by dispensing 1 mL of phosphate buffered saline (PBS) comprising 1 mg/mL of bovine serum albumin (BSA) into the 24-well plate manufactured by Japan Becton, Dickinson and Company, incubating the plate at 37 degrees Celsius for 2 hours, rinsing with PBS twice so as to wash extra BSA off, and drying it under sterile conditions in a clean bench), and (4) an untreated plate (a 24-well plate manufactured by Japan Becton, Dickinson and Company).
(2) Experimental Method
The NPLAd CHO cells were used as the cells and the NPL medium was used as the medium. The NPLAd CHO cells, which had been maintained in the NPL medium, were washed twice with the NPL medium. After washing, the cell aggregates were suspended in the NPL medium and the number of the cells was counted by a dye-exclusion test by using the improved Neubauer hemocytometer and trypan blue, and a viability was calculated. After it was confirmed that the viability was 90% or more, the cell number was adjusted to 50,000 cells/mL with the NPL medium. The cells were seeded in wells of the fibronectin-coated 24-well plate, the type I collagen-coated 24-well plate, the albumin-coated 24-well plate, and the untreated 24 well plate in an amount of 1 mL/well.
The plates, where the cells had been seeded, were incubated for five days under conditions of 37 degrees Celsius and 5% CO 2 . Then, it was observed by using an inverted phase-contrast microscope (40 magnifications) whether the cells adhered during culture.
(3) Results
FIG. 3 shows the cell morphologies on the respective plates five days after the start of the culture. The cells on the fibronectin-coated plate (Panel B), the type I collagen-coated plate (Panel C), and the albumin-coated plate (Panel D) were in the forms of aggregates, and suspended without adhesion, as the cells on the untreated plate. Among these cells, there was no difference. The possibility cannot be denied that the cells adhered once to a culture substrate and then detached from the culture substrate after the cells reached confluency. Therefore, the cells were continuously observed. As a result, it was observed that the NPLAd CHO cells proliferated without adhering to the culture substrate from the beginning of the culture. From the above results, it was understood that the reason why the cells of the adapted cell line were able to be suspended was not due to the deficiency of ECMs.
In the case where the disappearance of the adhesion property is not due to the deficiency of ECMs, another possibility is that a cell-adhesion factor such as integrin is not sufficiently generated. Further, alteration of the cell membrane structure can also be possible. The lipids including phospholipids are, in addition to those biosynthesized from sugars, incorporated into the cells through albumin that is a carrier protein in blood, and are used in, e.g., the cell membrane. In the case of the adapted cell line, there is a possibility that the structure of the cell membrane has been altered due to the deficiency of the lipids for a long period of time, which in turn has affected the adhesion property of the cells.
3. Verification of Reversibility of Phenotypic Alteration of the CHO Cells Adapted to a Protein-Free and Lipid-Free Medium
The CHO cells of the original cell line cannot proliferate in a protein-free and lipid-free medium. However, the cells of the adapted cell lines can proliferate under an oligotrophic condition because they have adapted to the protein-free and lipid-free medium. There is a possibility that this phenotypic change has resulted from a clone cell that had come to be able to proliferate under an oligotrophic condition by a genetic mutation and became dominant during the culture. In the case where the phenotypic change of the CHO cells is due to a genetic mutation, there is a possibility that an unpredictable transformation may have also been occurred due to, e.g., a genetic point mutation, a genetic deletion by a partial chromosome elimination, or a deletion of chromosome, thereby the cellular function per se may have been damaged. Such damaged cells are not ensured in terms of their stabilities as cells used in production systems. Further, similar properties may not necessarily be obtained even if the same procedure is used. Thus, the reproducibility of the medium adaptation method may not be ensured as well. Therefore, to investigate whether the phenotypic change of the adapted cell line is associated with a genetic mutation, reversibility of this phenotypic change was studied. Namely, the cells of the adapted cell line were returned in a medium supplemented with a serum, and whether the cells showed cell morphologies and growth rates similar to those of the CHO cells of the original cell line was examined.
(1) Experimental Method
(1-1) Reverse Adaptation Cultures of the DMAd CHO Cells and the NPLAd CHO Cells.
The DMAd CHO cells that had been continuously cultured for at least thirty passages after establishment and the NPLAd CHO cells that had been continuously cultured for at least two hundreds and eighty passages after establishment were used as the cells. The DMEM medium supplemented with 10% FBS was used as the medium.
The DMAd CHO cells and the NPLAd CHO cells were respectively washed twice with a DMEM medium, and then respectively suspended in the DMEM medium by dispersing cells of aggregates. Thereafter, the numbers of the cells were respectively counted by a dye-exclusion test by using the improved Neubauer hemocytometer and trypan blue, and viabilities were respectively calculated. By diluting with the DMEM medium supplemented with 10% FBS, the cell number was adjusted to 100,000 cells/mL. The diluted cell suspension, 5 mL, was poured into a culture flask of 25 cm 2 , and the cells were cultured under conditions of 37 degrees Celsius and 5% CO 2 . When the cells reached confluency, the cells were subcultured by the same procedures.
In the case where the cells adhered to the wall of the flask, after recovering suspended cells, the adhered cells were detached and dispersed by using trypsin. Not to select cells having properties of a specific tendency, when the cells were again seeded, a mixture of floating cells and adhered cells was used. The DMAd CHO cells and the NPLAd CHO cells, which had been reversely adapted, were respectively named as the reverse-adapted DMAd CHO cells and the reverse-adapted NPLA d CHO cells.
(1-2) Determination of Growth Rate of the Reverse-Adapted Cell Line
The CHO cells of the original cell line, the DMAd CHO cells, and the reverse-adapted DMAd CHO cells, which had been continuously cultured for at least twenty-five passaged in the reverse adaptation medium, were used. As the media, the DMEM medium supplemented with 10% FBS was used for the CHO cells of the original cell line and the reverse-adapted DMAd CHO cells, and the DMEM was used for the DMAd CHO cells.
Because the CHO cells of the original cell line and the reverse-adapted DMAd CHO cells adhered to the wall of the flask, they were detached and dispersed by using trypsin. Then, the numbers of the cells were respectively counted by a dye-exclusion test by using the improved Neubauer hemocytometer and trypan blue, and the viabilities were respectively calculated. The DMAd CHO cells were suspended in the DMEM medium to disperse the cells of aggregates. Thereafter, the number of the cells was counted by a dye-exclusion test by using the improved Neubauer hemocytometer and trypan blue, and the viability was calculated.
The CHO cells of the original cell line, the DMAd CHO cells, and the reverse-adapted DMAd CHO cells were respectively diluted with the respective passage media to 50,000 cells/mL. The cells were respectively seeded in wells of 24-well plates at 1 mL/well. The plates after seeding were incubated for seven days under conditions of 37 degrees Celsius and 5% CO 2 . At regular time intervals, the cell numbers were respectively counted by a dye-exclusion test by using the improved Neubauer hemocytometer and trypan blue, and the viabilities were respectively calculated. The NPLAd cells and the reverse-adapted NPLAd CHO cells were respectively cultured and their viabilities were calculated in the same manner.
(2) Results
FIG. 4 shows the cell morphologies of the CHO cells of the original cell line, the DMAd CHO cells, the NPLAd cells, the reverse-adapted DMAd CHO cells and the reverse-adapted NPLAd CHO cells, which had been cultured for reverse adaptation to the DMEM medium supplemented with a serum. The alterations of the cell morphologies were observed with the inverted phase-contrast microscope (40 magnifications). In the reverse adaptation cultures, parts of the DMAd CHO cells and the NPLAd CHO cells adhered just after the start of the culture with a serum. By continuing subculture, the DMAd CHO cells and the NPLAd CHO cells shifted to adhesive morphologies. In the reverse-adapted DMAd CHO cells of the third passage (Panel B) and the reverse-adapted NPLAd CHO cells of the second passage (Panel E), adhered cells and suspended cells having spherical shapes were observed in a mixed state. No differences in morphologies were observed between the reverse-adapted DMAd CHO cells of the twentieth passage (Panel C) and the CHO cells of the original cell line (Panel G), and between the reverse-adapted NPLAd CHO cells of the ninth passage (Panel F) and the CHO cells of the original cell line (Panel G).
FIG. 5 shows the growth rates of respective cell lines. The cell growth rates of the reverse-adapted DMAd CHO cells (-●-) and the CHO cells of the original cell line (-◯-) were higher than that of the DMAd CHO cells (-X-), and were almost the same. The reverse-adapted DMAd CHO cells and the CHO cells of the original cell line had the same cell growth rates up to the third day of culture. At the seventh day, the growth rate of the reverse-adapted DMAd CHO cells was slightly higher, but there was no significant difference, Similar results were obtained for the NPLAd CHO cells (the data were not shown).
The phenotypic change of the CHO cell line adapted to a protein-free and lipid-free medium, which had been established, was reversible, and it was possible to reverse the cell morphology and the proliferation property to those that are similar to the CHO cells of the original cell line by culturing in the presence of a serum. The DMAd CHO cells used and the NPLAd CHO cells used were, after their establishments, more than thirty passages and more than two hundreds and eighty passages, respectively. By this experiment, it was confirmed that their phenotypic changes were not fixed even though the cells were continuously cultured for a long period of time. Further, it was confirmed that the morphology of the NPLAd CHO cells, which had been continuously cultured for more than four hundred passages, was restored to that of the original cell line by the reverse adaptation with the addition of a serum (the data were not shown). From these results, it is thought that the phenotypic change of the CHO cell line adapted to a protein-free and lipid-free medium, which was established, is not an irreversible change associated with a genetic mutation.
It is thought that a cell line having properties similar to those of the cell lines of the present invention can be reproducibly established by the method of the present invention, because the adapted cell lines of the present invention involve no genetic mutation and the possibility that the properties were incidentally obtained was low. Thus, the present invention has realized desirable phenotypes important for the safety and productivity in biopharmaceutical productions without an unpredictable a phenotypic change due to mutation. Therefore, the adapted cells and the method for preparing them of the present invention are useful as a cell line for the stable production of biopharmaceuticals and as a method for preparing the cell line, respectively.
4. Reactivity of the CHO Cells Adapted to a Protein-Free and Lipid-Free Medium to Cell Growth Factors
For cell lines that are used for industrial application, high proliferation ability and high productivity of a substance are required. To enhance the growth rate of the adapted cell line of the present invention, responsiveness of the cells to cell growth factors were studied.
It is said that usually the CHO cells proliferate depending on growth factors that are supplied from a serum or biological materials in the medium. However, the protein-free and lipid-free medium, which was used for the culture for adaptation, does not comprise a serum or biological materials at all. Therefore, the growth factors are not supplied from the medium. Thus, it is thought that the cells of the adapted cell line produce growth factors in an autocrine-like manner to proliferate. There is a possibility that the membrane structure has been altered due to the deficient of the lipids for a long period of time, in which period of time the cells have been adapted to the protein-free and lipid-free medium. Therefore, it is thought that there is a possibility that the proliferation ability of the adapted cell line can be improved by increasing the expression of growth factors by the cells, or by normalizing the membrane structure so that signals of the growth factors can be fully received.
First, to study the involvement of an autocrine factor in the adapted cell line, a blocking test of a growth factor to its receptor was carried out by using a neutralizing antibody. As an autocrine factor of the adapted cell line, EGF was noticed. This is because there is a report (Fisher, et. al., Mead Johnson Symp Perinat Dev Med., 1988, 33-40) that EGF works as a growth factor in many types of epidermal or epithelial cells including CHO cells. Therefore, it was examined whether the proliferation was controlled by inhibiting the binding between EGF and the receptor by an anti-EGF neutralizing antibody. If the proliferation is inhibited by the anti-EGF neutralizing antibody, it can be judged that as an autocrine factor EGF is responsible for the proliferation of the adapted cell line.
Next, the addition of an endcrine factor was contemplated to induce further proliferation of the cells of the adapted cell line. As the endcrine factor, insulin was noticed. Insulin is a typical endcrine factor that is produced by the β-cells of the pancreatic islet of Langerhans, is an essential growth factor for many cells, and is reported to contribute to the proliferation of the CHO cells (Chun, et. al., Biotechnol Frog., 2003, 19, 52-7).
The insulin is a growth factor and was also commercialized in 1922 as a therapeutic medicine for diabetes (Rosenfeld, Clin Chem., 2002, 2270-88). It is one of the oldest recombinant pharmaceuticals. Its stability is higher than those of other proteinaceous growth factors, and it is inexpensive as compared to other recombinant growth factors because it is produced in a large scale. Because of these reasons, insulin was used in this study.
(1) Effect of Anti-EGF Antibody Against Proliferation of NPLAd CHO Cells and Induction of Cell Proliferation by Insulin
Commercially available anti-EGF antibody (by R & D Systems, Inc.) and commercially available recombinant insulin (by Sigma-Aldrich) were used.
The NPLAd CHO cells were used as the cells and the NPL medium was used as the medium. The NPLAd CHO cells that had been maintained in the NPL medium were washed twice with the NPL medium. After washing, the cell of aggregates were suspended and dispersed in the NPL medium. Thereafter, the number of the cells was counted by a dye-exclusion test by using the improved Neubauer hemocytometer and trypan blue, and the viability was calculated. After it was confirmed that the viability was 90% or more, the cell number was adjusted to 50,000 cells/mL in the NPL medium. The cells were seeded in wells of the 24-well plate at 1 mL/well. To a half of the wells, in which the cells had been seeded, the anti-EGF neutralizing antibody was added so as to be a concentration of 5 mg/mL.
To the wells containing seeded cells, to which the anti-EGF neutralizing antibody had or had not been added, insulin was added so as to be the concentrations of 0, 1, 2, 5, or 10 mg/L. The plates, where the cells had been seeded, were incubated for five days under conditions of 37 degrees Celsius and 5% CO 2 . Then, the numbers of the cells were respectively counted by a dye-exclusion test by using the improved Neubauer hemocytometer and trypan blue, and the viabilities were respectively calculated.
(2) Comparison of the Proliferation of the Insulin-Added NPLAd CHO Cells to that of the CHO Cells of the Original Cell Line
The CHO cells of the original cell line and the NPLAd CHO cells were used. For the NPLAd CHO cells, an NPL medium supplemented with 10 mg/L of insulin (by Sigma-Aldrich) was used. For the CHO cells of the original cell line, a DMEM medium supplemented with 10% FBS was used.
Because the CHO cells of the original cell line were adherent cells, they were detached and dispersed by using trypsin. Thereafter, the number of the cells was counted by a dye-exclusion test by using the improved Neubauer hemocytometer and trypan blue, and the viability was calculated. As for the NPLAd CHO cells, the cells of aggregates were suspended and dispersed in the NPL medium. Thereafter, the number of the cells was counted by a dye-exclusion test by using the improved Neubauer hemocytometer and trypan blue, and the viability was calculated.
The CHO cells of the original cell line and the NPLAd CHO cells were diluted to a cell number of 50,000 cells/mL in the DMEM medium supplemented with 10% FBS and the NPL medium supplemented with insulin, respectively. The entire cells were seeded at 1 mL/well on 24-well plates. The plates, on which the cells had been seeded, were incubated for five days under conditions of 37 degrees Celsius and 5% CO 2 . Then, the numbers of the cells were respectively counted by a dye-exclusion test by using the improved Neubauer hemocytometer and trypan blue, and the viabilities were respectively calculated. As the test to examine whether there was a significant difference, the Student's t-test was used.
(3) Results
The effects of EGF, and insulin, which had been said to have an effect of proliferation induction to CHO cells, on proliferation of the adapted cells were studied. FIG. 6 shows an insulin concentration-dependent cell proliferation of the NPLAd CHO cells on the fifth day from the start of the culture.
In the case where the anti-EGF neutralizing antibody was added to the NPL medium (-◯-), the proliferation of the NPLAd CHO cells was inhibited irrespective of the concentration of insulin added. Especially, in the case where insulin was not added and the anti-EGF neutralizing antibody was not added, the cell number (insulin concentration being 0 mg/L of -●-) was 235,000 cells/mL, whereas in the case where the insulin was not added and the anti-EGF neutralizing antibody was added, the cell number (insulin concentration being 0 mg/L of -◯-) was 155,000 cells/mL. Namely, the proliferation was inhibited by about 35%. This result reveals that the proliferation of the NPLAd CHO cells depends on EGF, irrespective of the presence or absence of insulin. Further, because the NPL medium comprise no EGF, it was suggested that EGF, of which binding to the receptor had been inhibited by the anti-EGF neutralizing antibody, was produced by the NPLAd CHO cells per se, namely, it was an autocrine growth factor. However, even if the binding of EGF was inhibited by the anti-EGF neutralizing antibody, the cell number increased to about three-fold from the number of the cells seeded (50,000 cells/mL) on the fifth day of culture. Thus, it is thought that an autocrine factor or factors other than EGF are involved.
The NPLAd CHO cells proliferated in an insulin concentration-dependent manner (-●-). The cell numbers were 400,000 cells/mL and 530,000 cells/mL at insulin concentrations of 2 mg/L and 10 mg/L, respectively. Thus, the cells were more than doubled at the insulin concentration of 10 mg/L compared to the cell number of the case where insulin was not added. It was studied to what extent the proliferation of the NPLAd CHO cells increases by adding insulin, as compared to the CHO cells of the original cell line. As a result, on the fifth day of culture, the NPLAd CHO cells in the NPL medium supplemented with 10 mg/L of insulin proliferated to about 550,000 cells/mL, whereas the cell number of the CHO cells of the original cell line was over 800,000 cells/mL (P<0.005) ( FIG. 7 ). From this result, it was suggested that only by adding insulin to the NPL medium, the growth rate of the NPLAd CHO cells would not be comparable to that of the CHO cells of the original cell line. However, the effect of insulin to induce proliferation of the NPLAd CHO cells in a concentration-dependent manner was confirmed.
As stated above, it was found that the cell proliferation of the NPLAd CHO cell line increased depending on the concentration of the added insulin, which was a paracrine growth factor. Further, it was also found that the cell proliferation was inhibited by the anti-EGF neutralizing antibody even though no EGF was added to the medium. Furthermore, it was revealed that, in the cell proliferation induced by the stimulation of insulin, the cell proliferation was also suppressed by inhibiting EGF with the anti-EGF neutralizing antibody. Because no EGF was added to the medium, it was thought that EGF, of which binding to the receptor had been inhibited by the anti-EGF neutralizing antibody, was an autocrine growth factor produced by the adapted cell line per se, and that EGF induced the proliferation of the same cells from which it was secreted by forming an EGF/EGFR (receptor) autocrine loop.
EGF is a protein that is composed of fifty-three amino acid residues and has a molecular weight of 6,045 Da, and controls cell proliferation by binding to EGF receptors that are present on the surfaces of cells. It has been reported that EGF induces the self-proliferation of the cells as an autocrine growth factor in various cells including epidermal or epithelial cells by forming an EGF/EGFR autocrine loop (Shvartsman, et. al., Am J Physiol Cell Physiol., 2002; 282: C545-59; DeWitt, et. al., J Cell Sci., 2001; 114: 2301-13). Growth factors that belong to the EGF family including EGF per se are not synthesized as a secretory form, but are expressed as precursors in cells. After translation, the precursors come out of the cell surfaces by passing through the membranes. Thereafter, they are cut with a protease on the surfaces of cells to be growth factors of a secretory form. As shown in FIG. 8 , EGF produced in a cell is present on the surface of a cell as a transmembrane protein (membrane-bound EGF) that is embedded in a cytoplasmic membrane. By being cleaved with a protease, the extracellular domain leaves the cell to be secretory EGF, which in turn binds to EGF receptor. By binding of secretory EGF to EGF receptor, the signal is transmitted to inside of the cell through the transmembrane domain of EGF receptor, and the cell proliferation is induced. The anti-EGF neutralizing antibody that was used in this study directly binds to EGF and inhibits the binding with the receptor. Therefore, as the reason that the cell proliferation of the adapted cell line was inhibited with the anti-EGF neutralizing antibody, it is inferred that the signal for proliferation from the receptor was not transmitted ( FIG. 8 ). Further, in the adapted cell line according to the present invention, the anti-EGF neutralizing antibody inhibited not only self-proliferation but also the proliferation by insulin that is a paracrine growth factor. Therefore, in the adapted cell line, the autocrine production of EGF is a very important factor for proliferation of the cells themselves.
As described above, it was thought that the signal transduction of EGF was important for cell-proliferation in the adapted cell line. Therefore, hereinafter, it was studied whether the growth rate of the adapted cell line was able to be facilitated by increasing the signaling efficiency of EGF.
Among autocrine factors other than EGF, it has been reported that IGF-1 (Insulin-like Growth Factor-1) induced the proliferation of CHO cells (Pak, et. al., Cytotechnology, 1996; 22: 139-46). Therefore, using the NPLAd CHO cells, the binding of IGF-1 was inhibited by an anti-IGF-1 neutralizing antibody. However, the cell proliferation was not suppressed. Therefore, it was thought that IGF-1 was not responsible for the autocrine proliferation of the adapted cell line. However, from the result that the cell proliferation of the adapted cell line was not entirely suppressed by inhibition of binding using the anti-EGF neutralizing antibody, it is highly likely that an growth factor other than IGF-1 is responsible for the proliferation of the adapted cell line as an autocrine factor.
5. Influence of GM3 on the Cell Proliferation of the CHO Cells Adapted to a Protein-Free and Lipid-Free Medium
Cell membranes are constituted by a lipid bilayer that has been formed from an arrangement of a number of phospholipids such as, mainly, phosphatidylcholine, sphingomyelin, phosphatidylethanolamine, and phosphatidylserine, with various proteins (such as transmembrane proteins and anchor proteins) and the like, that are embedded in the lipid bilayer. The lipid rafts are structures of the membrane and comprise lipids, especially, sphingolipid, sphingoglycolipid, and cholesterol in large amounts. It is thought that the lipid rafts are involved in signal transductions to the inside of a cell ( FIG. 9 ), because the transmembrane proteins as the receptors are concentrated in the lipid rafts. There are many reports that especially ganglioside, a sphingoglycolipid in a lipid raft, is responsible for the control of signal transductions. Further, it has been reported that the receptors for the EGF are localized in the lipid rafts (Balbis, et. al., J Cell Biochem., 2010; 109(6): 1103-8). Therefore, there is a possibility that the signal transductions via receptors are not fully functional if the formation of the lipid rafts is insufficient.
As described above, in the adapted cell line that had been continuously cultured in a protein-free and lipid-free medium for a long period of time, there is a possibility that its cell membrane structure has been altered due to the deficiency of lipids. Therefore, in the adapted cell line, there is a possibility that the formation of the lipid rafts is insufficient, and the signal transductions via EGF receptors are not fully functional. Thus, ganglioside GM3, a sphingoglycolipid, which plays an important role in the structure of the lipid raft, was noticed, and influences of the addition of GM3 to the cell morphology and growth rate of the adapted cells were studied. Namely, a possibility that the cell membrane structure is re-constructed and the cell adherent property is recovered by the addition of GM3, and another possibility that the presence or absence, or the concentration of GM3 results in alteration of the cell morphology, especially increase in the number of the adherent cells, or alteration of the size of the cell aggregates, were studied.
(1) Influence of GM3 on the Morphology of the CHO Cells Adapted to a Protein-Free and Lipid-Free Medium
A commercially-available ganglioside GM3 (Neu5A, Enzo Life Science) was used. As the cells, the NPLAd CHO cells were used. The aggregated NPLAd CHO cells were suspended and dispersed in the NPL medium. Then, the number of the cells was counted by a dye-exclusion test by using the improved Neubauer hemocytometer and trypan blue, and the viability was calculated.
The NPLAd CHO cells were diluted to a cell number of 50,000 cells/mL with the NPL medium supplemented with insulin at a concentration of 10 mg/L. The entire cells were seeded at 1 mL/well in wells of 24-well plates. Then, to the plates containing the cells, ganglioside GM3 was added so as to be concentrations of 0, 250, 1,250, or 2,500 ng/mL.
The plates, on which the cells had been seeded, were incubated for five days under conditions of 37 degrees Celsius and 5% CO 2 . Then, the alterations of the cell morphologies were observed with the inverted phase-contrast microscope. Thereafter, the numbers of the cells were respectively counted by a dye-exclusion test by using the improved Neubauer hemocytometer and trypan blue, and viabilities were respectively calculated. As the test to examine whether there was a significant difference, the Student's t-test was used.
(2) Comparison of the Growth Rate of the Insulin- and GM3-Added NPLAd CHO Cells to that of the CHO Cells of the Original Cell Line
The NPLAd CHO cells and the CHO cells of the original cell line were used. Because the CHO cells of the original cell line were adherent, they were detached and suspended by using trypsin. Thereafter, the number of the cells was counted by a dye-exclusion test by using the improved Neubauer hemocytometer and trypan blue, and the viability was calculated. As for the NPLAd CHO cells, the cell aggregates were suspended and dispersed in the NPL medium. Thereafter, the number of the cells was counted by a dye-exclusion test by using the improved Neubauer hemocytometer and trypan blue, and the viability was calculated.
The CHO cells of the original cell line and the NPLAd CHO cells were diluted to a cell number of 50,000 cells/mL, with the DMEM medium supplemented with 10% FBS and the NPL medium supplemented with insulin at a concentration of 10 mg/L and GM3 at a concentration of 2,500 ng/mL, respectively. The entire cells were seeded at 1 mL/well in wells of 24-well plates. Then, the plates, on which the cells had been seeded, were incubated for five days under conditions of 37 degrees Celsius and 5% CO 2 . At regular time intervals, the cell numbers were respectively counted by a dye-exclusion test by using the improved Neubauer hemocytometer and trypan blue, and the viabilities were respectively calculated. As the test to examine whether there was a significant difference, the Student's t-test was used.
(3) Results
FIG. 10 shows the result of observation about the alteration of cell morphologies by the addition of GM3. Irrespective of the presence or absence, or the concentration of added GM3, alteration of cell morphologies, such as increase in the number of adherent cells or alteration of the size of the cell aggregates, was not observed.
FIG. 11 shows the result of influence on the cell proliferation by the addition of GM3. In the case where GM3 was added at a concentration of 1,250 ng/mL to the culture medium for the NPLAd CHO cells, the cell number was significantly increased (P<0.05) as compared to the case where GM3 was not added. This effect was GM3 concentration-dependent. In the case where GM3 was added at a concentration of 2,500 ng/mL, the cell number increased to about 1,000,000 cells/mL, which was about twice of the case where GM3 was not added. Therefore, it was revealed that GM3 had an effect to induce cell proliferation of the NPLAd CHO cells.
Next, the facilitation of proliferation by the addition of insulin and GM3 was studied. FIG. 12 shows the results. In the case where insulin (10 mg/L) and GM3 (2,500 ng/mL) were added to the NPL medium, the NPLAd CHO cells (-◯-) showed a cell growth rate that is about the same as that of the CHO cells (-●-) of the original cell line in a medium supplemented with serum. Therefore, it was shown that, by adding insulin and GM3 to a medium, the NPLAd CHO cells showed a growth rate that was comparable to that of the CHO cells.
As described above, the proliferation of the NPLAd CHO cells was induced by adding GM3. Further, by using GM3 in combination with insulin, its growth rate increased to an extent similar to that of the CHO cells of the original cell line, in a static culture as well. Meanwhile, any change in the cell morphology was not observed. Therefore, it is thought that the deficiency of GM3 is not responsible for the ability of cells to be suspended.
It has been said that GM3 is responsible for the signal transduction of a cell, as well as that it is a major structural component of lipid rafts. However, as for the participation of GM3 to the signal transduction, there are contradictory reports that GM3 acts both suppressively and inducibly. Bremer, et. al., reported that the GM3 was a modulator of EGF receptor because, in A431 cells and KB cells overexpressing EGF receptors, addition of exogenous GM3 modulated the signal transduction by inhibiting the autophosphorylation of tyrosine kinase of EGF receptor, and inhibited EGF-dependent cell proliferation (Bremer, et. al., J Biol. Chem., 1986; 261: 243440). Whereas, Ji, et al., reported, using the same A431 cells, that the autophosphorylation of tyrosine kinase of EGF receptor was reduced by removing ganglioside on the cell surface with an endoglycoceramidase that was able to cleave sphingoglycolipid on the surface of a living cell under physiological conditions (Ji, et al., Glycobiology, 1995; 5: 343-50). Further, there is also a report that activities of tyrosine kinase of not only EGF receptor but also growth factors such as FGF, IGF-1 and PDGF, as well as their receptors, were inhibited, and thus the proliferation was inhibited by removing gangliosides with a glycosylceramide synthesis inhibitor, D-PPPP hydrochloride (D-1-threo-1-phenyl-2-hexadecanoylamino-3-pyrrolidino-1-propanol-HCl), in Swiss 3T3 fibroblast cells, but the inhibition was cancelled and proliferation was restored by adding exogenous gangliosides (Li, et al., J Biol. Chem., 2000; 275: 34213-23). From the above reports that are seemingly contradictory, it has been thought that gangliosides are a factor that is essential for the expressions of the functions of growth factors and receptors, and particularly the functions of receptors for various growth factors are deteriorated by deficiency of gangliosides, and, on the other hand, that the addition of exogenous GM3 to a cell line overexpressing EGF receptors acts to inhibit the functions. In recent studies about diabetes mellitus, there are reports that the elevated synthesis of GM3 due to the stimulation with TNF-α causes a functional abnormality of lipid rafts and suppresses selectively the metabolic signal of insulin (Tagami, et al., J Biol Chem., 2002; 277: 30855-92; Inoguchi, Himan-kenkyu (obesity research), 2006; 12: 260-2). It shows that excessive GM3 causes insulin resistance. It is thought from these facts that although GM3 in an amount that is necessary to form lipid rafts acts facilitatively, whereas excessive GM3 acts suppressively, to proliferation.
The cell line adapted to a protein-free and lipid-free medium according to the present invention is exposed for a long period of time to a state that is deficient for lipids, especially gangliosides. Therefore, there is a possibility that the receptors on lipid rafts have been affected. It is thought that, in the adapted cell line under a lipid-deficient condition, the functions of receptors on lipid rafts is normalized by adding GM3, which act in the direction of inducing proliferation ( FIG. 13 ).
6. Production of Recombinant Proteins in CHO Cells Adapted to a Protein-Free and Lipid-Free Medium
A transient method was used for verifying a production system of a substance. The productive capacity of a recombinant protein of the cells of the CHO cell line adapted to a protein-free and lipid-free medium was studied as compared to that of the CHO cells of the original cell line, according to the procedures shown in FIG. 14 by using the expression of secretory luciferase as an index.
(1) Experimental Procedures
(1-1) Transfection of Expression Vector Carrying a Gene of Secretory Luciferase
The CHO cells of the original cell line were cultured in a DMEM medium supplemented with 10% FBS. The DMAd CHO cells were cultured in a DMEM medium. The NPLAd CHO cells were cultured either in an NPL medium supplemented with insulin (10 mg/L) or in an NPL medium supplemented with insulin (10 mg/L) and GM3 (2,500 ng/mL).
The “TransIT-LT1 Transfection Regent” (by Takara, MIR2304) as a transfection reagent and the “NanoLuc® reporter vector pNL1.3. CMV [secNluc/CMV]” (by Promega, N1101) as an expression vector carrying a gene of secretory luciferase, were respectively used ( FIG. 15 ).
The CHO cells of the original cell line were detached by using trypsin and washed twice with the DMEM medium supplemented with 10% FBS. After washing, the number of the cells was counted by a dye-exclusion test by using the improved Neubauer hemocytometer and trypan blue, and the viability was calculated. The DMAd CHO cells were washed with the DMEM medium, and the NPLAd CHO cells were washed with the NPL medium supplemented with insulin (10 mg/L) or NPL medium supplemented with insulin (10 mg/L) and GM3 (2,500 ng/mL). Then, the cell aggregates were suspended and dispersed in each of the media. Thereafter, the numbers of the cells were counted by a dye-exclusion test by using the improved Neubauer hemocytometer and trypan blue, and the viabilities were calculated.
After the viabilities of 90% or more were confirmed, the cell number was respectively adjusted to 400,000 cells/mL in each of the media. The cells were seeded in wells of the 24-well plate at 0.5 mL/well. The plates, on which the cells had been seeded, were incubated for twenty-four hours under conditions of 37 degrees Celsius and 5% CO 2 .
To 700 μl, of the DMEM medium, 7 μL of 1 μg/μL of the “NanoLuc® reporter vector pNL1.3 CMV” was added and mixed. Then, the “TransIT-LT1 Transfection Regent,” 21 μL, was added and mixed. The mixture was kept standing at room temperature for thirty minutes to allow a transfection complex being prepared. As a control, a dummy complex was prepared in the same manner, except that TE buffer had been added instead of the “NanoLuc® reporter vector pNL1.3. CMV.”
The prepared transfection complex, 52 μL/well, was added dropwise to the wells of the plates, on which the cells had been seeded. For one combination of the cell and the medium, three wells were used. By gently rocking the plates, the contents in each well were mixed. The dummy complex was added dropwise to the wells of the plates and the contents in each well were mixed in the same manner (one well per combination of the cell and the medium). The plates were incubated for five days under conditions of 37 degrees Celsius and 5% CO 2 .
Hereinafter, the NPLAd cells that were obtained by culturing in an NPL medium supplemented with insulin (10 mg/L) and then being transfected, and the NPLAd cells that were obtained by culturing in an NPL medium supplemented with insulin (10 mg/L) and GM3 (2,500 ng/mL) and then being transfected, will be respectively referred to as “NPLAd CHO cells without GM3” and “NPLAd CHO cells with GM3.”
(1-2) Assay of the Specific Activity of Luciferase
The “Nano-Glo Luciferase Assay System” (by Promega, N1110) was used as a luciferase assay kit.
From each well of the plates, into which the cells were seeded and the transfection was completed, 10 μL of supernatant was taken 5, 24, 48, 72, and 120 hours after the completion of the transfection. The activity of secretory luciferase contained in the supernatant was assayed using the “Nano-Glo Luciferase Assay System” with a luminometer.
(1-3) Calculation of the Specific Activity of Luciferase
The specific activity of luciferase is the ratio of the luminescence of the supernatant of the adapted cell line under each incubation condition to that of the supernatant of the CHO cells of the original cell line, in which the supernatants were sampled at the same time. The calculation was carried out as follows:
[Mathematical Formula 1]
(1) the Specific Activity of Luciferase (%) of DMAd CHO Cells
{[(average luminescence intensity of transfected DMAd CHO cells)−(luminescence intensity of dummy DMAd CHO cells−blank)]/[(average luminescence intensity of transfected CHO cells of the original cell line)−(luminescence intensity of dummy CHO cells of the original cell line−blank)]}×100
(2) The Specific Activity of Luciferase (%) of NPLAd CHO Cells to which GM3 was not Added
{[(average luminescence intensity of transfected NPLAd CHO cells without GM3)−(luminescence intensity of dummy NPLAd CHO cells without GM3−blank)]/[(average luminescence intensity of transfected CHO cells of the original cell line)−(luminescence intensity of dummy CHO cells of the original cell line−blank)]}×100
(3) The Specific Activity of Luciferase (%) of NPLAd CHO Cells to which GM3 was Added
{[(average luminescence intensity of transfected NPLAd CHO cells with GM3)−(luminescence intensity of dummy NPLAd CHO cells with GM3−blank)]/[(average luminescence intensity of transfected CHO cells of the original cell line)−(luminescence intensity of dummy CHO cells of the original cell line−blank)]}×100
The experiment was repeated three times, and the data were shown as the average of specific activities of luciferase of all experiments±SD. As the test to examine whether there was a significant difference, the Student's t-test was used.
(1-4) Comparison of Luminescence Per Cell
To compare the luminescence for each group of cells, the luminescence of the supernatants, which were sampled with time after transfection, of each group of cells was divided by the number of cells increased in a period, of the same time, the same cell, the same composition of the medium, and the same incubation conditions. Namely, the luminescence per cell was presumptively calculated.
(2) Results
To study the protein productivity of the adapted cell line, the cells were transfected by a lipofection method with plasmid pNL1.3.CMV vector, carrying cDNA of secretory luciferase integrated downstream of the CMV promoter, and the activities of luciferase that had been respectively secreted into media of the CHO cells of the adapted cell line and the CHO cells of the original cell line were compared by assaying the luminescence. FIG. 16 shows the results. In the NPLAd CHO cells with GM3, the protein yield just after transfection was slowly increased. However, after 120 hours, there was no significant difference between the specific activities of luciferase of the CHO cells of the original cell line and the NPLAd CHO cells with GM3. The overall protein yield of the NPLAd CHO cells with GM3 (-●-) was comparable to that of the CHO cells of the original cell line. The DMAd CHO cells (-▴-) and the NPLAd CHO cells without GM3 (-◯-) showed specific activities of luciferase, which were three times or more of that of the CHO cells of the original cell line, at 120 hours after the transfection. The significant differences were p<0.05 and p<0.005 for the DMAd CHO cells and the NPLAd CHO cells without GM3, respectively. Therefore, it was thought that the protein productivities of the established cell lines were higher than that of the CHO cells of the original cell line.
To convert the data into luminescence per cell, the luminescence with time that was assayed in FIG. 16 was divided by the number of increased cells, for the same time point, the same cell, the same composition of the medium, and the same incubation conditions, thereby the luminescence per cell was presumptively calculated ( FIG. 17 ). As a result, it was estimated that, at 120 hours after the transfection, the luminescence per cell of the DMAd CHO cells (-Δ-) was almost the same as that of the NPLAd CHO cells without GM3 (-◯-), and was about four times that of the CHO cells of the original cell line (-X-). Further, it was estimated that, at 120 hours after the transfection, the luminescence per cell of the NPLAd CHO cells with GM3 (-●-) was almost the same as that of the CHO cells of the original cell line.
From these results, it was shown that each of the adapted cell lines was able to produce a recombinant protein at a productivity that is similar to or more than that of the CHO cells of the original cell line. The DMAd CHO cells and the NPLAd CHO cells without GM3 produced three times or more of luciferase as compared to luciferase produced by the CHO cells of the original cell line ( FIG. 16 ). Further, when the luciferase activity per cell was estimated, at 120 hours after the transfection, the activities of the DMAd CHO cells and the NPLAd CHO cells without GM3 were four times higher than that of the CHO cells of the original cell line, and the activity of the NPLAd CHO cells with GM3 was almost the same as that of the CHO cells of the original cell line ( FIG. 17 ).
The reason why the adapted cell lines show higher luciferase productivities than that of the CHO cells of the original cell line is not clearly understood. However, there is a possibility that alteration of the membrane structures of the adapted cell lines influenced. As described above, there is a possibility that, because the adapted cell lines were exposed to a condition of lipid-deficiency for a long period of time by passages in protein-free and lipid-free media, the structures of their cell membranes altered and thereby their transfection efficiencies were elevated. Further, there is another possibility that membrane permeability was increased for proteins synthesized in cells, and thus more luciferase protein was secreted.
From these results, it was demonstrated that an efficient production of a recombinant protein was able to be realized by ensuring a sufficient number of cells in culture before transfection by adding insulin and GM3 to a medium, and then transfecting the cells by a transient method after removing GM3. | A method for producing a recombinant protein includes steps of: (a) culturing a transformed cell in a protein-free and lipid-free medium containing no exogenous growth factors, in which the transformed cell is produced by transfecting a cell of a cell line derived from Chinese Hamster Ovary (CHO) cells, the cell line is adapted to a protein-free and lipid-free medium, and the cell is capable of proliferating in a suspended state in a protein-free and lipid-free medium containing no exogenous growth factors, with a vector containing a gene coding for the protein to be produced under the control of a promoter operable in the cell, and (b) recovering the protein produced by the transformed cell. | 2 |
FIELD OF INVENTION
This invention relates to containers and more particularly to knocked-down containers for chain saws and similar products.
BACKGROUND OF INVENTION
Since the development of chain saws, these devices have been primarily used in the logging and tree trimming industries. Substantial improvements, have been made in this type of equipment in recent years which have made them appealing to noncommercial purchasers.
With the present fossil fuel shortages and the spiraling cost of cord wood for use in stoves and fireplaces, a tremendous demand has been created for chain saws and related equipment. Since these saws are stored quite often over an extended period of time during the off season as well as being transported in vehicles not specifically designed for this purpose, the providing of containers to both protect the saw and prevent it from the snagging on surrounding items have been developed.
These containers have been in the form of everything from relatively heavy, bulky boxes to molded plastic cases generally conforming to the exterior shape of the saw. The box like containers, of course, are heavy and bulky and generally undesirable, particularly for noncommercial usage. The contoured cases on the other hand, although space saving as compared to box like containers, still require an unusually large amount of space, especially when shipped from the manufacturing plant to the consumer outlet. Because of this "shipping of air", transportation cost of the prior art cases or containers are unusually high. Due to the unsymmetrical configuration of the chain saw, nesting of case parts for shipment as well as other breakdowns of the same have not been deemed impractical. Other attempts at reducing shipping costs of these containers have been made but to the present have not provided a practical solution to the problem.
BRIEF DESCRIPTION OF INVENTION
After much research and study into the above-mentioned problems, the present invention has been developed to provide a contoured container for chain saws and the like which gives a unitary appearance in sight and feel and yet is so designed as to be shipped with the scabbard portion nestled within the engine portion of the case. This is accomplished through the use of uniquely designed interlocking wall sections with a snap-in projection for retention of the assembled portions. Because of the unique features of this container, the same can be shipped in much less space than ordinary containers of this general type and yet when assembled, serves the same function as the unitary container of the prior art.
In view of the above, it is an object of the present invention to provide a chain saw type container which can be shipped in partially knocked-down condition and yet can readily be assembled for use.
Another object of the present invention is to provide a chain saw container which can be shipped in unassembled condition and yet when assembled has the appearance and strength of a pre-formed unit.
Another object of the present invention is to provide interlocking wall portions with a securing pin for permanently connecting the sections of a container together.
Another object of the present invention is to provide a chain saw type container which is easily shipped and yet sturdy in assembled condition.
Another object of the present invention is to provide a blow molded double walled chain saw carrying case which is assembled through the use of reverse draft and interface fits.
Another object of the present invention is to provide a chain saw carrying case which is molded in three pieces including a lid, a base, and a scabbard section wherein, when assembled, the scabbard section is permanently attached to the base section.
Another object of the present invention is to provide a compression molded pin for permanently anchoring the scabbard section of a blow molded, double-walled carrying case to the base section thereof.
Another object of the present invention is to provide, in a chain saw type carrying case, a rear section which is lowered through a stepped parting line to allow a chain saw type tool to be more easily loaded into the case without binding or other interference.
Other objects and advantages of the present invention will become apparent and obvious from a study of the following description and the accompanying drawings which are merely illustrative of such invention.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a perspective view of the container of the present invention;
FIG. 2 is an exploded fragmentary view of the scabbard to base interlocking means;
FIG. 3 is a fragmentary view of the scabbard united with the base section;
FIG. 4 is a sectional view taken through lines 4--4 of FIG. 3; and
FIG. 5 is an end elevational view of the container of the present invention.
DETAILED DESCRIPTION OF INVENTION
With further reference to the drawings, the container of the present invention, indicated generally at 10, includes a base portion 11, a mating scabbard portion 12 and a pivoted lid portion 13. Both the base and lid portions are preferably of the blow molded, double walled type. These portions are assembled through use of an interlocking pin 14 so as to pivot along hinge line 15.
Side walls 16 and 17 and bottom 18 of base portion 11 are all of normal double walled thickness. The front or scabbard wall 19 angles out into a thickness several times that of walls 16 and 17 which can clearly be seen in FIGS. 2 and 3.
A generally U-shaped opening 20 is provided in front wall 19. This opening is bounded by a generally flat bottom area 21 with adjacent generally flat sloping areas 22. A generally triangular shaped indention 23 bounded by shoulders 24 forms the side areas of opening 20. An opening 25 is provided in the bottom area 21 of opening 20 and is adapted to retainingly receive anchoring pin 26 as will hereinafter be described in more detail.
A rather hefty, triangular-in-cross-section retaining projection 27 is provided on opposed sides 28 of scabbard portion 12. Each of these projections are so sized as to snugly mate with their respective triangular shaped indention 23 in base portion 11. When in such mated position, shoulders 24 will lie juxtaposed to a portion of the respective side 28 of scabbard 12. This combination of scabbard projections engaging base indentions and base shoulders engaging scabbard sides give a firm interlocking action between the base and scabbard portions when in the position shown in FIG. 3.
To retain the relationship of the parts as shown in FIG. 3, retaining pin 26 is compression molded onto the lower or bottom portion 32 of scabbard 12 and is in the form of a round or oval shaped shaft 29 with a retaining head 30 formed at the end thereof. The underside of this head forms a shoulder 31 which, when retaining pin 26 is pressed into the opening 25 of the inner wall of the base portion 11, shoulder 31 engages the back side thereof to permanently anchor base portion 11 to scabbard portion 12 as seen clearly in FIG. 4. This is, of course, not done until the container of the present invention is ready to be assembled such as at the time of purchase at a retail outlet. During shipment and storage, the container is, of course, in knocked-down configuration with the scabbard portion 12 being stored inside the cavity formed by the base portion 11 and lid portion 13.
One final comment concerning the interconnection of the base and scabbard portions, the reenforcing rib 33 on each side 28 of the scabbard 12 engage a notch shoulder 34 in the upper side areas of opening 20 of base 11 to give even more rigidity to the relationship of the portions as can clearly be seen in FIG. 3.
Snap latches 35 are provided on lid portion 13 for engaging corresponding locking shoulders 36 of base portion 11. Also a handle 37 is provided with lid portion 13 to allow the assembled container 10 to be easily picked up and transported.
Lid portion 13 also includes a notched area 38. When the assembled container 10 is in the closed position shown in FIG. 1, the notched area 38 will add even more rigidity to the relationship of the assembled parts.
Since the portions of the present invention are preferably formed from a semi-rigid material such as blow molded plastic, the sides of opening 20 can be distorted outwardly while the scabbard walls 28 can be distorted inwardly during the assembling process.
The base and lid portions 11 and 13 of the container 10 of the present invention are double walled and formed by blow molding. These two portions are then assembled at the hinge areas as above-described so that when the portions are closed, they form an interior area 39. The scabbard portion 12 is formed preferably as a single wall unit since it does not need to be aesthetically appealing on the interior as it is adapted to receive a projecting portion of the article (not shown) placed in the containers such as the cutter bar of a chain saw.
The container of the present invention can either be shipped in partially assembled condition with the lid and base portions connected at the hinge area 15 or they can be shipped separately in nestled form and assembled at the time of first use. In either case, the scabbard portion would be shipped with the container, preferably in the interior 39 of the assembled base and lid portions. Much less space is thus required during shipment thereby allowing more units to be shipped per load. Also during storage, prior to final assembly and use, much less valuable storage area is required for any given number of units than if the same were completely assembled.
Once it is desired to use the container of the present invention, the scabbard 12 is placed in the position shown in FIG. 2 and pressure is applied in the direction of arrow 40. The flat, generally beveled side 27' of projection 27 slidingly engages the upper edges of opening 20. Although double walled blow molded plastic articles are relatively rigid, there is some give inherent in the product. This give allows the same to be able to withstand impacts without breaking and, in the present case, allows the outer portions of opening 20 to be distorted outwardly and the sides 28 of the scabbard 12 to be distorted inwardly as the beveled portions 27' of projections 27 slide downwardly with the scabbard 12 into said opening 20. As the scabbard retaining projections 27 matingly enter indention areas 23 of base 11, the adjacent portions return to their normal undistorted positions with a snug fit being accomplished as shown in FIG. 3.
The final assembly is the use of a blount instrument such as a hammer handle pressing down on the interior of scabbard 12 above anchor pin 26 to form the same into opening 25 in the inner wall of base 11. Once the retaining head 30 has passed through the opening, the shoulder portion 31 will engage the underside of such inner portion thus permanently retaining the scabbard portion 12 relative to the base portion 11 as clearly seen in FIG. 4.
The rear portion of the container of the present invention opposite scabbard 12 is inclined as indicated at 42 to allow a chain saw or other article to readily be placed within the container. As can clearly be seen in FIG. 3, side 16 is distinctly lower than side 17 thus allowing for the end configuration to be readily formed.
Equipment such as a chain saw can then be placed in the container 10 with cutter bar of the saw extending into the scabbard of the container and the engine being disposed interiorly of the base and lid portions 11 and 13. Container 10 can then be closed, pivoting about hinge 15 with latches 35 engaging shoulders 36. The container and its product is then ready for storage, transport or the like.
From the above, it can be seen that the present invention has the advantage of providing a highly efficient interlocking system between the scabbard and base portions of a chain saw type container and yet provides a means for shipping and storing such container in space saving, knocked-down condition. Once the scabbard and base portions are snapped together (without the use of separate securing means), the same becomes an integral unit permanently connected together.
The terms "upper", "lower", "bottom", "top", "front" and so forth are used herein merely for convenience to describe the container and its parts as oriented in the drawings. It is understood, however, that these terms are in no way limiting to the invention since the container may obviously be disposed in many different positions when in use.
The present invention may, of course, be carried out in other specific ways than those herein set forth without departing from the spirit and essential characteristics of the invention. The present embodiments are, therefore, to be considered in all respects as illustrative and not restrictive and all changes coming within the meaning and equivalency range of the appended Claims are intended to be embraced therein. | This invention is a container designed for use in conjunction with elongated products such as chain saws. These containers can be shipped in space saving knocked-down or partially assembled condition and yet can quickly and easily be assembled to give the appearance and rigidity of a pre-formed container. | 1 |
REFERENCE TO RELATED APPLICATION
This application claims priority based on U.S. Provisional Patent Application Ser. No. 60/295,592, filed Jun. 4, 2001.
BACKGROUND OF THE INVENTION
The present invention relates generally to a caster and more specifically to a hubless caster for use in office furniture (chairs, tables, desks) as well as other devices or conveyances used primarily for transport of materials and pushed by hand (grocery carts, wagons). This new device is a caster that allows better inherent stability, easier rolling, and affords easy customization to enhance the overall aesthetic of the supported object (chair, table, cart, file cabinet, or other pieces of furniture). For the purpose of this patent, the attached device will assumed to be an office chair.
DESCRIPTION OF THE PRIOR ART
It can be appreciated that casters have been in use for decades. Casters are located between the chair and the floor on which the chair is rolling, and are usually used in groups of 4 or 5 per end device. Typically, caster designs tend to fall into one of two groups: the ‘single wheel’ and the ‘twin wheel’. The single wheel caster consists of one wheel with an axle through the center which is attached to a support base. The support base is fixed to the chair (or other object) by use of a vertical pin that allows the caster to pivot about a generally vertical axis while also permitting rotation of the wheel about a generally horizontal axis, thereby allowing the caster to move in any direction.
The other main type of caster design is the ‘twin wheel’ caster, which is identical to the first mentioned except two wheels are used instead of one. The two wheels share a common axle, but are free to rotate separately. The axle is affixed to the vertically extending base at a location in the middle of the two wheels. In this way, each wheel is free to rotate in opposite directions, facilitating a change in direction of the chair direction. Also, the wheels may turn in the same direction for straight-line movement of the chair.
The main problem of the ‘single wheel’ caster is its inability to turn easily about the pin pivot. The wheel needs to rotate about the straight line formed by the wheel's contact with the horizontal floor. Effectively, a portion of the contacting wheel needs to drag on the floor instead of freely rolling. Additionally, the central axle running through the centerline of the wheel is supported at the outsides of the wheel. These outside locations are unprotected from any collisions with other chairs or walls, often leading to a bent axle, which seriously impairs the usability of the caster. This design is still available though is less commonly used in modern office furniture.
The ‘twin wheel’ caster offered an improvement over the ‘single wheel’ in two important regards. The ability of the wheels to rotate in opposite directions at the same time greatly enhanced the ability to turn about the vertical pivot, making a change in overall direction of the chair very smooth. Also, the support of the central axle to the chair in the middle of the two wheels afforded greater protection of the thin axles, greatly reducing the possibility of damage to the axle and subsequent loss of performance. One problem germane to this caster type is the method of attachment of the wheel to the axle. Unlike the single wheel with its axle attachment on the two faces of the wheel, the double wheel design attaches each wheel to its respective end of the axle, the axle support to the base being disposed between the two wheels. This attachment configuration creates some inherent stability inefficiencies. By not allowing the axle to go through the wheel, the loading of the wheel on the axle is not symmetric. That is, the inside of the wheel is fully loading the axle while the outside is not loading the axle at all. Also, the limited space remaining in the device for the wheel thickness results in thin wheels, which directly result in narrow annular (limited) bearing surfaces of the wheel on the axle.
The overall attachment of the wheel to the axle is inherently not completely stable. With the simple method employing a pin (axle) in a hole (in the wheel), the resulting configuration is often fairly loose and sloppy. This can be easily verified by inspection of any casters of this type. Simply moving the wheels by hand shows the amount of ‘play’ in the assembly and lack of inherent design stability. Note these effects multiply over time as the friction in the joints further moves the features from the design ideals.
Both types of casters, additionally, suffer common drawbacks. In its most common embodiment, the wheels turn on the axle, relying on sliding friction to afford rotation. This type of friction is not as smooth and efficient as other types of motion. Additionally, over time the friction removes material in the hole, creating a larger hole and subsequent ‘wobble’ as the tight fit in the axle is lost.
Also, both casters rely on the wheels transferring load to axles located at the exact centerline of the wheel (s). This, at first glance, appears to be the most rational design dating back to the original wheel-about-axle. Certainly, this configuration is most stable for wheels turning very quickly, for example bikes or motorcars. But for wheels whose primary purpose is to carry load and turn at very slow rotational speeds (5 rpm and often, for long periods of time, zero), the center axle is not ideal. Under many loading instances, the wheels impart a moment about the wheel centerline perpendicular to the direction of travel, such as in turning of the caster. This moment occurs because the force on the wheel (at the floor contact) is multiplied by the distance to the axle, the wheel radius. This moment adds more loading of the aforementioned wheel/axle joint, further decreasing the inherent stability of the overall device.
Finally, there is a common failing in casters of either of the common designs. Needless to say, a caster is of no use by itself. The sole purpose of a caster is to provide greater functionality (ease of movement) to the overall object (office chair). As a piece of a greater whole, the caster should have the ability to enhance the overall design characteristics of the chair. This may be accomplished by replicating design features from the rest of the chair, using consistent materials, or in other ways complimenting the overall intent of the chair design. With the ‘twin caster’ design, the prominent wheels with their solid center walls, located on the outside of the device dominate the appearance of the caster assembly. This leads to few opportunities to customize this type of caster for a specific chair design.
With few opportunities for differentiation in the wheel, this caster design leads to the device being featured on almost all furniture products today without sharing any design traits (materials, color, design features) with the entire chair. Caster designs remain consistently the same from chair to chair, manufacturer to manufacturer, year to year.
The relevant prior art includes U.S. Pat. No. 4,045,096, a rotor is mounted within a shroud, and various embodiments of roller bearings are shown for mounting the rotor to the shroud. In U.S. Pat. No. 4,465,321, a hubless wheel is mounted within a fender that describes less than a full circle. The wheel is collapsible, and is supported by the surrounding fender. U.S. Pat. No. 5,248,019 shows motorcycle and bicycle constructions that use hubless wheels. The wheel is apparently mounted to the fixed rim with one bearing. U.S. Pat. Nos. 5,419,619 and 5,490,719 relate to a bicycle construction. Both are directed to the precise angular spacing of the bearings mounted on the fixed hoop of a hubless wheel assembly, and appear to rely on four bearings unequally spaced bearings. There is no teaching of a caster using hubless wheels, nor of a hubless wheel construction in which two hubless wheels are mounted on opposite sides of a common base ring.
SUMMARY OF THE INVENTION
The present invention generally comprises a hubless caster device for use with furniture, equipment, carts, and other conveyances. This new device provides better stability, better rolling functionality, and many flexible design implementations.
In these respects, the hubless caster substantially departs from the conventional concepts and designs of the prior art, and in so doing provides an apparatus primarily developed for the purpose of a unique caster for use in office furniture or equipment.
The hubless caster shares some basic features with prior art caster designs: the central base component providing structure and a vertical pin, which attaches the central base component to the chair and allows the caster to pivot about the vertical pin. However, the present invention is unique in a very fundamental way, which provides great advantages over existing art. The device employs two wheels, each located at opposite ends of the base. The wheels are not disc shaped as is most common. Rather, the wheels are annular (doughnut shaped) with no central disk wall or any other structure inside the opening that extends through the annulus. Thus the largest, most visually dominant portion of the typical prior art designs is eliminated, The outside diameter of the wheel is circular and smooth, for efficient ground-engaging contact. The inside diameter is provided with a toroidal groove that is adapted to receive roller bearings, either cylindrical or ball type. The central base component includes a ring body, and two arrays of roller bearings are disposed at opposed sides of the ring body, each array engaging the groove of one of the wheels. The bearings support the wheels and permit rolling friction of the wheel about an axis defined by the centering ring portion of the base. The two wheels share a common ring body but do not share a common axle, bearings, nor support groove, so that each wheel is free to rotate independently. By eliminating the common center axle, the need for the center section of the base is obviated. Thus the wheels and the center base are open through-and through, greatly altering the visual appearance (compared to prior art designs) by permitting light to pass through the center of the caster assembly.
The use of rolling bearings allows better rolling as line friction has been virtually eliminated. Of course, bearings are very commonly used in wheel applications, mostly as ball bearings. However, in this invention the bearing arrangement differs in that the balls ride in grooves that are integral to the wheel and the base. Also, the bearings are not concentrated close to the axis of symmetry, as in central axle designs in the prior art, but are spaced apart near the outside diameter of the wheel where the wheel makes contact. This location provides a far more stable wheeled device in that any side loads (moment) are not transmitted via a lever arm (the radius of the wheel) further out to the center of rotation. The loads are transmitted to the bearings, which occupy a minimum space, thereby reducing the lever arm and providing less play in the system. Also, the grooves ‘capture’ the bearings very tightly (each ball surrounded by four planes). In this way, the balled joint has very little play and greatly reduces any wobble that occurs when a wheel is simply supported by an axle.
The elimination of the small diameter central axle enhances stability by virtue of the geometry of the mechanics of the assembly. Stiffness of a section is enhanced by geometry in which features are far from the center of neutral axis. (I.e., a pipe is stiffer than a rod if both are made of same material and employ same amounts of material.) With the wheels (via the bearings and centering ring) riding on the base directly (and not on an axle), the entire base becomes sole support for the wheels, with the enhanced effects of better stiffness and therefore a more stable overall device. Additionally, the base is far stronger than a simple axle and is more resilient to any impact on the device, hence it has better longevity.
The elimination of a central axle and the material that would normally surround it in the base provides the hubless caster with a distinct advantage over the existing art. This ‘hubless’ feature removes the visual prominence of the wheel and allows the base (in its simplified form) to be more apparent. This leads to greater opportunities to customize the caster by incorporating design elements of the overall design of the end device, such as a chair or furniture item or skateboard. If left open, the hubless caster will allow a skateboard or chair itself to appear to be ‘floating’. If desired, the central hubless area may be used to add features that are consistent and/or distinctive with the entire chair such as holes, cutouts, different colors, imprinted logos, reflective surfaces, translucent materials, similar materials, fabrics, and so on. The ease of customization will allow an infinite number of possible customizations to allow the hubless caster to be tailored for visual distinctiveness and design conformance with the overall aesthetic. This feature makes it very distinctive over the ubiquitous black twin wheeled caster.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a perspective view of the hubless caster depicting overall part geometry and hubless center portion along with the king pin component.
FIG. 2 is an exploded view of the hubless caster assembly showing the internal mechanical components.
FIG. 3 is a detail depicting location of bearings and retainers in relation to the wheel.
FIG. 4 is a cross section view of the hubless caster assembly, taken along line 4 — 4 of FIG. 1 , showing relevant part mating geometry.
FIG. 5 is an exploded view of a further embodiment of the hubless caster utilizing a thinner structural frame which allows the king pin device to be customized.
FIG. 6 is an exploded view of a further embodiment of the caster using rollers rotating about pins fixed to the base of the device.
FIG. 7 is a detail perspective view showing a further embodiment of the device in which the frame contains features to allow accessory devices such as brakes, fenders, and keep-out safety devices as well as different structural attachment methods to be employed.
FIG. 8 is a perspective of a further embodiment of the hubless caster in which the open hubless portion of the device is provided with a decorative hub.
FIG. 9 is an exploded view showing the relationship of the decorative hub and hubless caster of FIG. 8 .
FIG. 10 is an exploded view of a further embodiment of the device in which the two wheels are attached to each other in a hubless design.
FIG. 11 is an exploded view of a further embodiment of the device in which a structural tube is fixed to the base. The tube carries the load, allowing the frame to be made of lower strength material than previous embodiments (for example, plastic instead of a metal).
FIG. 12 is a perspective view of a further embodiment of the hubless caster of the present invention.
FIG. 13 is a cross-sectional side elevation of the embodiment shown in FIG. 12 .
FIG. 14 is a cross-sectional view taken along line 14 — 14 of FIG. 13 .
FIG. 15 is a cross-sectional view taken along line 15 — 15 of FIG. 13 .
DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention generally comprises a hubless caster assembly for use with furniture, equipment, carts, and other conveyances. This new device provides better stability, better rolling functionality, and many flexible design implementations.
With regard to FIGS. 1-4 , the hubless caster assembly includes a ring body 1 having an open center portion 11 . A kingpin 4 extends outwardly from the ring body 1 and is supported by an integral boss 12 . (In the drawings, similar reference characters denote similar elements throughout the several views.) The kingpin may be received in a generally vertically oriented receptacle for pivoting motion about the kingpin axis, as is known in the prior art. The assembly also includes a centering ring 8 , which is provided with an annular body 13 and a reduced diameter portion 9 extending coaxially from the body 13 . A toroidal wheel 5 includes an outer surface adapted to be ground-engaging, and an inner annular surface 14 . A bearing race groove 16 is formed in the surface 14 at the inner end thereof. A plurality of bearings 6 are disposed in the race groove 16 , interspersed with bearing spacers 7 that maintain the spacing of the bearings 6 . The bearings 6 may be rollers, balls, or the like. The inner diameter of the race groove 16 is sufficiently small to clear the outer surface of the portion 9 of centering ring 8 , so that each wheel 5 is supported by the bearings 6 for rotation thereabout. Likewise, the inner diameter of portion 14 of each wheel 5 is greater than the outer diameter of portion 13 of the centering ring, so that the wheels are free to rotate about their respective centering rings. The wheels thus rotate independently, and are capable of counter-rotating, as when the caster is pivoted about the kingpin 4 . The close spacing of the centering ring surfaces to respective confronting surfaces of the wheels serves to limit the intrusion of dirt into the bearing space.
With regard to FIGS. 5 and 6 , an alternative embodiment of the hubless caster includes the ring body 1 and the kingpin 4 ′ extending from a boss 12 ′. In this embodiment, the king pin 4 ′ is reinforced by incorporation of an extension 21 of the structural frame from its interior ring portion 1 , allowing the king pin to function as before but without the need to be a rigid structural piece. In this embodiment, a plurality of pins 22 extend outwardly from each side of the ring body 1 , and a plurality of roller bearings 24 are each secured on the end of one of the pins 22 by retainer 23 . The wheels 5 and centering rings 8 function substantially as described previously. In this embodiment, no bearing spacers 7 are required. Also the pins and their roller bearings may be arrayed in unequally spaced fashion about the ring body; for example, more of the bearings may be disposed at the lower half of the ring body to absorb the primarily vertical load on the wheels.
With reference to FIG. 7 , the ring body I may extend in a nominal plane, and a connector member 26 may extend from the ring body in the same plane. The distal end of the connector member 26 terminates in a right angle flange 27 having bolt holes for attachment to an object or piece of furniture. The flange 27 and the lug 28 to allow accessory devices such as brakes, fenders, and keep-out safety devices as well as different structural attachment methods to be employed.
Note that the wheels and retaining rings have open central portions that correspond to the opening 11 in the ring body. Thus the caster assembly has no hub, no center, and thus is much less massive in appearance than prior art casters that have solid disk wheels and central bodies. Light passing through the aligned openings causes the caster assemblies to become rather unnoticeable, so that the furniture item appears to ‘float’ on the floor.
On the other hand, the hubless feature may be exploited in an opposite manner. As shown in FIGS. 8 and 9 , a hub cap 29 may be affixed to the opening of at least one centering ring 8 of a caster assembly of the invention. The hub cap 29 may bear a manufacturer's logo, or decorative imagery or indicia, or fabric covering to match the upholstery of a chair, or wood grain to match a desk, or the like. If the hub cap 29 is transparent or translucent, transmitted light will illuminate a logo or indicia borne thereon. The hub cap 29 is not necessary as a structural element, and may be removable, or replaceable. Note that the diameter of the cap 29 is only slightly less than the diameter of the wheels 8 , so that the caps 29 dominate the visual appearance of the caster assembly. Thus there is ample opportunity to stylize the appearance of the caster assembly in connection with the appearance and design of the end use item supported by the caster assembly.
With reference to FIG. 10 , a further embodiment of the hubless caster includes the ring body 1 and kingpin 4 extending therefrom. In this embodiment the opening 11 of the ring body is configured as a bearing race, and the roller bearings 6 and spacers 7 are arrayed about the inner surface of the opening 11 . Each wheel 30 is an annular object having an outer tread portion 31 and an inner neck 32 that extends through the bearing assembly to join the neck 32 of the wheel 30 on the opposite side of the ring body 1 . The necks 32 engage the bearings 6 to rotate freely therein, and the wheels 30 are joined for rotation in common. This embodiment eliminates the centering rings, and simplifies manufacturing and parts count. It may be advantageous in situations where a caster is fixed in direction, in which case the kingpin may be replaced by a non-pivoting mounting, as shown for example in FIG. 7 .
Another embodiment of the invention, shown in FIG. 11 , includes the ring body 1 and kingpin 4 extending therefrom. The central opening 11 of the ring body 1 secures a tube 34 extending rigidly therethrough. A wheel 36 and centering ring 37 are assembled to a respective end of tube 34 , with bearings 6 and spacers 7 secured in a race groove (as in the previous embodiments) in the inner surface of the wheel 36 . In thus embodiment the wheels rotate independently. The tube 34 carries the load, allowing the body 1 to be formed of lower strength material (for example, plastic instead of a metal) than embodiments described above.
An additional embodiment of the invention, shown in FIGS. 12-15 , includes a ring body 1 and kingpin 4 extending therefrom. The ring body 1 is provided with a pair of bearing race grooves 41 extending annularly and coaxially, and disposed on either side of the ring body. A pair of toroidal wheels 42 are provided, each wheel including an annular race groove 43 at an inner surface portion thereof, the outer surface being adapted to ground-engaging contact. The wheels are assembled to their respective sides of the body 1 , with the bearing races 41 and 43 disposed in confronting registration to contain a plurality of balls 44 arrayed therein. The wheels 42 rotate independently in low friction rolling motion on the balls 44 . Note that the centering ring of previous embodiments is eliminated. The bearing arrangment in this embodiment may comrprise the bearings 6 and spacers 7 of previous embodiments.
In all the embodiments described above, the construction shown allows the bearings to rotate about a common centerline, even though there is no shaft or other central structure in the assembly. The load is transmitted from the wheels to the bearings and to the body 1 . This design, by providing a large cross-section at the bearing assembly, provides a stiffer structure than a simple axle device. The body 1 is the main structural member and should be constructed of metal and/or strong plastic materials using mass-production (injection) manufacturing techniques or metal stamping. The body, by virtue of not having an axle through the center, allows the center section to be used for different design features more consistent with the overall furniture piece, such as holes, different materials, matching materials or textiles from the chair, and/or other design features replicated from the end use assembly.
The wheels 5 may be made of plastic or metal or rubber or a combination thereof. They may have patterns or textures or color treatments employed in the outside treads. In general, both the centering rings and the wheels incorporate raceways to share the bearings and transmit loads between the wheels to the frame. The raceways are either four flat annular surfaces or toroidally curved surfaces that match the bearing profile. In either configuration, the raceways provide a firm, close-fit with the balls. The shared geometry of the raceway between the wheels and the centering ring is required although the apportionment is not critical. That is, the enclosing cross section must be provided about the bearings but the enclosing features may be in the wheel, the centering ring, and/or may be provided through the addition of spacers.
The caster device described in any embodiment herein is infinitely scaleable. It may be used for very small items to be moved or very large. Its most useable application may be for furniture (seating, storage devices, and desks). The most distinctive and changeable portion of the caster is the unique unused ‘center section’. Without need for a central axle, the center base area may be used for design elements (logos, design features, different colors, symbols) or other additional apparatus (level-measuring devices, stationary brakes, odometers, illumination, etc).
The foregoing description of the preferred embodiment of the invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed, and many modifications and variations are possible in light of the above teaching without deviating from the spirit and the scope of the invention. The embodiment described is selected to best explain the principles of the invention and its practical application to thereby enable others skilled in the art to best utilize the invention in various embodiments and with various modifications as suited to the particular purpose contemplated. It is intended that the scope of the invention be defined by the claims appended hereto. | A hubless caster assembly includes a caster body and at least one wheel, the wheel comprising a toroidal member having a bearing race, and a complementary bearing race supported by the caster body. Bearing elements in the races support the wheel in free rotation. The caster body may comprise a ring body having an axial opening, whereby the caster assembly has a large central aperture extending entirely therethrough. A centering ring may be secured in the axial opening with the complementary bearing race formed therein. A hub cap with visual treatment may be secured over the central aperture. | 1 |
FIELD OF THE INVENTION
The invention relates to article handling machines, and more especially to a device for easing maintenance operations of such machines.
BACKGROUND OF THE INVENTION
Article handling machines are used in a wide range of industries to process articles, for instance in bottle industry, pharmaceutical industry or in food packaging industry. Maintenance operations of such machines require access to every part of the machines, even to the roof.
The roof is a critical part. Indeed, many elements which demand regular maintenance are only accessible from the roof.
For instance, bulky power devices, such as electrical cabinets, may be mounted on the roof, in order to minimize the occupied space on the floor, and to place the apparatus as near as possible to the machine and to let a free access to the interior of the machine by the sides.
Structural parts of the machine, such as wheel axis or cap feed rails may be fixed to the roof, and should hence be accessible for installation and maintenance purposes; whereby, operators mount and walk on the roof to achieve the necessary steps.
Such operations may be hazardous for operators. Indeed, the space on the roof is generally limited and, as a large portion is already occupied by machine parts, such as the electrical cabinet, operators do not have much room where to move and store their tools.
In order to bring an element of solution, handrails have been placed along roof edges of some machines to secure operators' movements on the roof.
However, the mere handrail is an incomplete solution. Indeed, even if the risk of falling is minimized, the room available for operators is still insufficient.
Moreover, such machines must be moved at least once, from their setting place to a client place, by common transportation means, involving to pass through public roads. As the machine may be bulky by itself, it is a conception matter not to increase the width of the machine and to keep its dimensions in a reasonable average.
SUMMARY OF THE INVENTION
It is an object of the invention to provide an article handling machine, the design of which facilitates access to the roof and movement thereon, and yet permitting easy transportation of the machine, on transportation vehicles adapted for public roads.
The proposed article handling machine comprises a frame for receiving article handling elements, a roof covering said frame, and a catwalk on one lateral side of the machine. The catwalk is pivotally mounted on the frame between an extended position in which it protrudes in a direction substantially perpendicular to the lateral side, with an inner edge facing the machine lateral side, and a folded position in which it stretches out in a direction substantially parallel to the lateral side.
In a preferred embodiment, the frame comprises a flange, on the lateral side, said flange comprising an aperture, and the lateral catwalk may comprises an axis positioned near the inner edge, in the flange aperture, so that the catwalk can swivel around the machine, between the extended position and the folded position, by the rotation of the axis in the aperture.
The aperture in the flange aperture has e.g. a profile comprising a horizontal section receiving the axis in the extended position, and a vertical section receiving the axis in the folded position.
In addition, the catwalk may be held in the extended position by means of a locking device, which includes e.g. apertures positioned on the catwalk and the machine, in such a way that, in the extended position, an aperture in the machine is coaxial with an aperture in the catwalk, the locking device further including a fixation lug mounted through the apertures, for holding the catwalk in the extended position. More precisely, the fixation lug may comprise a clamping device, for tightening the lug in the apertures, said clamping device including two pins transversally inserted through the fixation lug on end portions.
Moreover, the catwalk may also comprise a plate, stretching out substantially perpendicularly to the catwalk and which, in the extended position, comes into abutment with the lateral side and may be fixed to the frame. A stiffener may also be provided on the catwalk, extending outwardly from the plate.
In a preferred embodiment, the catwalk is positioned at roof-height. In the extended position, the catwalk preferably overhangs with respect of the machine frame.
The above and other objects and advantages of the invention will become apparent from the detailed description of preferred embodiments, considered in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top perspective view of an article handling machine according to the invention, provided with a lateral overhanging catwalk here shown in an extended position.
FIG. 2 is a side view of the machine of FIG. 1 .
FIG. 3 is a detail view of the machine of FIG. 2 , showing an articulation element between the machine and the catwalk.
FIG. 4 is a perspective view showing the roof of the handling machine of FIG. 1 , wherein the lateral overhanging catwalk is in its extended position, taken from a bottom point of view.
FIG. 5 is a detail view from FIG. 4 , showing the articulation element between the machine and the catwalk in the extended position.
FIG. 6 is a detail view from FIG. 4 , showing the contact between the machine and the catwalk.
FIG. 7 is a side view of the machine, wherein the catwalk is in an intermediate position.
FIG. 8 is a detail view from FIG. 7 , showing the articulation element between the machine and the catwalk in the intermediate position.
FIG. 9 is a bottom perspective view of the machine of FIG. 7 .
FIG. 10 is a side view of the machine, wherein the catwalk is in a folded position.
FIG. 11 is a detail view from FIG. 10 , showing the articulation element between the machine and the catwalk in the folded position.
FIG. 12 is a top perspective view of the machine of FIG. 10 .
DESCRIPTION OF PREFERRED EMBODIMENTS
Referring to the figures, it is shown a machine 1 for handling articles, to be placed on a ground, which comprises a frame 2 , delimiting an inner space wherein articles, such as bottles for liquid beverages, are processing. For example, bottles are held and moved on different carrousels inside the machine and they are rinsed, filled, and then capped. The frame defines a table onto which carrousels or other handling devices inside the machine are fixed.
The frame 2 supports a roof 3 . Some devices such as electrical cables or cap feed rails for bottles may run between the roof 3 and the frame 2 . Moreover, fixation elements of the handling devices inside the machine 1 are positioned on the top of the frame 2 and may extend to the outside.
This is why the roof 3 can preferentially be erected on piles 4 at a distance above the top of the frame 2 , as shown in the figures, in order to prevent an operator who needs to get to the top of the frame 2 from damaging devices that can be positioned thereon or from being injured by them.
Furthermore, the machine 1 comprises a catwalk 5 , positioned on a lateral side 6 of the machine 1 , comprising an inner edge 7 , an upper surface 8 and a bottom surface 9 . As it can be seen on the figures, the catwalk 5 is preferentially mounted on the machine 1 along the inner edge 7 . On the bottom surface 9 , a plate 10 is fixed parallel to the inner edge 7 . Stiffeners 11 are fixed to the bottom surface 9 of the catwalk and run outwardly from inner edge 7 to the opposite edge.
Between the frame 2 and the catwalk 7 , an axis 20 allows the catwalk 5 to swivel with respect of the frame 2 , between two positions: an extended position and a folded position.
In the extended position, the inner edge 7 of the catwalk 5 faces the lateral side 6 of the machine 1 , and the upper surface 8 extends in a direction substantially parallel to the roof 3 . In this position, the upper surface 8 comes in extension to the roof surface. No auxiliary elements link the catwalk 5 to the ground, so that it is hung with respect of the frame 2 .
As a matter of fact, in this position, the upper surface 8 is at roof 3 height as shown in FIG. 1-6 , so that the working room for an operator is increased, but it can also be at any height along the lateral side 6 .
In this position, the plate 10 is in abutment with the frame 2 , maintaining the catwalk 5 in position. The stiffeners 11 bring more resistance to the hung catwalk 5 and prevent it from collapsing when a torque in applied on the upper surface 8 , for instance under the weight of an operator.
In the folded position, the upper surface 8 comes in a direction substantially parallel to the lateral side 6 , whereas the inner edge 7 is facing the ground.
In order to minimize the width of the whole machine 1 in the folded position, the inner edge 7 of the catwalk preferably abuts against the roof 3 , and the bottom surface 9 is in the extension of the lateral side 6 , so that no part of the catwalk 5 protrudes outwardly from the machine side. That is why the axis 20 is placed forward to the inner edge 7 .
As it is clearly depicted in FIG. 3 , FIG. 5 , FIG. 8 and FIG. 11 , the axis 20 is held by an arm 21 , protruding outwardly from the catwalk 5 and fixed on the bottom surface 9 . The axis 20 is placed on an end portion 22 of the arm 21 , the further from the catwalk 5 . On an end portion 23 opposite to the axis 20 and below the catwalk 5 , the arm 21 comprises an aperture 24 .
Facing the arm 21 , on the lateral side 6 , the frame 2 comprises a flange 30 . In the case wherein the catwalk 5 is placed at roof-height, the flange 30 is fixed directly on and below the roof 3 . The flange 30 comprises two apertures 31 and 32 , placed on two end portions, respectively 33 and 34 .
The first aperture 31 , the nearest to the roof 3 , is intended to receive the axis 20 . The aperture 31 comprises a horizontal section 35 and a vertical section 36 , crossing each other, allowing the axis 20 to slide in at least two directions, in addition to the swiveling. For instance, the aperture 31 can be L-shaped, as depicted in the figures, but it can also be T-shaped, I-shaped or H-shaped. The horizontal section extends substantially parallel to the roof, the vertical section 36 direction being perpendicular to the horizontal section 35 .
The second aperture 32 is on the end portion 34 opposite to the first aperture.
In the extended position, the axis 20 on the arm 21 is positioned in the horizontal section 35 of the flange 30 . The catwalk 5 cannot be lifted in the folded position because of the presence of a locking device.
The locking device is managed by the second aperture 32 on the flange 30 , coaxial with the aperture 24 on the arm 21 . By inserting a fixation lug 37 through the two coaxial apertures 24 and 32 , the axis 20 is prevented both from rotating and sliding. The fixation lug 37 is blocked inside the apertures 32 and 24 by a clamping device, comprising two pins 38 inserted through the fixation lug 37 , on end portions, one pin 38 being positioned against the flange 30 , the other pin against the arm 21 .
Moreover, the plate 10 comprises drillings 39 , so that it can be fastened to the frame 2 .
Consequently, to put the catwalk 5 in the folded position, in a first step, it is necessary to remove the lug 37 from the apertures 32 and 24 and to unfasten the plate 10 .
Then, in a second step, the axis 20 slides in the first aperture 31 of the flange 30 , along the horizontal section 35 , moving away the catwalk 5 from the frame 2 , and slightly swivels, in an intermediate position, as shown in FIG. 7-9 . The second aperture 32 on the flange 30 and the aperture on the arm 21 are then no more coaxial, and the plate 10 is separated from the frame 2 . The axis 20 slides away from the frame 2 to one end of the horizontal section 35 , passing in the vertical section 36 .
In a third step, the catwalk 5 is lifted, the axis 20 sliding vertically in the aperture 31 , in such a way that the inner edge 7 is higher than the roof 3 , and the catwalk 5 is pivoted so that the inner edge 7 is substantially parallel to the roof 3 .
Eventually, in a fourth step, the inner edge 7 is put in abutment with the roof 3 , the axis 20 coming in a lower position inside the vertical section 36 ; whereby the catwalk 5 stands then in its folded position.
The reverse operation can be applied to put the catwalk 5 from the folded position in the extended position.
According to the present invention, the width of the machine 1 is not increased when the catwalk 5 is in the folded position, so that no special conditioning is required to transport the machine 1 . The machine 1 can still enter classic transportation vehicles.
Furthermore, when the machine 1 is undergoing setting or maintenance operations, the roof surface can be increased by the deployment of the catwalk 5 , so that an operator can stand on the roof 3 at ease for setting or maintenance operations. | Article handling machine ( 1 ) comprising a frame ( 2 ) for receiving article handling elements, a roof ( 3 ) covering said frame ( 2 ), and, on one lateral side ( 6 ) of the machine ( 1 ), a catwalk ( 5 ) pivotally mounted on the frame ( 2 ) between an extended position in which it protrudes in a direction substantially perpendicular to the lateral side ( 6 ), with an inner edge facing the machine lateral side ( 6 ), and a folded position in which it stretches out in a direction substantially parallel to the lateral side ( 6 ). | 1 |
BACKGROUND OF THE INVENTION
This invention relates generally to fittings coupled to tubes by swaging and more particularly to internal swage fittings.
A fitting is an auxiliary piece of equipment used to establish a terminus or junction site for a pipe, rod, or tube. In particular, a common use for a fitting is to connect separate tubes together to allow fluid to pass between, preferably without leakage. A fitting is also often used as a closure device to terminate the end of an otherwise open tube. Among many other applications, fittings are used in the aerospace industry to enclose tubes that convey fuel, hydraulic fluids, and the like from one location to another. In those and other critical applications, it is important that the fitting be sufficiently secure about the tube so as to withstand vibration, fluid characteristics and the like without failure.
Fittings are often coupled to tubes by welding. Welding can be a time-consuming, costly method of fitting affixation. Further, the weld may not be sufficient to ensure complete coupling and can cause unacceptable stress intensification factor of the tube. Swaging is an alternative mechanical process to join a fitting to a tube without the limitations associated with welding. There are two types of swaging processes: external swaging and internal swaging. External swaging involves the application of a fitting having external surface variations, such as radial or axial lands and grooves, to a tube. The applied fitting is swaged by forging, hammering, or squeezing, such that the external surface configuration is transferred to the interior of the fitting and thus to the tube. The tube is thereby deflected and contorted in the area where it contacts the fitting such that there is a secure coupling of the two. Unfortunately, the transfer of the fitting's external surface configuration may not be sufficient to establish an adequate coupling, or may cause tube cracking in high cycle fatigue.
Internal swaging addresses, in part, some of the problems associated with external swaging. Internal swaging involves the application of a fitting having internal surface variations, again such as lands and grooves, to a tube. The applied fitting is swaged by placing an expander device within the tube and forcing the tube outwardly onto the interior surface of the fitting, or by squeezing the fitting onto the tube. There is a more direct interface between the fitting's surface configuration and the tube exterior than exists with external swaging. The tube therefore generally conforms more closely to the original surface configuration, resulting in an improved connection between the fitting and the tube.
One type of internal swage fitting found to be suitable for some aerospace applications is described in U.S. Pat. No. 4,844,517 issued to Beiley et al. and assigned to Sierracin Corporation of Burbank, Calif. In one configuration, the Beiley fitting includes three or more radial rectangular grooves of specified width and depth dimensions. The groove closest to the end of the tube is of the same design as the other grooves. In another configuration, a series of ramped grooves are combined with a rectangular “end” groove. The rectangular end groove is substantially the same as the rectangular grooves of the first fitting configuration described. That is, the tube butts against it.
In commercial use, the Beiley fitting is most suitable for the swaging of tubes made of low ductility material, including Titanium. However, materials of relatively higher ductility, such as stainless steels including SS321, Inconel 625, and other similarly ductile materials, are also used in a wide array of tube applications, including aerospace fluid transfer systems. The materials of higher ductility “flow” to a greater extent than the lower ductility materials under equivalent swaging pressure. The swaging process performed on a low-ductility tube causes the tube to be drawn into the fitting and results in a bulging of the tube at the end groove. The flowing material is forced outwardly toward the fitting, placing significant axial load in that localized area. This bulging of the tube material can cause failure of the fitting as well as undesired changes in tube dimensions.
In order to account for the flowing or “sucking in” of the tube into the fitting during the swaging process, it is necessary to set the tube back in relation to the fitting. That is, the tube must be placed in an offset position with respect to the fitting terminus to accommodate the axial and radial flow of the tube material. The swaging process causes the tube to flow and fill into the fitting to make up the setback difference. Since the tube must be completely and securely affixed to the fitting, maintaining the correct setback accurately is important. That is achieved by applying a capture collar about the tube adjacent to the fitting location. The collar must be rigidly but releasably affixed about the tube. Upon completion of the swaging process the collar must be removed. The steps of accurately aligning and applying and removing the collar must be repeated for each fitting applied to each tube of relatively ductile material. Therefore, what is needed is an internal swage fitting that can be used with ductile tubing. What is also needed is such an internal swage fitting that eliminates the need for setback and the use of a setback collar.
SUMMARY OF THE INVENTION
The above-mentioned needs are met by the present invention, which provides an internal swage fitting that accommodates the flow of high-ductility tube materials. The fitting includes a hollow cylindrical body having an internal surface and an external surface, a tube receiving region and a tube connection region. The internal surface of the body in the tube connection region includes one or more grooves and an expansion cavity for receiving excess material of the tube during a swaging process. The fitting also includes a tube stop wall adjacent to the expansion cavity. A termination end of the tube abuts the tube stop wall when the tube is placed within the cylindrical body. The expansion cavity includes an end wall extending from the tube stop wall and away from the one or more grooves at an angle so as to establish a fill space region for flowing tube material to fill in without applying excessive axial pressure on the fitting.
The present invention and its advantages over the prior art will become apparent upon reading the following detailed description and the appended claims with reference to the accompanying drawings.
DESCRIPTION OF THE DRAWINGS
The subject matter that is regarded as the invention is particularly pointed out and distinctly claimed in the concluding part of the specification. The invention, however, may be best understood by reference to the following description taken in conjunction with the accompanying drawing figures in which:
FIG. 1 is a cross-sectional view of a ferrule (female) swage fitting with the internal configuration of the present invention.
FIG. 2 is a cross-sectional view of a ball nose (male) swage fitting with the internal configuration of the present invention.
FIG. 3 is a close-up cross-sectional view of the expansion cavity of the internal swage fitting configuration of the present invention.
FIG. 4 is a cross-sectional view of the combination of the ferrule and ball nose fittings in assembled relationship with tubes in place prior to swaging.
FIG. 5 is a cross-sectional view of the combination of the ferrule and ball nose fittings in assembled relationship with tubes in place subsequent to swaging.
DETAILED DESCRIPTION OF THE INVENTION
Referring to the drawings wherein identical reference numerals denote the same elements, FIG. 1 illustrates a female (or ferrule) internal swage fitting 10 of the present invention. The fitting 10 is fabricated of any material suitable for the particular application. For example, in the swaging of a tube formed of a ductile material such as SS321 stainless steel, Inconel 625, or the like, the fitting 10 may be fabricated of Titanium or A286. Of course, the fitting 10 may be formed of any material sufficient to cause flow of the tube during the swaging process without substantial distortion of the fitting 10 .
The ferrule fitting 10 includes a main hollow cylindrical body 12 having an external surface 14 and an internal surface 16 . The body 12 has a tube receiving region 18 and a tube connection region 20 . The internal surface 16 of the tube connection region 20 of the fitting 10 includes a plurality of radially arranged coupling grooves 22 spaced apart axially by a land 24 . As shown in FIGS. 1 and 3, the tube connection region 20 further includes a radially arranged expansion cavity 26 and a tube stop wall 28 . The tube stop wall 28 blocks forward progression of a tube-to-be-swaged in the fitting 10 . The expansion cavity 26 establishes a location for excess material of the tube to flow during the swaging process.
The expansion cavity 26 includes an entry sidewall 30 , a curved fill region 32 , and a backwall 34 . The fill region 32 extends beyond the stop wall 28 to permit excess tube material to flow therein without creating excess axial stress on the fitting 10 at the tube connection region 20 . The backwall 34 is angled away from the stop wall 28 to allow flow material to enter space 36 rather than move directly upward against the internal surface 16 of the fitting 10 . The dimensions of the grooves 22 , the land 24 and the expansion cavity 28 may be selected as a function of the structural characteristics of the tube 12 and the fitting 10 . The angle of the back wall 34 with respect to the tube stop wall 28 may also be selected as a function of the flow characteristics of the tube material and the hoop strength of the fitting 10 . The back wall 34 may be angled away from the stop wall 28 at an angle of between about 10° and about 75° and, in one embodiment at an angle of about 45°.
FIG. 2 illustrates a corresponding male (or ballnose) internal swage fitting 40 . The ballnose fitting 40 includes a main hollow body 42 and an external surface 44 and an internal surface 46 . The fitting 40 may be fabricated of a material suitable for swaging a tube of relatively ductile material. For example, the fitting 40 may be fabricated of Titanium or A286.
With continuing reference to FIGS. 2 and 3, the body 42 of the fitting 40 has a tube receiving region 48 and a tube connection region 50 . It is to be noted that the housing 42 of the fitting 40 may be of a selectable configuration. However, in order to provide structural reinforcement to the fitting 40 in the tube connection region 50 , it includes a structural region 45 . The structural region 45 is of greater thickness than the remainder of the wall thicknesses of the body 42 to provide hex flats of the fitting 40 to tighten or loosen the fitting on a tube after the fitting 40 has been swaged to a tube.
The internal surface 46 of the tube connection region 50 of the fitting 40 includes a plurality of radially arranged coupling grooves 22 spaced apart axially by a land 24 . The tube connection region 50 further includes a radially arranged expansion cavity 26 and a tube stop wall 28 . The tube stop wall 28 blocks forward progression of a tube-to-be-swaged in the fitting 40 . The expansion cavity 26 establishes a location for excess material of the tube to flow during the swaging process.
The expansion cavity 26 includes an entry sidewall 30 , a curved fill region 32 , and a backwall 34 . The fill region 32 extends beyond the stop wall 28 to permit excess tube material to flow therein without creating excess axial stress on the fitting 40 at the tube connection region 50 . The backwall 34 is angled away from the stop wall 28 to allow flow material to enter space 36 rather than move directly upward against the internal surface 16 of the fitting 40 . The dimensions of the grooves 22 , the land 24 and the expansion cavity 28 may be selected as a function of the structural characteristics of the tube 12 and the fitting 40 . The angle of the back wall 34 with respect to the tube stop wall 28 may also be selected as a function of the flow characteristics of the tube material and the hoop strength of the fitting 40 . The back wall 34 may be angled away from the stop wall 28 at an angle of between about 10° and about 75° and, in one embodiment at an angle of about 45°.
When two tubes are to be coupled together in a swaging process, the ferrule fitting 10 and the ballnose fitting 40 are arranged in relation to the tubes in a manner shown in FIG. 4. A first tube 52 is inserted into the tube-receiving region 18 of the ferrule fitting 10 . It is directed toward the tube stop wall 28 of the fitting 10 until it comes in contact with that surface. A second tube 54 is inserted into the tube-receiving region 48 of the ballnose fitting 40 . It is directed toward the tube stop wall 28 of the fitting 40 until it comes in contact with that surface. The fitting 10 is then swaged onto the tube 52 and the fitting 40 swaged onto the tube 54 using conventional swaging methods. The conventional swaging methods may include the use of either a roller swage or a bladder swage and mandrel inserted into the fitting/tube combination and removed upon completion of the swaging process.
The fittings 10 and 40 are shown in FIG. 4 in adjacent relation to one another prior to swaging. However, the respective tubes and fittings may be swaged apart from one another and then brought into communication with one another prior to final assembly. It can be seen that the wall thicknesses of the tubes 52 and 54 are substantially uniform and straight prior to swaging. The swaging process, as shown in FIG. 5, causes the tubes to distort in the vicinity of the grooves 22 and the expansion cavity 26 and a portion of the tube material to flow into those regions. The design of those regions of the internal fittings 10 and 40 allow the tube material in those regions to flow in a suitable direction without placing excess axial stress on the fittings. In addition, the stop 28 halts further inward movement of the tubes.
FIG. 5 illustrates one embodiment of the joining together of two tubes swaged with the internal swage fittings of the present invention. In particular, a threaded nut 56 is applied to fitting threads 58 of the fitting 40 to Ser. No. 09/668,940 13DV-13662 draw the two fittings together. A ballnose receiving mating surface 62 of the fitting 10 is placed in contact with a ferrule entering mating surface 60 of the fitting 40 . The nut 56 is then tightened onto the fitting 40 . The fitting 10 is drawn toward the fitting 40 because a ferrule capture wall 64 of the body 12 is grabbed by nut flange 66 as the nut 56 is threaded onto the fitting 40 . The threading action fixes the two fittings together. In the embodiment of the present invention shown in FIG. 5, the tubes 52 and 54 are securely coupled together so that fluid may pass between the two. It is to be noted that an alternative embodiment of the ballnose fitting 40 may be used as a termination of the tube 54 without coupling to another tube.
The internal swage fittings shown and described including the expansion cavity 26 enable reliable swaging of tubing of relatively high ductility without placing excessive axial force on those fittings. Further, expansion cavity 26 in combination with the stop wall 28 eliminates sucking in of the tube during the swaging process. Setbacks are no longer required and, therefore, collars and collar application and removal steps are eliminated.
The foregoing has described an improved internal swage fitting. While specific embodiments of the present invention have been described, it will be apparent to those skilled in the art that various modifications thereto can be made without departing from the spirit and scope of the invention as defined in the appended claims. | An internal swage fitting for swaging a tube. The fitting includes a tube connection region with one or more radial grooves and an expansion cavity at the end adjacent to the end of the tube to be swaged. The expansion cavity accommodates flowing tube material during the swaging process with minimal axial pressure on the fitting. The expansion cavity also includes a stop wall to fix the location of the tube in the fitting. The expansion cavity enables swaging of tube materials of relatively high ductility without accounting for setback. It therefore eliminates the need for a collar to establish setback during swaging. | 8 |
FIELD OF THE INVENTION
[0001] This invention relates to surgical methods and devices and, more particularly, to methods and devices used to facilitate insertion of implants.
BACKGROUND
[0002] The spine is made of bony structures called vertebral bodies that are separated by soft tissue structures called intervertebral discs. The intervertebral disc is commonly referred to as a spinal disc. The spinal disc primarily serves as a mechanical cushion between the vertebral bones, permitting controlled motions between vertebral segments of the axial skeleton. The disc acts as a synchondral joint and allows some amount of flexion, extension, lateral bending, and axial rotation.
[0003] The normal disc is a mixed avascular structure including two vertebral end plates, annulus fibrosis and nucleus pulposus. The end plates are composed of thin cartilage overlying a layer of hard, cortical bone that attaches to the spongy cancellous bone of the adjacent vertebral body.
[0004] The discs are subjected to a variety of loads as the posture of an individual changes. Even when the effects of gravity are removed, however, the soft tissue connected to the spine generates a compressive force along the spine. Thus, even when the human body is supine, the compressive load on the lumbar disc is on the order of 300 Newtons (N).
[0005] A spinal disc may be displaced or damaged due to trauma or a disease process. A disc herniation occurs when the annulus fibers are weakened or torn and the inner material of the nucleus becomes permanently bulged, distended, or extruded out of its normal, internal annular confines. The mass of a herniated or “slipped” nucleus tissue can compress a spinal nerve, resulting in leg pain, loss of muscle strength and control or even paralysis. Alternatively, with discal degeneration, the nucleus loses its water binding ability and dehydrates with subsequent loss in disc height. Consequently, the volume of the nucleus decreases, causing the annulus to buckle in areas where the laminated plies are loosely bonded. As these overlapping plies of the annulus buckle and separate, either circumferential or radial annular tears may occur, potentially resulting in persistent and disabling back pain. Adjacent, ancillary facet joints will also be forced into an overriding position, which may cause additional back pain.
[0006] When the discs wear out or are otherwise injured, a condition known as degenerative disc disease results. With this condition, discs do not function normally and may cause pain and limit activity. Recently, efforts have been directed to replacing intervertebral discs which display degenerative disc disease. In one such procedure, the damaged intervertebral disc is replaced by a prosthetic disc.
[0007] One well known intervertebral prosthetic disc is produced by DePuy Spine, Inc. of Raynaham, Mass. and is sold under the trademark CHARITÉ®. This disc prosthesis includes two metal endplates and a center polyethylene core. The center core includes a superior spherical bearing surface and an inferior spherical bearing surface. The superior endplate includes a concave surface that fits upon and is congruent with the superior bearing surface of the core. The inferior endplate includes a concave surface that fits under and is congruent with the inferior bearing surface of the core.
[0008] During a CHARITE® ( artificial disc replacement procedure, the damaged disc is typically removed via an anterior surgical approach and the end surfaces of the exposed vertebrae are cleared of debris. The vertebrae are spread apart and the metal endplates are positioned on the respective vertebra and tapped into place. The polyethylene core is then inserted between the endplates and the vertebrae are returned to their normal position. The pressure of the spinal column further seats the endplates into the vertebral bones and secures the core in place.
[0009] While the sequential implantation of components is effective, the amount of time required to position three separate components as opposed to implanting a single unit increases the duration of the procedure. Additionally, the increased number of steps increases the risk of the procedure.
[0010] In response to the foregoing limitations, some instrumentation has been developed wherein a distraction instrument may also serve as an installation instrument. In particular, in addition to being configured to spread apart the two vertebrae, the instrument is also configured to slide the assembled artificial disc into place while the vertebrae remain separated. A central ramp is provided on the instrument to facilitate sliding of the implant between the vertebrae. Once the artificial disc is positioned, the installation instrument is decoupled from the artificial disc and removed.
[0011] Such instruments are very effective. Nonetheless, they do have various limitations. For example, because of the various functions performed with the instrument, the instruments are complicated in construction, resulting in increased costs. Additionally, as a particular instrument becomes more complicated, the potential for a mechanical failure increases. A further limitation is that the artificial disc is retained in such instruments using spring force which can be unreliable.
[0012] Accordingly, it would be advantageous to provide a tool for implanting an artificial disc or other spinal implant which does not rely upon a spring to maintain a secure hold upon the artificial disc or other spinal implant. It would also be advantageous if the tool could be used in combination with a distraction tool. It would be further advantageous if such features could be provided while allowing an artificial disc or other spinal implant to be implanted as a unit.
SUMMARY
[0013] A method and system for insertion of an implant is disclosed. One embodiment of a system for use in implanting a spinal prosthesis incorporating principles of the invention includes an insertion assembly housing with a channel extending from a distal end portion to a proximal end portion, a gripper having a prosthesis coupling portion for coupling with a spinal prosthesis and an end portion, and a coupler member having a gripper coupling portion rotatably positioned within the channel and configured to couple with the end portion of the gripper within the channel.
[0014] One method incorporating principles of the invention includes identifying a vertebral implant, coupling a gripper member with the vertebral implant, rotating a coupler member within a housing to generate an axial force, translating the axial force to a compressive force on the gripper member, positioning the coupled vertebral implant, removing the compressive force from the gripper member and decoupling the gripper member from the vertebral implant after the vertebral implant has been positioned.
[0015] Another system for use in implanting a spinal implant includes an insertion assembly housing having an axis, a gripper with a spinal implant coupling portion configured to couple with a spinal implant and a coupling member configured to apply force to the gripper along the axis of the insertion assembly housing by rotation of the coupling member within the insertion assembly housing.
[0016] The above-described features and advantages, as well as others, will become more readily apparent to those of ordinary skill in the art by reference to the following detailed description and accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] The present invention may take form in various system and method components and arrangement of system and method components. The drawings are only for purposes of illustrating exemplary embodiments and are not to be construed as limiting the invention.
[0018] FIG. 1 shows a superior perspective view of a spinal implant in the form of an intervertebral disc prosthesis including a superior plate and a inferior plate separated by a core;
[0019] FIG. 2 shows a side cross-sectional view of the intervertebral disc prosthesis of FIG. 1 with the superior plate rotated to display flexion;
[0020] FIG. 3 shows a perspective view of the disc prosthesis of FIG. 1 held by a system including a distraction instrument and a prosthesis insertion assembly incorporating features of the invention;
[0021] FIG. 4 shows a cross-sectional view of the prosthesis insertion assembly of FIG. 3 with a gripper partially inserted into the housing of the prosthesis insertion assembly and coupled with a coupling member incorporating features of the invention;
[0022] FIG. 5 shows a side plan view of the prosthesis insertion assembly of FIG. 3 ;
[0023] FIG. 6 shows a perspective view of the base and knob portion of the system of FIG. 3 decoupled from the prosthesis insertion assembly and with the vertebra engaging members removed;
[0024] FIG. 7 is a partial cross-sectional view of the prosthesis insertion assembly of FIG. 3 with a gripper partially inserted into the housing of the prosthesis insertion assembly such that the neck portion of the gripper abuts the throat portion of the prosthesis insertion assembly;
[0025] FIG. 8 shows a side plan view of the prosthesis insertion assembly of FIG. 3 with a disc prosthesis coupled with a gripper which is partially inserted into the prosthesis insertion assembly and with the coupling member removed;
[0026] FIG. 9 shows an exploded perspective view of the system of FIG. 3 with the vertebra engaging members detached from the insertion assembly;
[0027] FIG. 10 shows a side plan view of the system of FIG. 3 with the fingers of the distraction instrument inserted into a space in which the disc prosthesis is to be implanted;
[0028] FIG. 11 shows a side plan view of the system of FIG. 3 with the disc prosthesis used to force the fingers of the distraction instrument into a distracted configuration in accordance with principles of the invention;
[0029] FIG. 12 shows a side plan view of the system of FIG. 3 after continued rotation of the knob of the distraction instrument has forced the fingers of the distraction instrument out of the space in the spine while the disc prosthesis remains in the space in accordance with principles of the invention;
[0030] FIG. 13 shows a side plan view of the system of FIG. 3 after the distraction instrument has been removed and while the gripper and the prosthesis insertion assembly are still coupled;
[0031] FIG. 14 shows an alternate embodiment of a gripper that may be used with the prosthesis insertion assembly of FIG. 5 in accordance with principles of the invention;
[0032] FIG. 15 shows an alternate embodiment of a disc prosthesis that may be used with the gripper of FIG. 14 in accordance with principles of the invention;
[0033] FIG. 16 shows the disc prosthesis of FIG. 15 coupled with the gripper of FIG. 14 ;
[0034] FIG. 17 shows a perspective view of an alternate implantation system incorporating the prosthesis insertion assembly of FIG. 5 and with the fingers of a distraction instrument inserted into a space in which the disc prosthesis is to be implanted;
[0035] FIG. 18 shows a side plan view of the system of FIG. 17 ;
[0036] FIG. 19 shows a perspective view of the system of FIG. 17 after an extension handle has been used to position the disc prosthesis within the prepared space using guide members on the prosthesis insertion assembly to align the disc prosthesis in accordance with principles of the invention; and
[0037] FIG. 20 shows a perspective view of the system of FIG. 17 after the distraction instrument has been removed, leaving the disc prosthesis in the prepared space.
DETAILED DESCRIPTION
[0038] With reference to FIGS. 1-2 , a spinal implant which in this embodiment is an intervertebral disc prosthesis 100 includes a superior plate 102 , an inferior plate 104 , and a core 106 . The core 106 is sandwiched between the superior plate 102 and the inferior plate 104 . The superior plate 102 and the inferior plate 104 ride upon the core 106 and are operable to rotate relative to the core 106 .
[0039] In one embodiment, the superior plate 102 is formed of metal. In particular, the superior plate 102 may be formed using a medical grade cobalt chromium alloy. The superior plate 102 includes an upper surface 108 and a lower surface 110 . An outer perimeter edge 112 defines the “footprint” of the superior plate 102 when the disc prosthesis is implanted.
[0040] The upper surface 108 of the superior plate 102 is designed for engagement with a vertebral surface of a patient. To this end, the upper surface 108 of the superior plate 102 may be slightly convex for close engagement with the slightly concave vertebral surface of the patient. Additionally, teeth 114 are included on the upper surface 108 of the superior plate 102 . The teeth 114 are designed to penetrate into the vertebral surface, helping to secure the superior plate 102 to the vertebral surface. A groove 109 extends across the upper surface 108 .
[0041] The lower surface 110 of the superior plate 102 is generally flat near the outer edge 112 . As shown more clearly in FIG. 2 , a collar portion 116 protrudes from the lower surface 110 and defines an inner concave surface 118 at the center of the collar portion 116 .
[0042] The inferior plate 104 is a mirror image of the superior plate 102 and is also made of a medical grade cobalt chromium alloy. The inferior plate 104 includes a slightly convex lower surface 120 and an outer perimeter edge 122 . A plurality of teeth 124 extend from the lower surface 120 . The teeth 124 are designed to help secure the inferior plate 104 to a vertebral surface. The lower surface 120 also includes a groove (not shown). The upper surface 126 of the inferior plate 104 includes a collar portion 128 with an inner concave surface 130 .
[0043] The core 106 is arranged within an interior space of the prosthesis 100 between the lower surface 110 of the superior plate 102 and the upper surface 126 of the inferior plate 104 . In one embodiment, the prosthesis core 106 is made from a plastic material having a high resistance to wear, such as ultra high molecular weight polyethylene (UHMWPE), which allows the endplates 102 and 104 to slide easily on the core 106 .
[0044] The prosthesis core 106 is generally disc shaped with an outer radial flange 132 , an upper spherical surface 134 , and a lower spherical surface 136 . The upper spherical surface 134 and the lower spherical surface 136 act as bearing surfaces/articulating surfaces that slidingly engage the bearing/articulating surfaces of the endplates 102 and 104 . Namely, the inner concave surface 118 and the inner concave surface 130 , respectively. As shown in FIG. 2 , a first groove 138 is formed between the flange 132 and the collar portion 116 of the superior plate 102 . A second groove 139 is formed between the flange 132 and the collar portion 128 of the inferior plate 104 .
[0045] When the prosthesis 100 is assembled, the concave surface 118 of the superior plate 102 and the upper spherical surface 134 of the core 106 slidingly engage one another and form articular surfaces. Likewise, the concave surface 130 of the inferior plate 104 and the lower spherical surface 136 of the core 106 slidingly engage one another and form articular surfaces.
[0046] A tool that may be used to position the prosthesis 100 within a patient is shown in FIG. 3 . The intervertebral distraction instrument 140 includes a first vertebra engaging member 142 , a second vertebra engaging member 144 , and a prosthesis insertion assembly 146 . A base 148 , which in this embodiment further functions as a handle, is located between the first vertebra engaging member 142 and the second vertebra engaging member 144 . A knob 150 is located rearward of the engaging members 142 and 144 .
[0047] In the embodiment of FIG. 3 , the first vertebra engaging member 142 is provided as an upper elongated distraction arm. The vertebra engaging member 142 includes a proximal end portion 152 and a distal end portion 154 . A finger 156 extends from the vertebra engaging member 142 at the distal end portion 154 . The finger 156 is a relatively thin tab with a vertebra engaging member 158 on the upper portion of the tab.
[0048] The second vertebra engaging member 144 is provided as a lower elongated distraction arm, and is generally symmetric to the upper vertebra engaging member 142 . Accordingly, the vertebra engaging member 144 includes a proximal end portion 160 , a distal end portion 162 , and a finger 164 . The finger 164 includes a vertebra engaging member 166 .
[0049] The upper vertebra engaging member 142 and the lower vertebra engaging member 144 are configured such that the finger 156 and the finger 164 converge. In the embodiment of FIG. 3 , this is accomplished by the provision of a bend 168 in the vertebra engaging member 142 and a bend 170 in the vertebra engaging member 144 . The bends 168 and 170 are located between the respective proximal end portion 152 or 160 and finger 156 or 164 such that the fingers 156 and 164 converge.
[0050] The prosthesis insertion assembly 146 is positioned between the vertebra engaging member 142 and the vertebra engaging member 144 . The prosthesis insertion assembly 146 is shown with a gripper 172 in FIG. 4 and includes an outer prosthesis insertion assembly housing 174 positioned outwardly of an inner sleeve 175 . The gripper 172 includes a stem 176 with a gap 178 that extends along a portion of the stem 176 . A pair of arms 180 and 182 are connected to the stem 176 through a neck portion 184 . A blind threaded bore 186 is located within the stem 176 at the end of the gripper 172 opposite to the arms 180 and 182 .
[0051] The outer prosthesis insertion assembly housing 174 includes guide members 188 , 190 , 192 and 194 (see also FIG. 5 ) while an inner channel 196 is defined by the inner sleeve 175 . A throat 198 is located within the inner channel 196 (see, e.g., FIG. 7 ) proximate to one end portion 200 of the prosthesis insertion assembly housing 174 while the other end portion 202 of the housing 174 is externally threaded.
[0052] The prosthesis insertion assembly 146 further includes a depth control member 204 and a coupling member 206 . The depth control member 204 is rotatably engaged with the inner sleeve 175 and includes an internally threaded bore 208 which extends completely through the depth control member 204 . The coupling member 206 includes a stem 210 with a threaded portion 212 . The coupling member 206 is rotatably connected to the depth control member 204 and further includes an internal bore 214 and a release mechanism 216 which extends into the internal bore 214 . The internal bore 214 is configured to receive a coupling portion 218 of a shaft 220 shown in FIG. 6 . The shaft 220 extends through the base 148 and is connected to the knob 150 . A threaded portion 222 of the shaft 220 threadingly engages the base 148 .
[0053] Operation of the insertion distraction instrument 140 may begin with the upper and lower vertebra engaging members disconnected and the prosthesis insertion assembly 146 decoupled from the shaft 220 . In such a procedure, the desired insertion depth is set by rotation of the depth control member 204 . The desired depth, which may be shown on an indicator 223 (see FIG. 8 ), may be established with the depth control member 204 at any time.
[0054] As the depth control member 204 is rotated, the threads of the internally threaded bore 208 engage the threads of the threaded end portion 202 of the outer prosthesis insertion assembly housing 174 causing relative movement between the outer prosthesis insertion assembly housing 174 and the inner sleeve 175 to which the depth control member 204 is rotatably engaged. Accordingly, the axial position of the guides 188 , 190 , 192 and 194 with respect to the throat 198 within the inner channel 196 may be adjusted. The insertion depth thus identifies the desired positioning of a disc prosthesis within a spinal column along the longitudinal axis of the instrument 140 when the disc prosthesis is inserted as discussed below.
[0055] Continuing with the present example, once the desired depth setting has been established, the stem 176 of the gripper 172 is inserted into the inner channel 196 through the end portion 200 . The stem 176 is sized to pass through the throat 198 . The neck portion 184 , however, is tapered from a diameter somewhat smaller than the diameter of the throat 198 to a diameter somewhat larger than the throat 198 as shown in FIG. 7 . Accordingly, once the neck portion 184 contacts the throat 198 , further axial movement of the stem 176 into the inner channel 196 is inhibited.
[0056] The disc prosthesis 100 is then coupled with the gripper 172 . In this embodiment, the gripper 172 is sized to provide a friction fit for a prosthesis 100 of a specific size. Specifically, the arms 180 and 182 are sized and shaped to frictionally engage the prosthesis 100 by insertion of the arms 180 and 182 into the slot 109 and the slot (not shown) on the lower surface 120 of the inferior plate 104 . Accordingly, a kit may include a number of different grippers for use with differently sized and/or configured disc prostheses. In this embodiment the prosthesis 100 is a modular disc prosthesis and the arms 180 and 182 are configured to hold the assembled modular disc prosthesis together as a unit.
[0057] If desired, the foregoing steps may be performed in a different order if desired. For example, the gripper 172 and the disc prosthesis 100 may be coupled prior to insertion of the gripper 172 within the prosthesis insertion assembly housing 174 . The gripper 172 may then be positioned within the housing 174 as shown in FIG. 8 .
[0058] Next, the threaded portion 212 of the shaft 210 is engaged with the threads of the threaded blind bore 186 (see, e.g., FIG. 4 ). In the embodiment of FIG. 4 , the coupling member 206 is rotationally coupled with the outer prosthesis insertion assembly housing 174 through the depth control member 204 . In alternative embodiments, the coupling member may be separately provided. In such embodiments, the shaft of the coupling member is inserted into the inner channel 196 to allow coupling of the coupling member and the threaded blind bore 186 .
[0059] Once the gripper 172 is coupled with the coupling member 206 within the housing 174 and with the disc prosthesis 100 , rotation of the coupling member 206 causes the axial force with which the neck portion 184 is forced against the throat 198 to increase. When sufficient axial force is provided, the axial force is translated to a compressive force by the neck portion 184 being pressed against the throat 198 . The gap 178 allows the arms 180 and 182 to move toward each other as indicated by the arrows 224 and 226 in FIG. 7 in response to the compressive force. As the arms 180 and 182 move toward each other, the diameter of the neck portion 184 narrows, allowing the stem 176 to move axially in the direction of the arrow 228 , further into the inner channel 196 .
[0060] The movement of the arms 180 and 182 is limited by the physical structure of the disc prosthesis 100 . Thus, while some amount of movement may occur, once the arms 180 and 182 are firmly positioned against the disc prosthesis 100 , continued rotation of the coupling member 206 primarily increases the gripping force which the arms 180 and 182 exert against the disc prosthesis 100 , thereby providing a firm coupling. In embodiments wherein the disc prosthesis does not stop movement of the stem further into the inner bore, stops may be provided on the stem to restrict such axial movement after the desired gripping force is achieved.
[0061] Because the axial location of the prosthesis 100 is fixed with respect to the neck portion 184 at this point, and because the throat 198 provides a stop for the neck portion 184 , the axial position of the prosthesis 100 with respect to the guides 188 , 190 , 192 and 194 is established by the depth established with the depth control member 204 .
[0062] When the disc prosthesis 100 is firmly coupled with the prosthesis insertion assembly 146 , the prosthesis insertion assembly 146 is coupled to the shaft 220 by insertion of the coupling portion 218 into the internal bore 214 resulting in the configuration shown in FIG. 9 . Next, the vertebra engaging members 142 and 144 are connected to the base 148 . As the vertebra engaging member 142 is connected, it is positioned within a space bordered by the guide members 188 and 190 . Similarly, as the vertebra engaging member 144 is connected, it is positioned within a space bordered by the guide members 192 and 194 resulting in the configuration shown in FIG. 3 .
[0063] Referring to FIG. 10 , once a space (S) has been prepared for receipt of the disc prosthesis 100 using any acceptable procedure, the fingers 156 and 164 are inserted into the space (S). Insertion of the fingers 156 and 164 into the prepared space (S) continues until the vertebra engaging members 158 and 166 contact the vertebras located adjacent to the prepared space (S) as shown in FIG. 10 . Next, the knob 150 is rotated in the direction of the arrow 232 while the vertebral engaging members 158 and 166 are pressed against the vertebras adjacent to the prepared space. Because the threaded portion 222 of the shaft 220 is threadingly engaged with the base 148 , rotation of the knob 150 causes the shaft 220 to move forwardly in the direction of the arrow 234 as well as rotate in the direction of the arrow 232 .
[0064] The coupling portion 218 of the shaft 220 is free to rotate within the internal bore 214 . Accordingly, as the shaft 220 rotates, the coupling member 206 does not rotate. The axial movement of the shaft 220 , however, forces the prosthesis insertion assembly 146 to move forwardly in the direction of the arrow 234 . As the prosthesis insertion assembly 146 moves, alignment with the vertebra engaging members 142 and 144 is maintained by the guides 188 , 190 , 192 and 194 .
[0065] The axially forward movement of the prosthesis insertion assembly 146 forces the disc prosthesis 100 against the distal end portions 154 and 162 of the vertebra engaging members 142 and 144 . This forces the fingers 156 and 164 against the vertebra adjacent to the prepared space (S), causing the vertebra to be forced apart and allowing the disc prosthesis 100 to move into the prepared space (S) as shown in FIG. 11 .
[0066] As the disc prosthesis 100 moves into the space (S), the guide members 188 , 190 , 192 and 194 come into contact with the vertebrae adjacent to the space (s). Accordingly, further forward movement of the prosthesis insertion assembly 146 is restricted. Thus, as the knob 150 continues to be rotated in the direction of the arrow 232 , the threaded portion 222 of the shaft 220 forces the base 148 to move in the direction of the arrow 236 , thereby pulling the fingers 156 and 164 out of the space (S) while the disc prosthesis 100 remains in the space (S) as shown in FIG. 12 .
[0067] Once the fingers 156 and 164 are clear of the space (S), the natural forces applied to the spinal column by the soft tissue attached to the spinal column will press the vertebrae adjacent to the space (S) against the disc prosthesis 100 . Thus, the teeth 114 are imbedded into the adjacent vertebrae, fixing the disc prosthesis 100 in place. If desired, the prosthesis insertion assembly 146 may be decoupled from the disc prosthesis 100 simply by forcing the distraction instrument 140 away from the spine to overcome the friction lock.
[0068] Alternatively, the prosthesis insertion assembly 146 may be detached from the rest of the distraction instrument 140 as shown in FIG. 13 by depression of the release mechanism 216 , which allows the shaft 220 to be removed from the internal bore 214 . Next, the coupling member 206 is rotated in the direction indicated by the arrow 238 . Such rotation of the coupling member 206 causes the neck portion 184 of the gripper 172 to be forced away from the throat 198 of the inner sleeve 175 . Thus, the resilient nature of the gripper 172 forces the arms 180 and 182 in a direction away from the disc prosthesis 100 .
[0069] The rotation of the coupling member 206 reduces the coupling force between the gripper 172 and the disc prosthesis 100 . Accordingly, the gripper 172 may be decoupled from the disc prosthesis 100 by pulling on the coupling member 206 .
[0070] FIG. 14 shows an alternative gripper 240 which may be used with the prosthesis insertion assembly 146 of FIG. 5 . The gripper 240 includes a coupling portion 242 , a neck portion 244 and a stem 246 in an unstressed condition. The coupling portion 242 includes a slit 248 and a slit 250 which extend through the coupling portion 242 and the neck portion 244 into the stem 246 . The slits 248 and 250 define two opposing pairs of arms 252 and 254 in the coupling portion 242 (only one arm of arm pair 254 is shown in FIG. 14 ). The neck portion 244 tapers from a larger diameter at the coupling portion 242 to a smaller diameter at the stem 246 . The stem 246 includes a threaded inner bore 256 which is configured to be engaged with the threaded portion 212 of the coupling member 206 .
[0071] The coupling portion 242 of the gripper 240 is configured to mate with an artificial disc such as the artificial disc 260 shown in FIG. 15 . The artificial disc 260 includes two endplates 262 and 264 which are separated by a core 266 . Each of the two endplates 262 and 264 include a number of engagement members 268 . In the embodiment of FIG. 15 , the engagement members 268 are generally in the shape of a cone, with the apex 270 of the engagement members 268 spaced apart from the respective endplate 262 or 264 . In alternative embodiments, the engagement members may be pyramidal, conical, or another shape. Preferably, the portions of the engagement members farthest away from the endplates, such as the apex of the engagement members 268 , are relatively sharp.
[0072] The endplates 262 and 264 further include four notches including notches 272 and 278 and two notches including the notch 280 and another notch not shown) that are symmetrical and spaced apart from the notches 272 and 278 to form two notch pairs. By way of example, the notch 280 which is shown in FIG. 16 in shadow form, is the symmetrical to and spaced apart notch for the notch 272 . Thus, the notch 272 and the notch 280 are a notch pair.
[0073] The four notches, 272 , 278 , 280 , and the notch not shown, are sized and shaped to snugly mate with the arms in the arm pairs 252 and 254 . Moreover, the distance between each of the notches in the notch pairs is substantially the same as the distance between the opposing arms of the arm pairs 254 and 256 when the arm pairs 252 and 254 are in an unstressed condition. The configuration of the notches including shape and location, may be modified to optimize the control over the implant based upon the approach being used. For example, some implants may be configurec to be used in an anterior approach whereas other may be configured for use in posterior or other approaches.
[0074] The gripper 240 is used in much the same manner as the gripper 172 described above. One difference, however, is that the configuration of the gripper 240 and the artificial disc 260 allows for a tighter coupling. Specifically, as depicted in FIG. 16 , the arm pairs 252 and 254 engage the notches, 272 , 278 , 280 , and the notch not shown, in a positive engagement as the individual arms are positioned within the notches, 272 , 278 , 280 , and the notch not shown. Accordingly, when the neck portion 244 is pulled against the throat 198 by rotation of the coupling member 206 as described above, the axial force is translated to a compressive force whereby the arm pairs 252 and 254 engage the notches, 272 , 278 , 280 , and the notch not shown more tightly and a very tight coupling is achieved between the gripper 240 and the artificial disc 260 . Thus, the potential for unintentional decoupling is reduced.
[0075] The prosthesis insertion assembly 146 may also be used with other distraction instruments such as the distraction instrument 290 shown in the system of FIGS. 17 and 18 . The distraction instrument 290 includes a first vertebra engaging member 292 and a second vertebra engaging member 294 . A handle 296 is provided on the instrument 290 along with a pivot assembly 298 . A ratchet assembly 300 is located on the handle 296 .
[0076] Fingers 302 and 304 extend from the vertebra engaging members 292 and 294 , respectively. The upper vertebra engaging member 292 and the lower vertebra engaging member 294 are configured such that the finger 302 and the finger 304 converge from an insertion opening 306 defined by the upper vertebra engaging member 292 and the lower vertebra engaging member 294 .
[0077] In the system of FIG. 17 , a gripper 308 is coupled with a disc prosthesis 310 in the manner described above. An extension handle 318 is configured similarly to the coupling member 206 except that the extension handle 318 is longer than the coupling member 206 . Thus, in a manner similar to the coupling member 206 , the extension handle 318 is coupled to the disc prosthesis 310 .
[0078] Operation of the system of FIG. 17 proceeds in a manner similar to the procedure described above with respect to the distraction instrument 140 . One difference is that as shown in FIG. 17 , the insertion assembly 146 need not be coupled with the distraction instrument 290 prior to the insertion of the fingers 302 and 304 into the space prepared for the disc prosthesis 310 . Thus, after positioning the fingers 302 and 304 into the space prepared for the disc prosthesis 310 , the extension handle 318 is used to manipulate the gripper 308 into position within the insertion opening 306 .
[0079] When the gripper 308 is positioned within the insertion opening 306 , the guide members 188 and 190 engage the upper vertebra engaging member 292 and the guide members 192 and 194 engage the lower vertebra engaging member 294 . Thus, the disc prosthesis 310 is placed into the desired alignment. Either before or after the guide members 188 , 190 , 192 and 194 engage the upper vertebra engaging member 292 and the lower vertebra engaging member 294 , the handle 296 is compressed, causing the upper vertebra engaging member 292 and the lower vertebra engaging member 294 to separate, thereby distracting the vertebra adjacent to the prepared space. As the handle 296 is compressed, the ratchet assembly 300 maintains the handle 296 in a compressed condition.
[0080] The disc prosthesis 310 is then positioned in the prepared space by guiding the gripper 308 toward the space with the guide members 188 , 190 , 192 and 194 engaging the upper vertebra engaging member 292 and the lower vertebra engaging member 294 until the guide members 188 , 190 , 192 and 194 contact the vertebra adjacent to the prepared space as shown in FIG. 19 . In this condition, the disc prosthesis 310 is positioned within the spine at the depth set using the depth control member 304 .
[0081] Next, the distraction instrument 290 is removed by releasing the ratchet assembly 300 . This allows the compressive force exerted on the spine by the surrounding soft tissue to force the vertebras adjacent to the space with the disc prosthesis 310 toward each other. This in turn forces the fingers 302 and 304 toward each other as the adjacent vertebras are pressed onto the teeth on the endplates of the disc prosthesis 310 resulting in the configuration of FIG. 20 . Removal of the distraction instrument 290 , the prosthesis insertion assembly 146 and the gripper 308 may then be accomplished in like manner to the previously set forth description.
[0082] While the present invention has been illustrated by the description of exemplary processes and system components, and while the various processes and components have been described in considerable detail, applicant does not intend to restrict or in any way limit the scope of the appended claims to such detail. Additional advantages and modifications will also readily appear to those ordinarily skilled in the art. The invention in its broadest aspects is therefore not limited to the specific details, implementations, or illustrative examples shown and described. Accordingly, departures may be made from such details without departing from the spirit or scope of applicant's general inventive concept. | A method and system for insertion of an implant is disclosed. One embodiment of a system for use in implanting a spinal prosthesis incorporating principles of the invention includes an insertion assembly housing with a channel extending from a distal end portion to a proximal end portion, a gripper having a prosthesis coupling portion for coupling with a spinal prosthesis and an end portion, and a coupler member having a gripper coupling portion rotatably positioned within the channel and configured to couple with the end portion of the gripper within the channel. | 0 |
THE CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The application claims priority from previously filed U.S. Provisional Patent Application No: 60/766,600, titled “BEARING ANTI CREEP DEVICE & METHOD” filed on Jan. 31, 2006 by John Horvat.
FIELD OF THE INVENTION
[0002] This invention relates to anti creep devices for ball bearings and more particularly relates to a bearing anti creep device, system and a method of employing the device.
BACKGROUND OF THE INVENTION
[0003] Typically a ball bearing, needle bearing or other types of bearings are mounted onto a shaft and also another object in order to permit rotation of the shaft relative to the object. Typically, the inner race of a bearing is pressed onto a shaft and the outer race of the bearing is pressed into a bearing seat defined within a housing. Due to longitudinal or axial thermal expansions and contractions of the shaft and/or the housing into which the bearing is seated, there must be made allowance for axial movement of the bearing relative to the shaft and/or relative to the housing. In order to provide for this longitudinal or axial movement, the bearing mounting must be loose enough to accommodate longitudinal or axial movement of the bearing. Upon rotation and loading of the bearing, the outer bearing and/or the inner bearing race may rotationally creep. For example the inner bearing race may creep (move) rotational on the outer diameter of the shaft causing abrasion, wear, distortion and/or fretting corrosion along the bearing seat contact surface.
[0004] This rotational creep is undesirable due to the damage that it can impart upon either the bearing, the housing that the bearing is mounted into and/or the shaft that the bearing is mounted onto.
[0005] The damage imparted by the rotational creep may become so extensive, that repair must be initiated which often can be expensive and require additional machining of housings and/or shafts and replacement of bearings which creates down time of the machine and therefore lost production to the manufacturing operation.
[0006] Therefore, it is desirable to have a device and/or a method for prevention of rotational creep in order to ensure that the outer race and the inner race do not move rotationally relative to the bearing.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] The invention will now be described by way of example only with reference to the following drawings:
[0008] FIG. 1 a side elevational view of a ball bearing together with an anti creep ball mounted in the inner race.
[0009] FIG. 2 is a front perspective view of a ball bearing with an anti creep ball mounted in the inner race.
[0010] FIG. 3 is a top schematic perspective view of a shaft showing a channel defined therein.
[0011] FIG. 4 is a front elevational view of a ball bearing mounted on a shaft together with an anti creep ball mounted on the inner race.
[0012] FIG. 5 is a front perspective view of a shaft having a ball bearing mounted thereon on one end together with a channel defined in one end.
[0013] FIG. 6 is a schematic cross sectional view of the arrangement shown in FIG. 5 showing a ball bearing mounted onto a shaft together with the anti creep ball.
[0014] FIG. 7 is a partial cut away schematic perspective view of the arrangement shown in FIG. 5 showing a ball bearing mounted onto a shaft together with the anti creep ball.
[0015] FIG. 8 is a front perspective view of a ball bearing showing an anti creep ball mounted in the outer race.
[0016] FIG. 9 is a schematic perspective view of the bearing shown in FIG. 8 with an anti creep ball shown mounted in the outer race.
[0017] FIG. 10 is a front perspective view of a housing showing a channel defined therein.
[0018] FIG. 11 is a front plan view of a bearing mounted into the bearing seat of a housing together with the anti creep ball mounted therein.
[0019] FIG. 12 is a front perspective view of the assembly shown in FIG. 11 .
[0020] FIG. 13 is a cross sectional view of the assembly shown in FIG. 12 in which a ball bearing is mounted onto a bearing seat defined in a housing together with a anti creep ball.
[0021] FIG. 14 is a front partial cut away perspective view of the arrangement shown in FIG. 13 .
[0022] FIG. 15 is a front plan view of a ball bearing showing a socket defined in a bearing face.
[0023] FIG. 16 is a schematic perspective view of a ball bearing shown with a socket defined in a bearing face.
[0024] FIG. 17 is a front schematic perspective view of a housing shown together with a socket defined in a shoulder of the housing.
[0025] FIG. 18 is a front elevational view of the assembled bearing and housing.
[0026] FIG. 19 is a front perspective view of the device shown in FIG. 18 .
[0027] FIG. 20 is a cross sectional view of the assembly shown in FIGS. 18 and 19 in which a ball bearing is shown mounted in a bearing seat abutting a shoulder shown together with an anti creep ball.
[0028] FIG. 21 is a partial cut away perspective view of the arrangement shown in FIG. 20 .
[0029] FIG. 22 is a schematic top perspective view of yet alternate ball bearing showing three different socket locations.
[0030] FIG. 23 is a schematic top perspective view of the ball bearing shown in FIG. 22 with the anti creep balls shown in stalled in the sockets.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0031] The first embodiment of the present invention is depicted in FIGS. 1 through 7 inclusively. FIG. 1 shows a ball bearing 102 which includes an outer race 104 and inner race 106 , bearing cage 108 having ball bearings 110 therein. Ball bearing 102 also includes an anti creep ball 100 shown mounted in the inner diameter 111 of the inner race 106 of ball bearing 102 . FIG. 2 a perspective schematic view of ball bearing 102 shows anti creep ball 100 , located roughly mid way across the width of the inner diameter 111 of the inner race 106 .
[0032] FIG. 3 shows a shaft 112 having a channel 114 defined therein. FIGS. 4 and 5 show a ball bearing 102 mounted on shaft 112 . Typically a bearing such as ball bearing 102 is either slideably received onto shaft 112 in the longitudinal direction 122 and/or is pressed onto the end of shaft 112 in the longitudinal direction 122 due to a friction fit between the inner race 106 and the outer diameter 113 of shaft 12 . Anti creep ball 100 registers with longitudinal channel 114 as ball bearing 102 is pushed longitudinally over shaft 112 into the installed position as shown in FIG. 5 . Referring now to FIGS. 6 and 7 which schematically show in cross section along the longitudinal direction 122 , ball bearing 102 mounted onto shaft 112 . Anti creep ball 100 is preferably a small ball bearing which is seated in a socket 120 defined in inner race 106 of ball bearing 102 . Channel 114 is preferably a semi circular shaped groove adapted to receive therein substantially one half of the anti creep ball. The depth of socket 120 is approximately ½ of the diameter of anti creep ball 100 and therefore the depth of channel 114 is also approximately ½ the diameter of anti creep ball 100 . In order to assemble ball bearing 102 onto shaft 112 , anti creep ball 100 is mounted into socket 120 and held in place with a small amount of grease for example. Thereafter, ball bearing 102 with anti creep ball 100 mounted in socket 120 can be slideably fit over the end of shaft 112 provided that anti creep ball 100 registers and travels along channel 114 during the assembly procedure along longitudinal direction 122 . Person skilled in the art will recognize that there must be sufficient clearance between anti creep ball 100 and channel 114 to allow assembly. A person skilled in the art will note that the inclusion of anti creep ball 100 will prevent rotation of the inner race 106 in rotational direction 124 relative to shaft 112 due to the locking function of anti creep ball 100 which is simultaneously mounted in socket 120 and also channel 114 . The use of anti creep ball 100 allows ball bearing 102 to move in the longitudinal direction 122 , however prevents bearing creep in the rotational direction 124 shown in FIG. 4 .
[0033] FIGS. 8 through 14 show a second embodiment of the present invention. Ball bearing 103 depicted in FIGS. 8 and 9 shows a anti creep ball 100 mounted in the outer diameter 115 of the outer race 104 of ball bearing 103 . In this application, ball bearing 103 is mounted into a housing 140 having a bearing seat 142 , a shoulder 144 and a channel 114 . Shown in assembled position in FIGS. 11 and 12 , ball bearing 103 is slideably mounted onto bearing seat 142 by slideably urging ball bearing 103 in the longitudinal direction 122 onto bearing seat 142 until it is flush with shoulder 144 defined in housing 140 . FIGS. 13 and 14 show schematically in partial cross section view the mounting of ball bearing 103 into housing 140 . Ball Bearing 103 is slideably urged in longitudinal direction 122 into bearing seat 142 by aligning and registering anti creep ball 100 with channel 114 in order to install ball bearing 103 into housing 140 . In similar fashion as the previous embodiment, anti creep ball 100 is located simultaneously in a socket 120 and also in a channel 114 . Socket 120 has a depth approximately ½ the diameter of anti creep ball 100 and channel 114 has a depth again of approximately ½ the diameter of anti creep ball 100 . Therefore, ball bearing 103 is free to move in the longitudinal direction 122 , however will prevent rotational creep in rotation direction 124 .
[0034] The third embodiment of the present invention is depicted in FIGS. 15 through 21 in which ball bearing 105 includes a socket 120 defined in the bearing face 131 of the outer race 104 . A housing 141 having a shoulder 144 and a bearing seat 142 has defined on the shoulder 144 a socket 120 . Socket 120 is a spherical dome adapted to receive up to one half of the anti creep ball. As best shown in cross sectional view as in FIGS. 20 and 21 , the depth of socket 120 defined in shoulder 144 is approximately ½ of the diameter of anti creep ball 100 and the socket 120 defined in the outer race 104 of bearing 105 , also has a depth of approximately ½ of anti creep ball 100 . Therefore, bearing 105 can move freely in the longitudinal direction 122 for installation purposes. To install ball bearing 105 is urged longitudinally along bearing seat 142 until outer race 104 of ball bearing 105 abuts with shoulder 144 of bearing seat 142 . In order for outer face 131 of outer race 104 of ball bearing 105 to make contact with shoulder 144 , socket 120 defined in shoulder 144 and socket 120 defined in outer race 104 must align and register in order to accommodate therein anti creep ball 100 . Additionally a retaining device is used to fix ball bearing 105 into bearing seat 142 thereby minimizing longitudinal movement of ball bearing 105 . The retaining device not shown could be a circlip, retaining plate, or any other means to fix ball bearing 105 into bearing seat 142 . A person skilled in the art will recognize that a shaft passing through inner race 106 can move longitudinally relative to ball bearing 105 .
[0035] Inner diameter 111 , outer diameter 115 , and bearing face 131 are examples of bearing mounting surfaces. A mounting surface may be any surface of a bearing used to hold the bearing in place. Shoulder 144 , bearing seat 142 shaft outer diameter 113 , are examples of mating surfaces used to mate with a mounting surface to hold a bearing in place.
[0036] A person skilled in the art will note that ball bearing 102 and 103 are examples of how the anti creep ball could be installed in typical installations. The reader will note that the anti creep ball and this method of preventing rotation of creep can be applied to needle bearings, thrust bearings, roller bearings and/or any other type of bearing which is subject to rotational creep. The reader will also note that this method and device for preventing rotational creep allows for movement of the bearing in the longitudinal direction 122 , however prevents movement of the bearing in the rotational direction 124 , namely rotational creep relative to the bearing seat and/or the shaft.
[0037] Therefore, a person skilled in the art will note that ball bearing 102 and 103 is free to move in the longitudinal direction 122 ; however the presence of anti creep ball 100 and the socket 120 will prevent rotational creep.
[0038] Referring now to FIGS. 22 and 23 which depict ball bearing 201 having three distinct sockets defined at different locations of the bearing namely, socket 220 on outer diameter 230 , socket 222 defined on the inner radial face 236 of inner race 206 and socket 224 defined in inner diameter 232 of inner race 206 . This particular ball bearing 201 is shown with a dust cover 208 which covers up the bearing cage and the ball bearings which are located under the dust cover 208 . Ball bearing 201 includes an outer race 204 , having an outer diameter 230 and an outer radial face 238 . Socket 220 is defined in the outer diameter 230 of outer race 204 . Ball bearing 201 further includes an inner race 206 which has an inner radial face 236 and also an inner diameter 232 . Socket 222 is defined in inner radial face 236 of inner race 206 . Socket 224 is defined in inner diameter 232 of inner race 206 .
[0039] A person skilled in the art will note that sockets 220 , 222 and 224 are dimensioned to accept approximately ½ of anti creep ball 250 therein.
[0040] Ball bearing 201 is an example of how a bearing could be arranged to include sockets in various locations of the bearing in order that one is able to use an anti creep ball 250 with the ball bearing in any one of the configurations as shown in the previous embodiments.
[0041] The reader will also note that a ball bearing could be manufactured with no sockets from the original equipment manufacturer, in which case one would have to retrofit the existing bearing with a socket. One could also manufacture the ball bearings with one and/or more sockets already in place from the manufacturer thereby making it simpler to take advantage of the use of anti creep ball 250 . | The present invention is an anti rotational creep bearing including a socket designed in the inner race of the bearing for partially receiving an anti creep ball therein, further including a shaft onto which the bearing is to be longitudinally mounted, including a channel defined along a longitudinal direction for receiving there along the anti creep ball projecting from its socket, wherein the depth of the socket plus the depth of the channel is at least equal to the diameter of the anti creep ball, such that when the bearing is installed on the shaft, the anti creep ball prevents creep in the rotational direction, however allows movement in the axial direction. | 5 |
TECHNICAL FIELD
This application relates generally to the protection of sensitive data, such as credit card information, in a networked environment.
BRIEF DESCRIPTION OF THE RELATED ART
Distributed computer systems are well-known in the prior art. One such distributed computer system is a “content delivery network” or “CDN” that is operated and managed by a service provider. The service provider typically provides the content delivery service on behalf of third parties. A “distributed system” of this type typically refers to a collection of autonomous computers linked by a network or networks, together with the software, systems, protocols and techniques designed to facilitate various services, such as content delivery or the support of outsourced site infrastructure. Typically, “content delivery” means the storage, caching, or transmission of content, streaming media and applications on behalf of content providers, including ancillary technologies used therewith including, without limitation, DNS query handling, provisioning, data monitoring and reporting, content targeting, personalization, and business intelligence.
The distributed and shared network infrastructure as described above is used, among other purposes, to deliver content from a plurality of web sites. Representative web sites include e-commerce retailers at which end users may shop and purchase products and services. In the prior art, CDN service providers provide the content delivery for these on-line retailers but, when it comes time for an end user to complete a purchase, the associated payment services typically are handled by third parties. In part, this is because such payment services involve the processing and storage of sensitive data, such as end user credit card data.
BRIEF SUMMARY
Using cryptographic techniques, sensitive data is protected against disclosure in the event of a compromise of a content delivery network (CDN) edge infrastructure. These techniques obviate storage and/or transfer of such sensitive data, even with respect to payment transactions that are being authorized or otherwise enabled from CDN edge servers.
The foregoing has outlined some of the more pertinent features of the disclosed subject matter. These features should be construed to be merely illustrative. Many other beneficial results can be attained by applying the disclosed subject matter in a different manner or by modifying the subject matter as will be described.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of the present invention and the advantages thereof, reference is now made to the following descriptions taken in conjunction with the accompanying drawings, in which:
FIG. 1 is a simplified block diagram of a content delivery network (CDN) in which the disclosed techniques herein may be implemented;
FIG. 2 is a simplified block diagram of a representative CDN edge machine on which the disclosed techniques may be implemented; and
FIG. 3 is a block diagram of an edge server process interacting with a merchant origin server and an third party credit card issuer according to the teachings of this disclosure.
DETAILED DESCRIPTION
In a known system, such as shown in FIG. 1 , a distributed computer system 100 is configured as a content delivery network (CDN), and it is assumed to have a set of machines 102 a - n distributed around the Internet. Typically, most of the machines are servers located near the edge of the Internet, i.e., at or adjacent end user access networks. A network operations command center (NOCC) 104 manages operations of the various machines in the system. Third party sites, such as web site 106 , offload delivery of content (e.g., HTML, embedded page objects, streaming media, software downloads, and the like) to the distributed computer system 100 and, in particular, to “edge” servers. Typically, content providers offload their content delivery by aliasing (e.g., by a DNS CNAME) given content provider domains or sub-domains to domains that are managed by the service provider's authoritative domain name service. End users that desire the content are directed to the distributed computer system to obtain that content more reliably and efficiently. Although not shown in detail, the distributed computer system may also include other infrastructure, such as a distributed data collection system 108 that collects usage and other data from the edge servers, aggregates that data across a region or set of regions, and passes that data to other back-end systems 110 , 112 , 114 and 116 to facilitate monitoring, logging, alerts, billing, management and other operational and administrative functions. Distributed network agents 118 monitor the network as well as the server loads and provide network, traffic and load data to a DNS query handling mechanism 115 , which is authoritative for content domains being managed by the CDN. A distributed data transport mechanism 120 (comprising a metadata control server and a set of staging servers) may be used to distribute control information (e.g., metadata to manage content, to facilitate load balancing, and the like) to the edge servers.
As illustrated in FIG. 2 , a given machine 200 comprises commodity hardware (e.g., an Intel Pentium processor) 202 running an operating system kernel (such as Linux or variant) 204 that supports one or more applications 206 a - n . To facilitate content delivery services, for example, given machines typically run a set of applications, such as an HTTP proxy 207 (sometimes referred to as a “global host” or “ghost” process), a name server 208 , a local monitoring process 210 , a distributed data collection process 212 , and the like. The For streaming media, the machine typically includes one or more media servers, such as a Windows Media Server (WMS) or Flash server, as required by the supported media formats.
A CDN edge server is configured to provide one or more extended content delivery features, preferably on a domain-specific, customer-specific basis, preferably using configuration files that are distributed to the edge servers using a configuration system. A given configuration file preferably is XML-based and includes a set of content handling rules and directives that facilitate one or more advanced content handling features. The configuration file may be delivered to the CDN edge server via the data transport mechanism. U.S. Pat. No. 7,111,057 illustrates a useful infrastructure for delivering and managing edge server content control information, and this and other edge server control information can be provisioned by the CDN service provider itself, or (via an extranet or the like) the content provider customer who operates the origin server. U.S. Pat. No. 7,240,100 describes techniques for applying the edge server content control information at the edge server. The CDN may include a storage subsystem, such as described in U.S. Pat. No. 7,472,178. The CDN also may operate a server cache hierarchy to provide intermediate caching of customer content; one such cache hierarchy subsystem is described in U.S. Pat. No. 7,376,716. These disclosures are incorporated herein by reference.
The CDN may provide secure content delivery such as described in U.S. Publication No. 20040093419, or as described in U.S. Pat. No. 7,363,361. Secure content delivery as described therein enforces SSL-based links between the client and edge server process, on the one hand, and between the edge server process and an origin server process, on the other hand. This enables an SSL-protected web page and/or components thereof to be delivered (to the end user client browser) via the edge server. Typically, an SSL-protected web page is served to an end user process when an end user navigates to a web site merchant checkout page from an e-commerce web site that is being delivered via the CDN). The merchant checkout page typically is delivered from the origin server (not the CDN) and, in particular, from an application server (within the origin infrastructure) that comprises part of an order management system or gateway. In the past, the CDN service provider has not been involved in the processing of the actual order, in large part due to the sensitivity of handling credit card data during the payment transaction itself. As noted above, this techniques disclosed herein enable the CDN service provider to facilitate the payment transaction.
As used herein, the term “sensitive data” should be broadly construed, depending on the context. Thus, for example, in connection with an e-commerce transaction, which is the preferred embodiment, the term typically refers to any PCI sensitive data, such as credit or debit card number, bank account number, and the like. The “sensitive data” also may be identity information (such as personally identifiable information (PII)), health care information (such as HIPAA-related data), finance information (such as GLBA-related data), other confidential information, and the like.
Handling Sensitive Data
As noted above, the distributed and shared network infrastructure as described above is used, among other purposes, to deliver content from web sites, typically the web sites of CDN customers. Representative web sites include e-commerce retailers at which end users may shop and purchase products and services. In the prior art, CDN service providers provide the content delivery for these on-line retailers but, when it comes time for an end user to complete a purchase, the associated payment services are handled by third parties. This is the case even if the CDN provides secure content delivery, e.g., over SSL or TLS links, such as described in U.S. Publication No. 20040093419.
The disclosed subject matter extends the CDN infrastructure to facilitate payment services within that infrastructure. Because the providing of payment services involves the handling of end user credit card and other sensitive user data, there is a need to enhance the operation of the CDN to ensure that such data remains fully protected. A method of securing sensitive data (e.g., end user credit card information) is described below. In short, the technique allows the CDN service provider to process credit cards (and perhaps other personally identifiable information or “PII”) without storing any data that could be exploited by a hacker to retrieve the actual card numbers (or other PII). Even if a hacker recovered everything that the CDN has stored, the hacker would not be able to reveal any confidential information.
The high level technique is now described. According to this disclosure, and in the context of protecting PCI data, a CDN key pair (PK_I, SK_I) is created for each card issuer I (e.g., VISA or AMEX). Thus, for issuer I, PK_I) is the public key, and SK_I) is the secret key. According to this disclosure, the value of SK_I) is not stored on or in association with the CDN but, rather, only at the site of card issuer I (or some other location designated by the issuer but, once again, not on the CDN).
An end user visits the e-commerce web site in the usual manner. Typically, the CDN serves the non-secure pages of the site in the usual manner, such as described in U.S. Pat. No. 7,596,619. As the end user navigates through the site, he or she may identify certain products or services that he or she desires to purchase. One common technique that is used for this purpose is to associate a “shopping cart” (or, more generally, a data structure) with the user's browsing session. When the user selects an item for purpose, information about the item is stored in the cart. Then, when the user indicates a desire to “checkout” from the site (i.e., to purchase the items in the shopping cart), typically the CDN sets up a pair of SSL-links (although the shopping session may have initiated over SSL). In the usual case, a first secure link is established between the end user browser and the edge server, and a second link is established between the edge server and the origin server order management application.
After the SSL links are established, the origin server typically serves a “checkout” page. The end user then enters his or her credit card or other PII-related information, and hits “enter” on his or her browser. This creates an HTTP POST message, which includes the sensitive data. The sensitive data thus is received at the CDN edge server. According to the subject disclosure, however, instead of passing this data on through to the origin server, the edge server recognizes the POST, removes the PCI data, and computes a function. In particular, if the end user's credit card (CC) is from some issuer J, the CDN edge server process computes v=PK_J (CC) and then immediately discards the true credit card CC. In particular, the CC data is not stored on disk or other persistent store, and in-memory storage is kept to a minimum (just what is necessary to facilitate the above-described computation). According to this disclosure, all future processing of the card (and thus the CC) is done using V.
Preferably, the edge server maintains a database of tokens. The database may be in the form of an array, a linked list, an index table, or any other convenient data structure. A hash table may also be used. A token (or, more generally, a “data string”) associates a value V with an identifier W associated with a web site (or portion thereof, including sub-domain). In response to receipt of the POST and the calculation of the value V, the edge server process then performs a lookup in the database to determine if the CDN has processed V for this web site W. If so, a token T for (V, W) will be present in the database. If (as a result of the lookup) it is determined that the CDN has processed V for this web site W before, the edge server sends the token T for (V, W) to the order management system to which the edge server is now coupled (on its forward processing side). If, however, it is determined that the CDN has not processed V for this site (because there is no such token in the database), the server randomly creates a new token T for (V, W). The new token is unique for W. The edge server process adds the new token to its database and then sends T to the web site over the forward connection.
The processing of tokens proceeds in the natural way until the web site order management system wants the CDN to process a request for authorization, or request for payment for a token T. The order management system communicates with the edge server process over the connection that is maintained (preferably in a persistent manner) between the two. When the edge server receives a response from the order management system indicating that the CDN edge server process should then “authorize” the transaction or make the actual payment request, the CDN edge server uses the token T and the value W to retrieve the value of V. The CDN edge server processor then opens up a new connection, to a card issuer network for J. Because the CDN edge server no longer maintains CC, however, it cannot transmit it; instead, the CDN edge server just sends V to the card issuer network. This value is sent via an intermediate (or subordinate) request, as the request typically is made while the overall checkout process is on-going. In a process external to the CDN, the card issuer J (or its delegate) then uses the secret key value SK_J to decrypt and retrieve CC.
For additional security, the decryption by or on behalf of card issuer J using SK_J preferably is done only if the transmission of V has been authenticated to have come from a CDN server.
A key advantage to this approach is security. Even if the CDN edge server is compromised, no credit card data is lost because the CDN edge server does not maintain such data. Moreover, because only the secret key SK_J can be used to retrieve the card numbers, access to the CDN edge server does not compromise the PCI data, because the secret key preferably resides only at the issuer (or on some server that the issuer has some degree of control over). (A CDN server may also be positioned at the card issuer). Thus, using this approach, a CDN service provider has no greater risk of exposure for payment services than it would if it were just passing the credit card to the CDN customer. Indeed, the risk is lower because the CDN provider no longer sends the card anywhere using the described above. While it is possible that the values of PK_J (CC) might be exposed by a hacker, these values are only of use if they are sent by the CDN. Thus, if PK_J (CC) is sent by another entity, then the card issuer would have knowledge, a priori, that the edge server has been compromised (and the value stolen) because it would have been encrypted using a CDN service provider key pair but not sent from a CDN machine.
FIG. 3 illustrates a typical use case scenario. In this example, the client browser (or equivalent rendering engine) sends an HTTP POST (or equivalent) message to the edge server 300 during an order checkout to the merchant origin server 302 . Origin server 302 has an associated order management system and database 304 . The edge server 300 also interfaces to a card issuer payment gateway 306 that is associated with payment gateway database 308 . The edge server comprises a token database, a public key PK associated with each issuer (such as the issuer associated with gateway 306 ), together with software (one or more computer programs, processes, utilities or the like) to carry out the above-described functionality. In particular, this software receives the HTTP POST, parses it to remove the sensitive data, generates the value V, retrieves (or creates the token T), and forwards the POST with the sensitive data replaced with the token. When the merchant origin server 302 requests transaction authorization or payment (e.g., by returning the token T), the CDN edge server performs this function by making the intermediate (subordinate) request to the payment gateway (which holds the secret key SK needed), passing the value V, and receiving the response (e.g., the payment authorization or the like). In this manner, the edge server performs or facilitates the payment service without exposing the sensitive data, which is deleted upon generation of the value.
The disclosed technique may have many variants. Thus, for example, instead of discarding the CC, the CDN edge server process may maintain some small portion thereof, such as the last four (4) digits, or some arbitrary CDN customer-defined data payload. As another alternative, the edge server process may first pad the CC with CDN-specific data before generating PK_J (CC). Optionally, the edge server process may extend this step to add other obfuscation data to prevent rainbow attacks against the token store. The functionality described herein may be used with or without credit card tokenization, which is a technique whereby a credit card number is exchanged with a token (by a third party token provider).
As another variant, the encryption step may be carried out on an end user device using CDN-provided client software, thereby ensuring that the credit card number is never even received with the edge server infrastructure.
The public key PK_J may be maintained secret for added security.
In another alternative approach, a second level of encryption using a secret CDN key is also used. In this approach, a public decryption key is then provided to the card issuer (or its delegate). This enables an extra level of authentication, namely, a way to verify that the transmission comes from the CDN and not some unauthorized intermediary. Other cryptographic techniques may be used as required. Thus, for example, the edge server may apply a digital signature to the value V.
The method described here covers the case where the protected information (e.g. a credit card number) only needs to be sent to a single entity (e.g., the network for the card issuer). The subject disclosure is not limited to this scenario. In the event the sensitive data (e.g., a medical record or the like) needs to be sent to multiple entities (e.g., various hospitals), then the edge server process creates and stores an encrypted copy of the data for each entity that requires it (using the secret key for each such entity). This requires that the CDN know ahead of time the identities of those entities. If this is not possible, the CDN service provider may retain a copy of a secret key in a highly secure location and manner so that it can recover the original version of the protected information (and, in particular, so that it could be encrypted later using an as-yet unknown public key).
The above-described technique may be used to secure any sensitive data within the context of a CDN service.
The above-described edge server process preferably is implemented in computer software as a set of program instructions executable in one or more processors, as a special-purpose machine. In one embodiment, the edge server process is an HTTP proxy that has been enhanced to provide the recited functions. Typically, an instance of the process is instantiated per HTTP request received from an end user browser, and that process instance maintains appropriate data structures to facilitate the processing described. The edge server process comprises a front end portion to which the client browser is coupled, and a back end portion to which the process is coupled to the origin server gateway (or the card issuer network, as described). The edge server process is capable of opening up and maintaining multiple connections. Control over the edge server process may be maintained using XML-based metadata provided to the edge server. Thus, because the edge server typically is handling content for multiple CDN customers, each CDN customer may provide its own unique configuration that is enforced at the edge server.
Representative machines on which the subject matter herein is provided may be Intel Pentium-based computers running a Linux or Linux-variant operating system and one or more applications to carry out the described functionality. One or more of the processes described above are implemented as computer programs, namely, as a set of computer instructions, for performing the functionality described.
Having described our invention, what I claim is set forth below. | Using cryptographic techniques, sensitive data is protected against disclosure in the event of a compromise of a content delivery network (CDN) edge infrastructure. These techniques obviate storage and/or transfer of such sensitive data, even with respect to payment transactions that are being authorized or otherwise enabled from CDN edge servers. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a slider unit with a built-in moving-coil linear motor, which has been extensively used in semiconductor and liquid crystal display industries, measuring instruments, assembling machines, machine tools, industrial robots, conveyors and others. More particular, the present invention relates to a slider unit with a built-in moving-coil linear motor of the type in which an exciting coil is installed in the side of moving element.
2. Description of the Prior Art
In recent years, multi-axis stages and moving mechanisms such as X-Y plotters employed in the diverse technical fields as stated just above have required more and more a slider unit, which is compact or slim in construction and light in weight, and moreover able to operate with high propulsion, high speed and high response to provide high speed travel and accurate position control for works, tools, articles and instruments. Linear motors commonly used in the slider units involve two broad types. The first, called moving-magnet linear motor has a stator of an armature coil arranged lengthwise over the entire length of a bed of stationary part, and a moving-field magnet of permanent magnet arranged on a table movable in a sliding manner along the length of the bed. The second, called moving-coil linear motor has a stator of field magnet mounted on the bed, and moving-armature coils distributed in space one after another on the table such that they are a preselected electrical angle out of phase.
A moving-coil linear motor is disclosed in Japanese Patent Publication No. 49099/1983. As shown in FIGS. 1 and 2 in the Japanese publication recited earlier, the prior linear motor has flat permanent-magnet pieces that are each magnetized in thickness-wise direction. The permanent magnets are arranged such that the poles on either magnet alternate lengthwise in polarity along a traveling direction of a moving element while like poles are placed in opposition to each other across the traveling direction of the moving element. A center yoke is arranged between confronting like poles in such a relation as to oppose the permanent-magnet pieces. The moving coil is composed of two winding parts each of which has a length half the width of the permanent-magnet piece, the two winding parts being arranged on a coil bobbin fit in the center yoke. Thus, the moving coil is allowed to move in a clearance defined between the permanent magnets and the center yoke.
Another example of the prior moving-coil linear d-c motor is disclosed in Japanese Patent Laid-Open No. 254682/1987. The prior moving-coil linear d-c motor, as seen from FIGS. 1 and 2 in the publication cited above, is the same found in Japanese Patent Publication No. 49099/1983, other than the moving part of coils composed of more than one set of three-phase coil.
Japanese Patent Laid-Open No. 107728/1995 discloses a linear d-c motor to drive an X-Y table, in which the stationary side is composed of a yoke of roughly U-shaped configuration in cross section and a permanent magnet secured on a bottom of the yoke, while a moving side is supported on the stationary side for lengthwise reciprocation and composed of an iron core encircled with coils, and a pair of magnetic members attached to fore-and aft ends of the iron core.
Referring now to FIGS. 11 and 12, there is shown a prior slide unit with a built-in moving-coil linear motor disclosed in Japanese Patent Laid-Open No. 333435/2000, which is co-pending senior application. In the accompanying drawings, FIG. 11 is a perspective view showing the slide unit having a built-in moving-coil linear motor, while FIG. 12 is an illustration to explain how the linear motor operates to drive the slider unit.
A slider unit 70 is of an elongated structure made reduced in the overall height and mainly comprised of a bed 2 for a base member mounted to any one, ordinarily stationary side, not shown, of relatively movable parts by means of screws fit in fixing holes 4 , and a table 10 on which is mounted a counterpart, ordinarily a work, not shown, of the relatively movable parts. The bed 2 has a shallow U-shape, when viewed in cross section traversing the moving direction of the table 10 , which is composed of an elongated bottom 2 b and upright walls 2 a arranged at widthwise opposing edges of the bottom 2 b . A pair of track rails 3 is arranged lengthwise of the bed 2 in parallel with each other at a height identical with each other and fixed to the bed 2 with machine screws 17 . The table 10 is secured by machine screws 46 onto more than one sliding element 11 that rides on the elongated track rails 3 for sliding movement. A moving-coil linear motor 20 inboard the slider unit 70 is comprised of a magnet yoke 21 having an U-shaped configuration in cross section, a pair of field magnets 30 , 31 attached to the magnet yoke 21 , and a moving-coil assembly 40 supported on the table 10 .
Attached on lengthwise opposing ends of the bed 2 are end blocks 5 , one to each end, to define a tolerable stroke range where the table 10 is allowed to move along the track rails 3 . Recesses 7 opened downwards are formed at the outermost end faces 5 a of the end blocks 5 . An operator may easily lift or carry the slider unit 70 by putting his hands on the recesses 7 . Stoppers 8 of elastic body such as urethane rubber are attached to inside surfaces 5 b of the end blocks 5 , one to each end block, to provide buffers for protecting the table 10 from a collision against the end blocks 5 when the sliding element 11 comes close to the limit of its stroke. Limiters, although not shown, are arranged on the lengthwise opposing ends of the bed 2 and fixed to the bed 2 with machine screws 19 , while the table 10 has detecting means to sense the limiters when approaching any one of the opposing ends of the bed 2 .
The table 10 , while secured by machine screws 46 onto more than one sliding element 11 , is made with many threaded holes 12 , four holes shown in figures, for fixing a work. The sliding element 11 constitutes, in combination with the track rails 3 , for example a small linear motion guide unit 16 in which rolling elements are allowed to run through recirculating passage including raceways defined between the confronting surfaces of the rack rails 3 and the sliding elements 11 , and turnarounds and return passages in the sliding elements 11 .
The table 10 is allowed to move lengthwise of the bed 2 with respect to the bed 2 by virtue of the small linear motion guide units 16 . Both the bed 2 and the table are made of aluminum alloys to reduce in weight the slider unit 70 , improving the acceleration performance, and realizing high speed and high responsibility.
A linear motor 20 drives the table 10 along the bed 2 . The moving-coil assembly 40 is supplied with electric power through a power line. Signals representing the positions of the table 10 with respect to the bed 2 are applied to an external controller where the electric power supplied through the power line is regulated, depending on information as to the positions applied via the sensor cord.
The moving-coil linear motor 20 inboard the slider unit 70 includes a magnet yoke 21 of U-shape in cross section perpendicular to the moving direction of the table 10 to support the field magnets 30 , 31 thereon. The magnet yoke 21 will be considered a stator part of the moving-coil linear motor 20 , which extends lengthwise over the entire length of the bed 2 and is mounted to the bed 2 . The magnet yoke 21 is composed of an upper web 22 and a lower web 23 , which are arranged in opposing relation to each other to provide an elongated gap 32 between them, and a connecting web 24 interconnecting integrally the confronting upper and lower webs 22 , 23 at any one side of widthwise opposing edges. The magnet yoke 21 , although made thin in thickness and slim in construction, may be kept high in its overall stiffness to be less subject to the deflection owing to the magnetic attraction over a tolerable minor extent where no trouble might take place in operation of the linear motor. The magnet yoke 21 is fixed to the bed 2 by tightening more than one screw 25 through the connecting web 24 into the bed 2 . The magnet yoke 21 is also provided with a sidewise opening 32 a between the confronting upper and lower webs 22 , 23 at another side of the widthwise opposing edges.
The field magnets 30 , 31 in the form of sheet are arranged on the inwardly opposing surfaces: lower surface 27 and upper surface 28 of the confronting webs 22 , 23 , one to each surface. The field magnets 30 , 31 are composed of thin magnet pieces 30 a , 30 b , 30 c , 30 d . . . and 31 a , 31 b , 31 c , 31 d . . . , which are magnetized such that the poles on either piece alternate in polarity lengthwise of the bed 2 or in the direction along which the table 2 slides. The magnet pieces 30 a , 30 b , 30 c , 30 d . . . and 31 a , 31 b , 31 c , 31 d . . . are closely placed side by side such that unlike poles oppose directly to each other across an air gap 32 . The magnet pieces are each made of thin rectangular piece magnetized thickness-wise. An unlike pole pitch spanned between adjacent magnet pieces of unlike poles along the lengthwise direction of the bed 2 is identical with the width of magnetic pole of either magnet piece, which is measured in the lengthwise direction of the bed 2 .
The moving-coil assembly 40 is arranged to extend in the air gap 32 through the sidewise opening 32 a of the magnet yoke 21 of U-shape in cross section, and supported to the bed 2 . The armature coils 42 made in the form of flat three-phase coreless coils of rectangular shape are arranged on any even surface in juxtaposition along the sliding direction of the table in such a relation that three armature coils are allotted to four pole width of the field magnets 30 , 31 to provide a so-called four-pole, three-coil construction.
Modern advanced slider units need a further high propulsion performance. Increasing a number of the armature coils to cope with this raises a major problem of rendering the overall length of the moving-coil assembly large. As a result, the table enlarges in fore-and-aft length and, therefore the slide unit is made shorter in its tolerable stroke. For seeking to ensure the stroke length comparable with the slide units ever used, the bed must be much extended so that the slider unit will inevitably become much bulky.
To deal with the problem stated earlier, the moving-coil d-c linear motor as disclosed in Japanese Patent Laid-Open No. 254682/1987 has been developed, in which coils are arranged perpendicularly to the sliding direction to form bobbins, which are then arranged side by side on a center yoke for sliding movement. According to the motor construction stated just above, much armature coils are allotted to one pole width of the field magnet, and correspondingly the coil sides in the armature coils contributing to thrust production increase in number so as to realize high propulsion. With the moving-coil linear motor constructed as stated earlier, nevertheless, the motor large in the length of stroke needs the center yoke that is also too large in length, so that the center yoke is liable to deflection, which might cause the interference of the center yoke with the bobbins, thus obstructing the sliding movement of the table. Moreover, the center yoke, as heavy in weight, is unfit for the long slider unit.
With the slider unit having the bed supporting a magnet yoke thereon and the table arranged for sliding movement relatively to the bed, in which a current in the armature coils supported on the table to be disposed in an clearance between the confronting field magnets will interact with the magnetic flux developed by the field magnets installed on the confronting inside surfaces of the magnet yoke to force the table relatively to the bed, it is desirable to develop the improved slider unit that will realize high propulsion for moving the table at high speed and also allow highly accurate speed and position control of the table, with even keeping the construction slim in thickness as with the slider unit ever used.
SUMMARY OF THE INVENTION
The present invention, therefore, has as its primary object to overcome the major problem as described just above and more particular to provide a slider unit with a built-in moving-coil linear motor to drive a table with respect to a bed, in which the moving-coil linear motor inboard the slider unit is made slim in construction so as to reduce the overall height of the slider unit, whereby the slider unit allows providing a high propulsion, with even keeping the dimensions equivalent to the slider unit ever used.
The present invention is concerned with a slider unit with a built-in moving-coil linear motor, comprising a bed supporting thereon a magnet yoke, a table movable in a sliding manner with respect to the bed, a pair of field magnets arranged on inwardly facing surfaces of confronting sections of the magnet yoke in such a manner that poles on the field magnets alternate in polarity along a moving direction of the table and also like poles confront each other across an air gap between the field magnets, and a moving-coil assembly mounted to the table to lie in the air gap between the confronting field magnets, wherein the moving-coil assembly is composed of an iron core of platy-configuration extending in the air gap along the moving direction, and at least one set of three-phase armature coils wound in a direction intersecting the moving direction, whereby a current in the armature coils interacts electromagnetically with a field flux created by the field magnets to force the table moving with respect to the bed.
In one aspect of the present invention, there is disclosed a slider unit with a built-in moving-coil linear motor in which the confronting sections of the magnet yoke is connected to each other along any one side of widthwise opposing sides thereof.
In another aspect of the present invention, there is disclosed a slider unit with a built-in moving-coil linear motor in which the table is arranged for a sliding movement with respect to the bed through a linear motion guide unit, which is comprised of a guide rail mounted to the bed, and a sliding element fixed to the table.
In a further another aspect of the present invention, there is disclosed a slider unit with a built-in moving-coil linear motor in which the moving-coil assembly is supported by arms extending from the table through a sidewise opening left at another side of the confronting sections of the magnet yoke.
With the slider unit constructed as stated earlier, since the moving-coil assembly is composed of an iron core of platy-configuration, and at least one set of three-phase armature coils wound around the iron core in the form of flat rectangular configuration in a plane intersecting the sliding direction, the slider unit itself may be made slim or compact in construction, with even longer stroke range in which the table is allowed moving. Moreover, there are provided much coil sides of the armature coils contributing to the propulsion and, therefore the high propulsion may be realized.
The construction in which like poles on either field magnet are placed in opposition to each other across the air gap, as opposed to the prior slider units in which unlike poles on either field magnet are in opposition to each other, allows canceling the magnetic attraction thereby to reduce the load on the linear motion guide unit, so that the table allowed withstanding much load capacity. In addition, the armature coils of the present invention, as wound around the iron core high in stiffness, will withstand well against the high propulsion occurring in the armature coils to act on the moving-coil assembly.
In another aspect of the present invention, there is disclosed a slider unit with a built-in moving-coil linear motor in which the moving-coil assembly is composed of more than one set of armature coils and each set of armature coils corresponds to one pole width. The moving-coil assembly constructed as stated just above will succeed in keeping stable the propulsion acting on the moving-coil assembly.
In another aspect of the present invention, there is disclosed a slider unit with a built-in moving-coil linear motor in which the iron core is formed in a rectangular platy-configuration in cross section and made longer than an overall length of the armature coil, but set at a length roughly equivalent to a summation of several times the pole width in the field magnets and a half the pole width, and further the iron core is fixed at its fore-and-aft ends to the arms. The iron core constructed as stated above is different in phase of magnetic flux acting on any one end from on another end, thus contributing to eliminating cogging or variations in sliding movement.
In another aspect of the present invention, there is disclosed a slider unit with a built-in moving-coil linear motor in which any adjoining poles of field magnets are chamfered off at their corners coming into abutment against each other and facing the air gap. The field magnets constructed as stated earlier serve well for relaxing any adjoining field strength, thus providing the ideal distribution of magnetic flux strength to realize a smooth movement of the table.
In a further another aspect of the present invention, there is disclosed a slider unit with a built-in moving-coil linear motor in which the iron core is made of a lamination of thin steel sheets overlaid one on another. The iron core constructed as stated just above serves well to suppress the generation of eddy current in the iron core to be kept from becoming heated.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front elevation, partially broken away, showing a preferred embodiment of a slider unit with a built-in moving-coil linear motor in accordance with the present invention:
FIG. 2 is a top plan view of the slider unit illustrated in FIG. 1 :
FIG. 3 is a cross-sectional view of the slider unit of FIG. 2, taken on the plane of the lines I—I of that figure including a part broken away:
FIG. 4 is a left-side elevation of the slider unit shown in FIG. 2 :
FIG. 5 is a bottom plan view of a table detached from the slider unit:
FIG. 6 is a fragmentary longitudinal section taken on the plane of the lines II—II of FIG. 2 :
FIG. 7 is a cross-sectional elevation view taken on the plane of lines III—III of FIG. 6 :
FIG. 8 is an illustration showing relations of the moving coils and field magnets to explain how the moving-coil linear motor operates:
FIG. 9 is a schematic fragmentary longitudinal section showing another embodiment of the slider unit with built-in moving-coil linear motor according to the present invention:
FIG. 10 is a cross-section showing a further another embodiment of the slider unit with built-in moving-coil linear motor according to the present invention:
FIG. 11 is a perspective view, partially broken away, showing a conventional slider unit with built-in moving-coil linear motor: and
FIG. 12 is an illustration to explain how the moving-coil linear motor inboard the prior slider unit of FIG. 11 operates.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Preferred embodiments of a slider unit with a built-in moving-coil linear motor according to the present invention will be explained hereinafter in detail with reference to the accompanying drawings. Components and parts identical in function with that previously described in the prior slider unit of FIGS. 11 and 12 are given the same reference characters.
Referring now to FIGS. 1 to 4 showing the first preferred embodiment of the present invention, a slider unit 1 with a built-in moving-coil linear motor is mainly comprised of an elongated bed 2 formed in a rectangular shape in top plan view and made of aluminum alloys, a linear motion guide unit 16 composed of a pair of track rails 3 arranged lengthwise of the bed 2 in parallel with each other at a height identical with each other and a sliding element 11 riding astride any one of the paired track rails 3 for sliding movement, and a flat table 10 of rectangular shape made of aluminum alloys and fixed to the table 10 .
The bed 2 is made with holes 4 in which fixing bolts fit to mount the bed 2 onto any one, for example a basement and so on, of relatively movable parts. In contrast, the table 10 is a counterpart of the relatively movable parts and is made with threaded holes 12 open upwards, into which fixing screws are screwed to secure any work to be moved towards any desired position with respect to the stationary part. The sliding element 11 movable along the associated track rail 3 is secured to the table 10 by driving fixing screws 46 into threaded holes made in the table 10 .
Attached on lengthwise opposing ends of the bed 2 are end blocks 5 to protect the table 10 against runaway out of the ends of the bed 2 . Recesses 7 are formed at the outermost end faces of the end blocks 5 . An operator may easily lift or carry the slider unit 1 by putting his hands on the recesses 7 . Stoppers 8 of elastic body such as urethane rubber are attached to inside surfaces of the end plates 5 , facing the fore-and-aft ends of the table 10 , to provide buffers for protecting the table 10 from a collision against the end plates 5 .
Moreover, the slider unit 1 is provided with sensor means 33 of an optical linear encoder for detecting the position of the table 2 with respect to the bed 2 . The sensor means 33 includes a strip of optical linear scale 34 disposed lengthwise on an inside surface of a recess 19 sank in the bed 2 nearby a sidewise opening 32 a of the magnet yoke 21 . On the bottom of the recess 19 there is provided an origin mark 35 , shown in FIG. 3, while limit plates 13 are arranged at the lengthwise opposing ends of the recess 19 , one to each end, to define a tolerable range where the table 10 is allowed to move.
Referring to FIGS. 3 and 5 to 7 , there is shown in detail a moving-coil linear motor 20 inboard the slider unit 1 . The moving-coil linear motor 20 is comprised of a magnet yoke 21 of sidewise U-shaped configuration in cross section left open at any one lengthwise side thereof, the magnet yoke being arranged lengthwise of the bed 2 between widthwise opposing linear motion guide units 16 , a pair of field magnets 30 , 31 each of which has poles placed closely side by side in such a way that the poles alternate in polarity lengthwise, with unlike poles on either field magnet opposing directly to each other across an air gap, and a moving-coil assembly 40 supported by a pair of nonmagnetic brazen arms 43 depending from the bottom of the table 10 . The nonmagnetic arms 43 are connected to the table 10 by fixing screws 47 . The field magnets 30 , 31 are made of rare-earth magnet such as neodymium and so on, which is high in magnetic force.
The moving-coil assembly 40 is secured at its fore-and-aft ends to the arms 43 depending from the table 10 in such a way that the assembly 40 extends at the center of the air gap 32 between the confronting field magnets 30 , 31 . The moving-coil assembly 40 is comprised of an iron core 41 having roughly rectangular shaped configuration in cross section and extending lengthwise in parallel with the sliding direction, and armature coils 42 , eighteen coils in total, wound around the iron core 41 in the form of a flat rectangle and placed side by side along the sliding direction. The armature coils 42 are grouped into six three-phase coil sets 42 a ˜ 42 f , each of which includes three coils for U-, V- and W-phase, respectively. Any adjacent coil sets of 42 a ˜ 42 f are wound in the counter direction to each other. Thus, the coils in either coil set alternate in winding direction lengthwise of the table 10 as illustrated in FIG. 6 where the coils in any coil set opposite in winding direction to the coils in the adjacent coil sets are given the reference characters U, V and W under lines.
As will be understood from FIG. 6, an unlike pole pitch Fm in the field magnets 30 , 31 is rendered equal with a pole width Wm: Pm=Wm, while a coil thickness T of any one armature coil 42 , which is measured in the sliding direction of the table 10 , is determined to keep such a relation that a thickness Lt of any one coil set is identical with the pole width: 3T=Wm. Moreover, the iron core 41 , as shown in FIG. 7, is defined to keep a dimensional relation in which a length Lm of the field magnet 30 , 31 measured in perpendicular to the sliding direction of the table 10 is roughly equal with a width Wy of the iron core 41 : Wy≈Lm. An effective length Lc contributing to the propulsion in each armature coil 42 is made somewhat larger than the length Lm of field magnets 30 , 31 . As shown in FIG. 6, a length Ly of the iron core in the sliding direction of the table 10 is given by
Ly=n×Wm+½ Wm, where n is an integer As the iron core is made larger in length than the overall length of the armature coils 42 , spacers 44 are inserted at the fore-and-aft ends of the iron core 41 , one to each end, to compensate for clearances between any one of the fore-and-aft end coils 42 and the associated supporting arm 43 , which is connected to the iron core 41 by a fixing screw 48 .
Installed underneath the table 10 confronting the bed 2 , as shown in FIG. 5, is an optical sensor head 37 for providing a counterpart included in the sensor means 33 to monitor the position of the table 10 with respect to the bed 2 . The optical sensor head 37 is placed at the roughly fore-and-aft midway of the table 10 in opposition to the optical linear scale 34 . The optical sensor head 37 , when sensing an origin mark 35 on the bed 2 , will detect a position corresponding to the origin of the table 10 relatively to the bed 2 . Limit sensors 39 are also attached underneath the table 10 to sense the limit plates 13 arranged at the lengthwise opposing ends of the bed 2 , one to each end, to detect the limit of the stroke range of the table 10 , thus keeping the table 10 from travelling over the tolerated stroke range where the table 10 is allowed to move. Nearby any one of the limit sensors 39 , moreover, a before-the-origin sensor 39 a is installed underneath the table 10 . The before-the-origin sensor 39 a is to sense any limit plate 13 ahead of the detection of the origin mark 35 by the optical sensor head 37 , thereby permitting detection of the situation where the table 10 has reached just before the origin. Thus, the controller may decelerate the table 10 running for the origin, depending on a signal issued from the before-the-origin sensor 39 a.
A wiring board 45 is attached underneath the table 10 . The wiring board 45 has thereon a printed circuit to connect the armature coils 42 , the limit sensors 39 and the before-the-origin sensor 39 a to a power chord 15 and a signal line 14 , which are communicated to any external instruments, thus allowing electric power supply to the armature coils 42 and signal transmission from the limit sensors 39 and the before-the-origin sensor 39 a.
With the slider unit 1 constructed as stated earlier, when the armature coils 42 carry current, the magnetic flux generated so as to revolve around the coil sides of the armature coils interacts with the magnetic flux that exists always in perpendicular to the sliding direction of the table 10 between the field magnets 30 , 31 and the iron core 41 confronting at its both sides the field magnets 30 , 31 . Thus, the armature coils 42 experience a force in the sliding direction according to the Fleming's rule, whereby the table 10 having thereon the moving-coil assembly 40 of more than one armature coil 42 and the iron core 41 is forced to move. Turning over the direction of current in the armature coils 42 in compliance with the direction of magnetic flux created by the field magnets 30 , 31 allows the table 10 to move in a sliding manner to any desired position.
Referring next to FIG. 8, there is shown a condition where the armature coil assembly 40 carries a current. In (a), (b) and (c) of FIG. 8, the armature coil assembly 40 is shown in conditions displaced from each other by an electrical angle of 30 degrees. With the armature coil assembly 40 in which the armature coil sets 42 a ˜ 42 f , each including three coils of U-, V- and W-phase, alternate on winding direction lengthwise of the table 10 , the armature coil assembly 40 carries a current in either position or negative direction in compliance with the direction of the magnetic flux, thus moving rightwards viewed in the figure on the basis of the Fleming's left-hand rule. Since each coil 42 carries a current that varies sinusoidally with time, any armature coil 42 at a boundary between any two adjacent poles as shown in (b) rests to conduct the current. In contrast, other armature coils 42 will carry the current either toward reader or away from reader, thus continuing to drive the armature coil assembly 40 in the direction F. As a result, the table 10 is allowed to make the desired linear motion.
In initial conduction, controller is previously stored with information as to the unlike pole pitch Pm in the field magnets 30 , 31 , resolving-power of the sensor means 33 , direction toward the origin, and so on. The instant the armature coils 42 carry current, the conducting position is detected and the controller starts to regulate the operation of the moving-coil assembly 40 . The moving-coil assembly 40 is firstly servo-locked and then driven to a desired position found according to the detected signal representing the conducting position. When it is desired to make the origin the home position of the operation, the moving-coil assembly 40 is driven initially towards the origin mark 35 . At standstill, no current flows in the moving-coil assembly 40 . To get the moving-coil assembly 40 into motion, accordingly, once the table 10 is moving, the controller begins operating to return the moving-coil assembly 40 to the position where it has come to a standstill. Thus, the moving-coil assembly 40 may remain in whatever position the moving-coil assembly 40 last ceased moving. It will be understood that the controller allows the slider unit 1 to move lengthwise as well as stop moving at any desired position.
Another embodiment of the slider unit according to the present invention will be hereinafter described with reference to FIG. 9 in which there is illustrated the cooperative arrangement of the moving-coil assembly with the field magnets in the slider unit. As the slider unit to be stated later is substantially identical in construction to the first embodiment stated earlier, rather than the configuration of the field magnets, the like reference numerals designate the components or parts identical or equivalent in function with that used in the slider unit stated earlier, so that the previous description will be applicable.
According to the second embodiment, any adjoining poles 52 , 53 of field magnets 50 , 51 are both chamfered off to provide skewed areas 54 at their corners coming into abutment against each other and facing the air gap 32 . In detail, each pole 52 , 53 tapered at its opposing corners is made by chamfering off the widthwise opposing corners, each of which is about one-third of the pole width in length and about two-thirds of the pole thickness in depth. The poles 52 , 53 chamfered at 54 serve for relaxing any influence of field strength, thus providing the ideal distribution, or sinuous distribution of magnetic flux strength to realize a smooth movement of the table 10 .
Finally referring to FIG. 10, there is shown a further another embodiment of the slider unit according to the present invention.
As an arrangement of the field magnets 30 , 31 with a moving-coil assembly 60 for the slider unit in FIG. 10 is substantially identical in construction to the first embodiment stated earlier, rather than the configuration of an iron core 61 , the like reference numerals designate the components or parts identical or equivalent in function with that used in the slider unit stated earlier, so that the previous description will be applicable.
In the embodiment stated later, the iron core 61 is made of a lamination of thin steel sheets overlaid one on another. Although the iron core 41 in the first embodiment, as shown in FIG. 7, is formed in a configuration of roughly rectangular sheet in cross section, the iron core 61 in FIG. 10 is made of more than one thin steel sheet 62 arranged lengthwise in perpendicular to the paired field magnets 30 , 31 and laminated in close contact relation, with an insulating layer being interposed between any two adjoining steel sheets, to form the configuration of rectangular sheet similar to the iron core 41 in the first embodiment. The iron core 61 constructed as stated just above serves well to suppress the generation of eddy current in the iron core 61 to be kept from becoming heated.
While the power capacity of the slider unit according to the embodiments stated earlier is up to 200 W, the power capacity of 100 W would be sufficient. However, the power capacity of 200 W is preferable to provide high propulsion. | A slider unit having built in a moving-coil linear motor ensuring high propulsion, is kept slim in overall height. A moving-coil assembly is made slim, with high stiffness, and is composed of an iron core of platy-configuration, and at least one set of three-phase armature coils wound around the iron core in the form of flat rectangular configuration in a plane intersecting the sliding direction. Comparatively more coil sides of the armature coils contribute to high propulsion. Like poles on either field magnet are placed in opposition to each other across the air gap, whereby the magnetic attraction is cancelled to reduce the load on the linear motion guide unit. | 5 |
This application is a continuation, of application Ser. No. 676,016, filed Nov. 29, 1984, abandoned.
Reference to related applications, the disclosure of which is hereby incorporated by reference, assigned to the assignee of the present application:
U.S. Ser. No. 620,458, filed June 14, 1984, LEIBER now U.S. Pat. No. 4,568,130;
U.S. Ser. No. 620,466, filed June 14, 1984, LEIBER et al now U.S. Pat. No. 4,575,160.
SAE Technical Paper Series No. 830 483, dated Feb. 28-Mar. 4, 1983. The First Compact 4-Wheel Antiskid System with Integral Hydraulic Booster.
The present invention relates to automatic braking systems (ABS), customarily referred to as anti-skid or anti-lock braking systems, for use in vehicles, and especially automotive vehicles, and more particularly to an arrangement which monitors the operability and proper functioning of such an ABS.
BACKGROUND
It has previously been proposed to provide anti-skid systems in which a pump supplies hydraulic fluid to form a pressure source for a closed braking circuit. Valves are included in the braking circuits to, respectively, control admission, maintenance of pressurized brake fluid, or drainage of pressurized brake fluid in accordance with operating requirements of the vehicle. Such systems may include a supply valve which supplies pressurized brake fluid to the actual control valve which varies the braking fluid pressure at the brake, the supply valve insuring that, at all times, sufficient pressurized brake fluid is available for the actual hydraulic brake cylinder-piston arrangement at the respective brakes. It has already been proposed to monitor the pressure within the braking fluid pressure supply which, if the pressure should drop below a predetermined level, issues a warning signal and/or a switching signal which controls supply of the pressurized brake fluid to the supply valve and, rather, permits brake actuation under control from the master cylinder of the braking system.
Braking systems of the above-mentioned type are discussed in an SAE ("Society of Automotive Engineers") report, which describes the system including a warning switch constructed as an opening-type switch which provides an immediate indication if a signal line is interrupted since interruption of the signal line will also simulate opening of the switch. Such opening of the switch or interruption of the signal line is indicated, representing either electrical malfunction or failure of the pressure which is being monitored to drop below a predetermined level.
THE INVENTION
It is an object to improve the warning system to insure proper operation thereof so that, even if there should be some malfunction in the warning system itself, drop in pressure will be reliably indicated.
Briefly, the pressure fluid supply system has at least two switch means coupled thereto, individually connected for individually monitoring the pressure supply system or assembly to provide hydraulic pressure to the brake valve. The system, thus, provides for redundancy in which, one of the switches, preferably, is set for a first switching threshold which normally causes operation of an electrical pressure supply pump to reestablish operating pressure to the hydraulic fluid circuit. If a failure should occur within this system, and pressure continues to drop, the switch will reach a third switching position which provides a warning signal. In addition, a second switch is provided which, at the second lower threshold level, responds in case the first switch did not properly respond.
In accordance with a feature of the invention, the output circuits of the switches are logically interlocked in such a manner that they are mutually checking, and the circuit arranged to be fail-safe, that is, upon malfunction of any component, a warning indication will be given. The warning indication may be of two kinds--first a warning lamp or indication and, secondly, a lock-out of the automatic brake control system (ABS) pending repair thereof, coupled with an indication that the ABS is disconnected and inoperative, leaving the operator of the vehicle to control braking pressure as if no automatic braking control system were present.
The pressure which is applied from the supply valve to the actual brake control valve can be the pressure of the pressure supply system itself; preferably, however, and as described for example in the referenced applications Ser. No. 620,458 and Ser. No. 620,466, both filed June 14, 1984, now U.S. Pat. Nos. 4,568,130 and 4,575,160, the pressure may be a supply pressure derived from the main or master cylinder, and which is to be supplied to the piston or pistons of the master cylinder. The supply valve then can separate the master cylinder from the anti-skid control valves during operation of the anti-skid system (ABS) or, selectively, supply hydraulic pressure, additionally, to the valves controlling the actual brake cylinders, or to the brake cylinders themselves.
DRAWINGS
FIG. 1 is a schematic diagram of the system of the present invention, in which all parts not necessary for an understanding thereof, including drain lines and the like, have been omitted;
FIG. 2 is a detailed diagram of the control valve and switching unit in connection therewith;
FIG. 3 is a schematic diagram of another type of pressure measuring apparatus; and
FIG. 4 is a circuit diagram in schematic, block diagram form of a monitoring arrangement utilizing the brake pressure sensing element of FIG. 3, for example.
DETAILED DESCRIPTION
A master cylinder 1 is connected to a pressure supply system 3 including a pump P coupled to a pump motor 3a and a pressure vessel or storage vessel 3b. A brake pressure amplifier 2 controlled by an operator controllable brake pedal 2a is coupled to the master cylinder 1. The brake pressure is applied via a control valve 4 to the brake cylinder of a wheel 5. Only one control loop for one wheel is shown to simplify the drawings; other valves 4 can be coupled to other wheels 5 similar to the one shown. Only one drain line S' from valve 4 is shown. All other drain and return lines have been omitted from the diagram of FIG. 1 for simplicity, and can be installed as well known in systems of this kind, for example as described in the referenced applications Ser. No. 620,458 and Ser. 620,466, both filed June 14, 1984, now U.S. Pat. Nos. 4,568,130 and 4,575,160.
A pressure sensing switch 6 is coupled to receive pressure fluid from the pumped pressure supply system 3. The switching signals from the pressure sensing switch 6 are applied to an ABS-electronic control unit 7 to which also a sensor provided at wheel 5 is coupled in known manner. The switch 6 as well as the control unit 7 are connected to a warning indicator lamp 8. The pressure sensing switch 6 is connected through a connecting line 6a to the motor 3a. The output signals from the control unit 7 control a supply valve 9 as well as the control valve 4.
The anti-brake lock system (ABS) control unit 7, as well known in the literature, controls operation of the respective valves 4 and 9 via lines 9a and 4a. Lamp 8 is controlled by lines 6c, 7c.
During operation of the ABS, the supply valve 9 provides pumped pressurized supply fluid from the hydraulic brake pressure amplifier, for example of the power-brake type, to the hydraulic brake circuit. This prevents exhaustion of pressurized braking fluid in the master cylinder 1 if the valve 4 is controlled to drain some of the brake fluid back to a supply sump S, through drain line S', in accordance with well known operation of an ABS.
For safety, it is necessary to monitor supply of pumped pressurized brake fluid, reliably and uninterruptedly. In case there is a pressure drop in the pumped supply system 3 and the control value 4 remains energized, a complete loss of brake fluid pressure may result. One embodiment of such a monitoring system is shown in FIG. 2.
Two pressure-responsive piston elements 20, 21--see FIG. 2--are located to fit into a pressure chamber 22 which is supplied with pressurized brake fluid in accordance with the arrow P S , that is, for example at the inlet connection of the unit 6 (FIG. 1). If the pressure in chamber 22 is adequate for proper operation, both piston elements 21, 22 are pushed to their topmost position and the terminals S1, S2, coupled to the piston elements as schematically shown by broken lines 20b, 21b, will be connected as shown in solid lines in FIG. 2. Unit 62, corresponding to unit 6 of FIG. 1, thus includes the pressure supply chamber 22, the pressure-responsive elements and the switches S 1 , S 2 .
The piston elements 20, 21 are normally biassed downwardly by suitable springs 20a, 21a. A return line R is provided to accept any leakage which might arise, and return leakage fluid to the supply sump S (FIG. 1).
The switching thresholds of the switches S 1 , S 2 , determined for example by suitable selection of the diameters of the piston elements 20, 21 and the spring constants of the springs 20a, 21a are so arranged that, if the pressure drops, the switch terminal S 2 will change from the terminal position a to an intermediate position b. In the intermediate position b, the line 6a to the pump motor 3a will be energized thus starting the motor 3a driving the pump, and recharging pressure to the pressure vessel 3b. If, for example due to leakage, malfunction, failure in the connecting line 6a or the like, the pressure should continue to drop, switch S 2 will reach the third position c. In this position an AND-gate 23 will have ground level voltage applied thereto; likewise, ground level voltage will be applied to the input of an inverter 24, so that an OR-gate 25 will receive a signal at one of its input terminals and provide a switching signal to a terminal 26 which, is connected to the control unit 7 (FIG. 1) to block further controlling of the valves 4, 9 so that the system will then operate under operator's control.
Additionally, warning lamp 27 is connected from a voltage source through terminal c of switch S 2 to ground and, hence, will provide an indication of malfunction. Lamp 27, generally, thus has in part the function of lamp 8, FIG. 1.
If pressure within the chamber 22, as communicated at pressure input line P S , continues to drop, switch S 1 will open and, then, cause signals to appear at the second inputs of AND-gate 23 and OR-gate 25. The situation may arise that, due to malfunction, the switch S 2 has not yet effected energization of terminal 26 and hence blocking of values 4 and 9. Blocking, then, is positively commanded by opening of the switching S 1 which, thus, provides for a redundant monitoring of pressure level, and energization of terminal 26 through resistor 26a.
The AND-gate 23 is provided to monitor operability of the switch S 2 . If switch S 2 should malfunction, opening of the switch S 1 will remove the ground from line 6b and provide a malfunction signal to one input of AND-gate 23. Since, under those conditions, switch S 2 has not yet reached its top position, that is terminal c, so that the line from terminal c of switch S 2 is open (not yet grounded), AND-gate 23 will switch due to voltage through resistor 23a and will set over the OR-gate 28 a malfunction memory MF, for example in form of a flip-flop (FF) connected to terminal 29. Malfunction memory MF disconnects the ABS, via terminal MF; until reset through terminal R S , which, preferably, should be so arranged that it can be done only manually, for example after maintenance and repair by authorized repair personnel.
As can be seen, the system is fail-safe due to its inherent arrangement, in which, upon failure of switch operation S 2 , switch S 1 will still respond; of course, break in any one of the lines to the And-gate 23 and Or-gate 25 will have the same effect as switch operation due to the loss of pressure. In either case, a ground connection is removed permitting voltage supplied through resistors 23a or 26a to become effective in controlling the logic system of the gates 23, 25.
In accordance with a feature of the invention, operation of the pump motor 3a can readily be monitored, and specifically if the motor 3a operates too often, or for too long a period of time, thus, for example, indicating a leak or break in a brake fluid line. Timing elements 30, 31, 32 are provided in order to check the operating time of the motor 3a.
The timing elements 30, 31, 32 have such timing periods and are so connected through circuit elements 24, 33, 35 that, if motor 3a operates longer than the timing period T 1 , as determined by the timing circuit 30, a signal is generated which is connected through OR-gate 28 to disable the ABS through terminal 29. Of course, under those conditions, the ABS also provides a warning output signal to the warning indicator 27 (connection not shown) Inverter 33 inverts the signal on line 6a and starts the timing period. The connecting line to the timing circuit 30 is, additionally, connected to a pair of serially connected timing units 31, 32. The timing unit 31 will immediately provide a signal and extend that signal after the input signal applied through line 6a has terminated. The output signal from timing unit 31 is extended by the time period T 2 . The timing constant T 2 of the timing circuit 31 is so dimensioned that, in normal ON-OFF operation, that is, normal connection frequency of the pump motor 3a, the output signal of the timing circuit 31 is terminated before the pump is again connected. The timing circuit 32, with timing constant T 3 , is reset each time in ordinary operation of the pump. The timing constant T 3 is so selected that it provides an output signal only if the pump is connected in shorter intervals than under normal operation for example once or twice in sequence. The timing constant, thus, is greater than that of the usual connection period of the pump plus the ordinary interval period between connecting phases of the pump, for example about twice the normal connection period of the pump. Consequently, the output of the serially connected timing circuits 31, 32 will generate a signal only when the timing circuit 31 provides a signal which, due to the time constant T 2 and the rapid reconnection of the pump exceeds the timing period T 3 .
The system includes further inverters 34, 35 with control terminals 34a and 35a to which a diagnostic test apparatus can be connected to check the operability of the system by coupling appropriate control signals to the terminal 34a or 35a.
The monitoring effected by the AND-gate 23 (FIG. 2) assumes that the tolerance gap of the monitoring thresholds of switches S 1 and S 2 , terminal c, do not overlap, so that, under normal conditions, switch S2 has already switched to terminal position c before, in any event, switch S 1 switches, i.e. opens. This may lead to problems in connection with manufacturing tolerances. The embodiment of the switch 63 (FIG. 3) elimintes such tolerance difficulties.
Embodiment of FIGS. 3 and 4: Redundant measurement of pressure is carried out by means of a Burdon tube and Hall sensors; the respective switching thresholds are obtained by comparator elements.
A pressure sensor 40 in form of a Bourdon tube is secured to a block 40a which receives the pressure signal P S at a connecting inlet 41. In dependence on applied pressure, the Burdon tube 40 more or less deflects away from the block 40a, in the direction of the arrow 42. Magnets 43a, 43b then will be separated more or less from cooperating Hall sensors 44a, 44b secured to block 40a, and thus the output signals of the Hall sensors will change. These output signals are applied to an evaluation circuit 45, the details of which are shown in FIG. 4. Such an evaluation circuit can be readily constructed as an integrated circuit.
FIG. 4 illustrates, again, in schematic form, the Hall sensors 44a, 44b of FIG. 3. Each sensor 44a, 44b is connected to two respective threshold switches 46a, 46b, 47a, 47b, which provide output signals when signals of predetermined level are applied to the respective switches. The threshold levels of the threshold switches are so selected that, for example, the threshold switch 46a, 47a--even under consideration of tolerances--switches just below a pressure limit of, for example, 100 bar applied at inlet 41 (FIG. 3), and threshold switches 46b and 47b switch at a lower threshold level, for example just below 90 bar, and provide respective output signals at the switching levels.
If one or both of the threshold switches 46a or 47a provide a signal, a warning lamp 48 is connected to light to provide an indication of low pressure. At the same time, OR-gate 49 and/or OR-gate 50 are energized to interrupt current supply to a relay 52, normally controlled from the ABS control unit 7. When relay 52 drops out-which will also be the case if there is general malfunction in the system or a break in the line between AND-gate 51 and relay 52, the ABS operation is interrupted, and pressurized fluid which may drain, that is, which is being circulated, is interrupted until sufficient pressure has, again, built up.
The threshold switches 46b and 47b monitor if the threshold switches 46a and 47a are operable. AND-gates 53 and 54 provide this checking feature, the AND-gates 53, 54 being connected in the following logic connection:
S.sub.47b.S.sub.46a and S.sub.46b.S.sub.47a (1).
If one of the AND-gates 53 or 54 provides an error signal based on this combination of these signals, one of the OR-gates 49 and 50 will disconnect the ABS system via AND-gate 51. At the same time, one of the AND-gate 55 or 56 is also blocked thus removing the signal from terminal 57. Lack of a signal a terminal 57, with relay 52 open, is an indication of malfunction of the system. The ABS is then blocked via AND-gate 28a and terminal 29 connected to malfunction memory MF (FIG. 2) until external repair is carried out; alternatively, or additionally, a malfunction memory like memory MF (FIG. 2) can also be SET, to be RESET only upon external intervention, for example at a repair station. The connections can be made as shown in FIG. 2, for example from terminal MF', from the malfunction memory MF to the ABS control unit 7
Various changes and modifications may be made within the scope of the inventive concept. | To improve the reliability of operation of an anti-skid braking system, and to provide a warning indication if malfunction should occur in such a system (ABS), a pressure-responsive switch (6, 62, 63) having two switching elements (S 1 S 2 ; 43a, 44a, 43b, 44b, 46a, 46b, 47a, 47b) is connected to a pressurized hydraulic brake fluid connection line to a control valve for a vehicle brake, the switches providing, respectively, control signals of different levels of pressure applied thereto, and, in case of failure of one switch to respond to a higher pressure level, at which time a pump motor is to be energized to resupply the pressure, a second switch, responsive to a lower pressure value, is provided, providing a further warning indication and, if appropriate, disconnecting the ABS with a disconnect indication to the operator that the braking system is placed back under operator control. | 8 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a toilet flushing device, and more particularly to a dual-flush toilet device that is capable of controlling and saving water thereof with one toilet flushing handle and is commonly applicable to all kinds of toilet cisterns.
[0003] 2. Brief Description of the Related Art
[0004] FIG. 1 illustrates the existing dual-flush toilet device, wherein a toilet flushing handle set 11 is disposed at lateral surface of a toilet cistern 10 . The toilet flushing handle set 11 comprises a first toilet flushing handle 111 and a second toilet flushing handle 112 , wherein the first toilet flushing handle 111 links up with a first connecting rod 113 . One end of the first connecting rod 113 is attached to an end of a first chain 133 , wherein the other end of the first chain 133 is attached to a lower valve body 122 . The lower valve body 122 is disposed on top of a flush valve 120 of an overflow tube 12 and the front side thereof is connected to an auxiliary float body 123 . The second toilet flushing handle 112 links up with a second connecting rod 114 , wherein one end of the second connecting rod 114 is attached to an end of a second chain 132 ; and the other end of the second chain 132 is attached to an upper valve body 121 that is disposed on top of the lower valve body 122 . The second chain 132 is further disposed of a small float ball 131 . When flushing stool, press the first toilet flushing handle 111 to lift the lower valve body 122 and discharge water; since the auxiliary float body 123 positioned in front of the lower valve body 122 has a large volume, the time required for the lower valve body 122 to cover up the flush valve 120 is longer and the discharged water amount is therefore larger. When flushing urine, press the second toilet flushing handle 112 to lift the upper valve body 121 and discharge water; since the small float ball 131 is of small volume, the time required for the upper valve body 121 to cover up the lower valve body 122 is shorter and therefore the discharged water amount is smaller.
[0005] The foregoing prior arts of the dual-flush toilet device (hereinafter the prior arts) are of the following deficiencies:
1. The first and second connecting rods 113 and 114 of different kinds of toilet cisterns are of different pressing angles, therefore the repair parts are not commonly applicable. When the original model's production stops, it has to be replaced by a repair part of different model or different brand, and the water discharge amount is hence inaccurate. 2. The first and second connecting rods 113 and 114 are capable of controlling the water discharge amount; however, the using of the small float ball 131 and the auxiliary float body 123 of the prior art to control water discharge amount is actually not accurate due to the swaying movement of the small float ball 131 and the auxiliary float body 123 caused by the water flow in the toilet cistern 10 .
SUMMARY OF THE INVENTION
[0008] In order to overcome the deficiencies of the prior art, a primary object of the present invention is to provide a dual-flush toilet device that is capable of controlling and saving water thereof with one toilet flushing handle and is commonly applicable to all kinds of toilet cisterns.
[0009] With the above object in mind, the dual-flush toilet device of the present invention comprises an outer casing, a gear set, a ring disk set, a connecting rod set and a drive set; wherein the drive set comprises a toilet flushing handle. By pressing or lifting the toilet flushing handle towards different directions, the discharged water amount can be controlled accurately and thereby achieves the goal of water saving.
[0010] The outer casing is disposed of a ventilation set comprising an air cell disposed in a first casing body thereof, a control valve, a connecting base and an air duct. The drive set is comprised of a toilet flushing handle, a fixing axle cover, a drive rod, a cistern fixing nut and a fixing rotate screw.
[0011] The connecting rod set is comprised of a connecting rod head having a connecting rod, and a stop seat.
BRIEF DESCRIPTION OF THE INVENTION
[0012] The detail structure, the applied principle, the function and the effectiveness of the present invention can be more fully understood with reference to the following description and accompanying drawings, in which:
[0013] FIG. 1 is a perspective view illustrating the prior art;
[0014] FIG. 2 is an exploded perspective view according to the present invention;
[0015] FIG. 3 is a perspective view of the first casing body according to the present invention;
[0016] FIG. 4 is a perspective view of the second casing body according to the present invention;
[0017] FIG. 5 illustrates an embodiment according to the present invention;
[0018] FIG. 6 is a sectional view according to the present invention;
[0019] FIG. 7 is a schematic representation of urine-flushing operation according to the present invention;
[0020] FIG. 8 is a schematic representation of the gear set actuation according to the present invention;
[0021] FIG. 9 is the first I-I sectional view according to the present invention;
[0022] FIG. 10 is the second I-I sectional view according to the present invention;
[0023] FIG. 11 is a schematic representation of stool-flushing operation according to the present invention;
[0024] FIG. 12 is the first II-II sectional view according to the present invention; and
[0025] FIG. 13 is the second II-II sectional view according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0026] The above and further objects and novel features of the invention will more fully appear from the following detailed description when the same is read in connection with the accompanying drawing. It is to be expressly understood, however, that the drawing is for purpose of illustration only and is not intended as a definition of the limits of the invention.
[0027] With reference to FIGS. 2 and 5 , wherein the toilet flushing device A of the present invention comprises an outer casing 2 , a gear set 3 , a ring disk set 4 , a connecting rod set 5 and a drive set 6 .
[0028] Please refer to FIGS. 3 and 4 , wherein the outer casing 2 is comprised of a first casing body 21 and a second casing body 22 . The first casing body 21 has a receiving space 210 , and a plurality of fixing studs 212 is disposed therein. A first axle hole 211 penetrates the center of the first casing body 21 . The second casing body 22 is disposed of a second axle hole 221 and a plurality of fixing hole columns 224 at the inner surface thereof. At least one arc-shaped retaining wall 223 is disposed to surround peripheral edge of the second axle hole 221 , and the fixing hole columns 224 correspondingly fit with the fixing studs 212 to allow a bolt C to screw lock thereon. One of the lateral surface 225 of the second casing body 22 is disposed of a notch 222 .
[0029] The gear set 3 comprises:
a drive seat 31 having a seat body 312 and a first gear 311 disposed at the bottom thereof, wherein at least one third convex rib 313 is disposed at peripheral edge of the seat body 312 , and a housing aperture 314 penetrates through center of the seat body 312 ; a driven seat 32 having a seat body 322 , wherein a second gear disposed at the bottom of the seat body 322 and a third axle hole 323 that is polygonal is disposed at the center of the seat body 322 ; a third gear 33 meshing with the second gear 32 ; a fourth gear 34 meshing with the third gear 33 ; and a fifth gear 35 coaxially linking up with the fourth gear 34 and meshing with the first gear 311 of the drive seat 31 .
[0035] The ring disk set 4 comprising:
a ring disk body 41 having a rounded hole 410 , wherein a plurality of supporting pieces 412 are disposed along the periphery edge of the ring disk body 41 and an arc-shaped groove 415 is disposed at the bottom lateral surface of the ring disk body 41 , with an air hole 416 disposed thereon, as illustrated in FIG. 9 ; further, an arc-shaped chamber 411 and a stop block 414 are provided at the top surface of the ring disk body 41 , wherein a fixing column 413 is convexly disposed at one side of the arc-shaped chamber 411 ; a spring 42 fitting with the fixing column 413 ; and an arc-shaped pushing seat 43 disposed inside the arc-shaped chamber 411 and being pushed by the spring 42 .
[0039] The connecting rod set 5 comprising:
a connecting rod head 51 comprising a connecting rod 514 extends from the periphery edge of a rounded main body 511 , wherein a plurality of hanging holes 515 is disposed at the connecting rod 514 to allow hanging of a chain 516 as illustrated in FIG. 5 ; the rounded main body 511 further comprises a fourth axle hole 512 and a notch 513 , wherein at least one first convex rib 517 is disposed on the inner wall of the fourth axle hole 512 ; a stop seat 52 having a polygon hole 521 , wherein a stop piece 522 and at least one second convex rib 523 are disposed along the periphery edge of the stop seat 52 .
[0042] The drive set 6 comprising:
a toilet flushing handle 61 having a handle body 611 , wherein a rod body 612 extends from one side of the handle body 611 , and a first joining section 615 , a second joining section 613 and an external thread section 614 is disposed on the rod body 612 ; a fixing axle cover 62 having an axle hole 621 penetrating the center thereof to allow insertion of the rod body 612 , and peripheral edge of the fixing axle cover 62 provides an external thread section 622 ; a cistern fixing nut 63 screw locked to the external thread section 622 of the fixing axle cover 62 ; and a fixing rotate screw 64 having an inner thread hole 641 to allow screw locking with the external thread section 614 of the rod body 612 .
[0047] The outer casing 2 of the toilet flushing device A further comprises a ventilation set 7 as illustrated in FIGS. 2 , 3 and 5 . The ventilation set 7 comprises:
an air cell 214 disposed in the first casing body 21 , wherein the air cell 214 has a valve hole 213 to receive a control valve 71 , and is further disposed of a first through hole 215 and a second through hole 216 that are in connection to the valve hole 213 ; the control valve 71 having a control handle 711 extending from the upper end thereof; a connecting base 72 having a hollow through hole 721 , wherein one end of the connecting base 72 fits with the second through hole 216 and the other end of the connecting base 72 fits with an end of an air duct 73 ; and the air duct 73 , wherein the other end thereof is connected to an air connector 931 of a valve body 93 that covers a flush valve 92 as illustrated in FIG. 5 .
[0052] Referring to FIGS. 2 , 5 and 6 , the toilet flushing device A assembled by the foregoing assemblies can be installed to a toilet cistern 90 at a pivot hole 90 thereon; hang one end of the chain 516 on the hanging hole 515 of the connecting rod 514 , and the other end of the chain 516 on a hanging part 932 of a valve body 93 . One side of the valve body 93 suspends on a suspension part 911 of an overflow tube 91 , and the valve body 93 covers a water outlet 94 of the flush valve 92 .
[0053] With reference to FIGS. 7 , 8 , 9 and 10 ; when flushing urine, the user should lift the toilet flushing handle 61 . As the toilet flushing handle 61 is lifted upwards, the rod body 612 links up with the driven seat 32 , the second gear 321 of the driven seat 32 meshes with and actuates the third gear 33 , the third gear 33 meshes with and actuates the fourth gear 34 , the fourth gear 34 rotates and coaxially actuates the fifth gear 35 , and the fifth gear 35 meshes with and actuates the first gear 311 . By the foregoing method a decelerate effect is achieved and the third convex rib 313 fits with the first convex rib 517 in order to allow the rotation of the connecting rod head 51 , thereby control the speed of the connecting rod 514 lifting the valve body 93 to prevent it from moving too fast, and hence the discharged water amount can be smaller.
[0054] With reference to FIGS. 11 , 12 and 13 ; when flushing stool, the user should press the toilet flushing handle 61 . As the toilet flushing handle 61 is pressed downwards, the rod body 612 of the toilet flushing handle 61 links up with the stop seat 52 and drives it to rotate, the second convex rib 523 of the stop seat 52 fits with the first convex rib 517 to rotate the connecting rod head 51 in order to allow the connecting rod 514 to lift the valve body 93 . Since there is no buffer therebetween, the discharged water amount is larger. Further, during the handle-pressing process, the stop piece 522 pushes the arc-shaped pushing seat 43 to drive it to slide along the arc-shaped chamber 411 of the ring disk body 41 ; by the buffer of the spring 42 , the lifting angle of the connecting rod 514 is bigger and thereby extends the water discharging time.
[0055] The ventilation set 7 of the toilet flushing device A adjusts the speed of the valve body 93 covering the flush valve 92 ; it controls the discharged water amount by controlling the amount of air flowing in and out. The covering is faster when the air amount is larger, and the discharged water amount is therefore smaller; and the covering is slower when the air amount is smaller, and the discharged water amount is therefore larger. On the contrary, as the air throughput amount is smaller or without any airflow, the covering time of the valve body 93 is longer since the covering relies on only the water, and the discharged water amount is therefore larger.
[0056] While the invention has been described with reference to a preferred embodiment thereof, it is to be understood that modifications or variations may be easily made without departing from the spirit of this invention, which is defined in the appended claims. | The present invention relates to a toilet flushing device including an outer casing, a gear set, a ring disk set, a connecting rod set and a drive set; wherein the drive set includes a toilet flushing handle. By pressing or lifting the toilet flushing handle towards different directions, the discharged water amount can be controlled accurately and thereby achieves the goal of water saving. | 4 |
This is a division of application Ser. No. 07/716,901 filed Jun. 18, 1991 and now U.S. Pat. No. 5,149,676.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a silicon layer for a semiconductor device having an increased surface area and to a method for manufacturing the same, and more particularly, to a silicon layer having an increased surface area by providing a highly granulated surface area, and a method for manufacturing the same. The highly granulated surface of the silicon layer of the present invention provides greater surface area relative to the surface area of the present silicon layer where both layers have the same (length and width) dimensions.
2. Information Disclosure Statement
In general, as the unit area of the semiconductor device decreases, the integrity thereof increases. This has necessitated an improvement in the stacked capacitor of the semiconductor device to enhance the capacity for storing information. However, upon further increasing the integrity of the semiconductor device, there is still room for improvement in the capacity of the stacked capacitor. To this end, a stacked capacitor has been developed which is constructed with multiple layers to increase the capacitance of the capacitor.
However, with the use of the multiple layered stacked capacitor, the profile of the resulting semiconductor device is usually less than desirable, i.e. slopped. That is when the multi-layered stacked capacitor is used it is difficult to perform a desired contact mask pattern process in the contact region stacked semiconductor device. Furthermore, when depositing a conducting layer on the contact region, an excessively large difference between the resulting conducting layer and the contact region cannot be avoided.
None of the present processes are directed to increasing the effective surface area to yield the advantages disclosed herein. That is, the present processes for forming a silicon layer merely deposit such a layer where needed without any of the subsequent process steps being directed to increasing the effective surface area.
Therefore, it is an object of the present invention to solve the problems set forth above and provide a silicon layer having an increased surface area by forming the surface of the silicon layer into a highly granulated topography, which may be used as a charge storage electrode in a stacked capacitor to enable the capacitance of the stacked capacitor to be increased relative to a prior art stacked capacitor having the same area of the silicon layer but with less granulated topography, and to provide a method for manufacturing the same.
It is a further object of the present invention to provide a highly granulated silicon layer having an increased surface area relative to the surface area of the silicon layer as presently produced.
It is a further object of the present invention to provide a process of making a highly granulated silicon layer having an increased surface area relative to the existing methods of making a silicon layer and its associated surface area.
The preceding objects should be construed as merely presenting a few of the more pertinent features and applications of the invention. Many other beneficial results can be obtained by applying the disclosed invention in a different manner or modifying the invention within the scope of the disclosure. Accordingly, other objects and a fuller understanding of the invention may be had by referring to both the Summary of the Invention and the Detailed Description, below, which describe the preferred embodiment in addition to the scope of the invention defined by the claims considered in conjunction with the accompanying drawings.
SUMMARY OF THE INVENTION
A silicon layer having an increased surface area in a highly granulated form, and a method for manufacturing such a layer of the present invention is defined by the claims with a specific embodiment shown in the attached drawings. For the purpose of summarizing the invention, the invention relates to a process for manufacturing a highly granulated silicon layer on a substrate, that is, a unit semiconductor element, e.g. a MOSFET, which is partially completed on a silicon substrate or a silicon substrate, and which comprises sequentially depositing a first insulating layer, a first silicon layer and a second insulating layer on the silicon substrate. A second silicon layer is deposited on the second insulating layer which simultaneous unevenly etches away the second insulating layer forming a plurality of pin holes through the second insulating layer to expose the first silicon layer thereunder at each pin hole. The first silicon layer and the second silicon layer are preferably selected from a group consisting of poly silicon and amorphous silicon. The second silicon layer is etched to expose the second insulating layer and the first silicon layer exposed at each pin hole of the plurality of pin holes formed in the second insulating layer. The first silicon layer exposed by the plurality of pin holes formed in the second insulating layer is etched to form a plurality of cavities into the first silicon layer. The second insulating layer is etched to removed it and simultaneously deepen each cavity of the plurality of cavities to form a highly granulated silicon layer having an effectively increased surface area. The second insulating layer may be removed while simultaneously deepening each cavity of said plurality of cavities by successively performing an over-etching process. Thereafter the resulting structure is wet-etched by dipping into HF solution to that the second insulating layer is completely removed.
Preferably, an additional silicon layer, hereafter referred to as a third silicon layer, is deposited to a predetermined thickness on the entire surface of the first silicon layer to repair any damage that may have occurred to the surface of the first silicon layer caused by removing the second insulating layer thereby forming a damage protected and highly granulated silicon layer resulting in an effectively increased surface area. The third silicon layer is preferably selected from the group consisting of polysilicon and amorphous silicon.
The second insulating layer formed on the first silicon layer may be formed with an oxide layer by forming the oxide layer to a thickness of 5-30 Angstroms on the first silicon layer utilizing a solution of H 2 SO 4 and H 2 O 2 . Also, the second insulating layer formed on the first silicon layer may be formed with an oxide layer by forming the oxide layer to a thickness of 100-500 Angstroms on the first silicon layer at a temperature of 800-900 degrees Celsius in the presence of oxygen. The resulting oxide layer is then dry-etched, i.e. anisotropically etched, to a thickness of 50-200 Angstroms.
The second insulating layer deposited on the first silicon layer may be ion-implanted to enhance the cohesion of the second insulating layer to the first silicon layer.
The plurality of cavities is formed by dry-etching the second silicon layer, any remaining layer of the second insulating layer and the first silicon layer exposed by the plurality of pin holes, such that the ratio of the etching selectivity of the first and second silicon layer to the remaining 3A second insulating layer is over 5:1. The dry-etching process preferably takes place in the presence of a gas selected from the group consisting of Cl 2 and SF 6 .
Preferably, each cavity of the plurality of cavities is deepened by wet-etching until the second insulating layer is completely removed.
The second embodiment of the present invention is a process for manufacturing a highly granulated silicon layer, on a silicon substrate comprising sequentially depositing a first insulating layer, such as an oxide or a nitride, and a first silicon layer, such as a polysilicon and an amorphous silicon, on the surface of the silicon substrate. Preferably, the thickness of the first silicon layer is from several hundred to several thousand Angstroms. A second insulating layer is deposited on the first silicon layer. The second insulating layer is preferably formed of an oxide having a thickness of 100-500 Angstroms. The second insulating layer is etched in a manner to unevenly erode the second insulating layer such that the thickness of the second insulating layer varies and a plurality of pin holes is formed in the second insulating layer with each hole exposing a portion of the first silicon layer. The second insulating layer is preferably etched by dry-etching or by sputter-etching. The first silicon layer exposed by the plurality of pin holes in the second insulating layer is etched to form a plurality of cavities in the first silicon layer and to further etch the unevenly eroded second insulating layer. The first silicon layer and the second insulating layer are selectively etched to deepen each cavity of the plurality of cavities and to remove the second insulating layer. The plurality of cavities formed in first silicon layer is successively etched to deepen each cavity and to remove the second insulating layer to form a highly granulated silicon layer having increased surface area.
Preferably, selective etching is performed by anisotropic etching utilizing a gas selected from the group consisting of Cl 2 or SF 6 such that the ratio of the etching selectivity of the first silicon layer to the remaining second insulating layer is over 5:1. After successively etching the plurality of cavities a wet-etching process is performed by dipping the resulting structure into HF solution in order to ensure that the second insulating layer is completely removed. After the wet-etching process an additional silicon layer, hereafter referred to as a third silicon layer 16, is preferably deposited to a predetermined thickness on the entire surface of the first silicon layer to repair any damage that may have occurred to the surface of the first silicon layer caused by removing the second insulating layer thereby forming a damage protected and highly granulated silicon layer resulting in an effectively increased surface area.
The present invention further includes the highly granulated silicon layer produced by the present process.
The more pertinent and important features of the present invention have been outlined above in order that the detailed description of the invention which follows will be better understood and that the present contribution to the art can be fully appreciated. Additional features of the invention described hereinafter form the subject of the claims of the invention. Those skilled in the art can appreciate that the conception and the specific embodiment disclosed herein may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes of the present invention. Further, those skilled in the art can realize that such equivalent constructions do not depart from the spirit and scope of the invention as set forth in the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
For fuller understanding of the nature and objects of the invention, reference should be had to the following detailed description taken in conjunction with the accompanying drawings in which:
FIG. 1 is an enlarged photograph illustrating the surface state of the silicon layer as presently produced;
FIG. 2 is an enlarged photograph illustrating the surface state of the silicon layer according to the present invention;
FIGS. 3A through 3E are process steps for forming a silicon layer according to the first embodiment of the present invention; and
FIGS. 4A through 4E are process steps for forming a silicon layer according to the second embodiment of the present invention.
Similar reference characters refer to similar parts throughout the several views of the drawings.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows a SEM (Scanning Electron Microscope with a magnification ratio of 25,000:1) photograph of the surface of the silicon layer for a charge storage electrode prepared according to a prior art process, i.e. without any of the process steps subsequent to depositing the silicon layer being directed to increasing the effective surface area of this layer.
FIG. 2 shows a SEM (Scanning Electron Microscope with a magnification ratio of 25,000:1) photograph of the surface of the silicon layer for charge storage electrode, absent the third silicon layer 7,16 (described below) according to the present invention.
On comparing the photographs, it can be readily appreciated that the surface of the silicon layer of FIG. 2 is more granulated than the surface of the prior art silicon layer of FIG. 1. Thus, the silicon layer of the present invention has a greater surface area relative to the silicon layer of the prior art.
FIGS. 3A through 3E present process steps for manufacturing a silicon layer according to the first embodiment of the invention.
Referring to FIG. 3A, it is assumed that either a silicon substrate 10 is formed or a unit semiconductor element, for example a MOSFET etc., (not shown) which is partially completed is formed on the silicon substrate 10 upon which the silicon layer according to the present invention will be deposited. A first insulating layer 1, for example, an oxide layer or a nitride layer, is formed on the resulting structure of the silicon substrate 10. A first silicon layer 2, for example, a poly silicon layer or an amorphous silicon layer, is then deposited to a predetermined thickness of several hundred to several thousand Angstroms on the entire surface of the first insulating layer 1. A second insulating layer 3, for example, an oxide layer or a nitride layer, is deposited to a predetermined thickness on the entire first silicon layer 2.
Two methods are described for forming the second insulating layer 3 as an oxide layer. One method is to form an oxide layer by developing it to a thickness of 5-30 Angstroms for about 10 minutes in the mixture solution of H 2 SO 4 and H 2 O 2 . The second method is to form an oxide layer by developing it to a thickness of 100-500 Angstroms at a temperature of 800-900 degrees Celsius in a furnace, with the simultaneous application of Oxygen gas, which is the conditional gas, and by either dry-etching or sputter-etching the resulting oxide layer to the extent of a thickness of, approximately, 50-200 Angstroms, utilizing a gas such as either CHF 3 or CF 4 gas.
After the second insulating layer 3 has been deposited, an ion-implanting process is performed on the second insulating layer 3 to promote the formation of the pin holes through the second insulating layer during the deposition of the second silicon layer 5. It is believed that the ion-implant process increases the cohesion of the oxide layer 3 resulting in a more dense layer which is more easily eroded during the deposition of the second silicon layer 5. and which is more easily etched during the following etching process (FIGS. 4A and 4B) However, other explanations are possible and the inventor does not consider that this explanation is the only explanation.
FIG. 3B illustrates a cross section in which a second silicon layer 5, for example, a poly silicon layer or an amorphous silicon layer, is deposited on the second insulating layer 3. Here, when the second silicon layer 5 is deposited on the second insulating layer 3, the second insulating layer 3 is also unevenly etched to thereby form a plurality of pin holes 4 therein, due to the relative thinness of the second insulating layers 3. Thus, portions of the second insulating layer 3 remain on the first silicon layer 2 (a first remaining layer 3A) thereby exposing portions of the first silicon layer 2 as shown in the drawing. The second silicon layers 5 will contact the exposed first silicon layer 2 through the plurality of pin holes 4 as illustrated at FIG. 3B.
Referring to FIG. 3C, the second silicon layer 5, the remaining second insulating layer 3 (first remaining layer 3A) and the first silicon layer 2 are sequentially etched to completely remove the second silicon layer 5, to etch into the first silicon layer 2 and to only minimally etch the remaining 3A second insulating layer 3. This result is due to the etching selectivity of the first and second silicon layer 2, 5 which have a ratio greater than the etching selectivity of the first remaining layer 3A of the second insulating layer 3. In this embodiment, anisotropic etching having the etching selectivity as mentioned above is performed utilizing a gas, such as Cl 2 or SF 6 , under conditions where the ratio of the etching selectivity of the first and second silicon layer 2, 5 to the second insulating layer 3 (first remaining layer 3A) is over 5:1.
Each of the pin holes of the plurality of pin holes is then successively etched to form a plurality of cavities 6A into the first silicon layer 2. During the formation of the cavities minimal etching of the remaining 3A second insulating layer 3 takes place to result in a second remaining layer 3B of the second insulating layer 3.
FIG. 3D illustrates a sectional view in which the second remaining layer 3B of the second insulating layer 3 shown in FIG. 3C is completely removed by successively performing an over-etching process, and each cavity 6A of the plurality of cavities is further etched into the first silicon layer 2 to deepen each cavity 6B of the plurality of cavities.
Referring to FIG. 3E, in order to completely remove any of the second remaining layer 3B of the second insulating layer 3 present after the etching process, FIG. 3D, wet-etching is performed by dipping the resulting structure as illustrated in FIG. 3D into HF solution. During this process, the surface of the first silicon layer 2 can be undesirably damaged. In order to repair or guard against this problem, a third silicon layer 7 is deposited to a predetermined thickness on the entire surface of the resulting structure as shown in FIG. 3E. As described above, a silicon layer having increased surface area 8 can be obtained by granulating the surface according to the invention.
FIGS. 4A through 4E illustrate process steps for manufacturing a silicon layer according to the second embodiment of the invention. In this embodiment, the extended surface area of the silicon layer is granulated, by directly forming a plurality of holes 14B into the first silicon layer 12 without the step forming the second silicon layer 5 of FIG. 3B.
Referring to FIG. 4A, it is assumed that a silicon substrate 20 is formed or a unit semiconductor element (not shown) which is partially completed is formed on the silicon substrate 20. A first insulating layer 11, for example, an oxide layer or a nitride layer, is formed on the resulting structure of the silicon substrate 20. A first silicon layer 12, for example, a poly silicon layer or amorphous silicon layer, is then deposited to a predetermined thickness of several hundred to several thousand Angstroms on the entire surface of the first insulating layer 11. A second insulating layer 13 is then deposited, for example, an oxide layer or a nitride layer, on the first silicon layer 12. If an oxide layer is used as the second insulating layer 13, the thickness of the oxide layer of 100-500 Angstroms is desirable. Here, the method for forming the second insulating layer 13 with the oxide layer on the first silicon layer 12 and the method of ion-implantation are the same methods which were fully described in connection with FIG. 3A. Hence, the description hereat will be abbreviated in order to avoid any unnecessary repetition.
FIG. 4B illustrates the second insulating layer 13 (first remaining layer 13A) unevenly formed on the first silicon layer 12 as a result of dry-etching the second insulating layer 13 of FIG. 4A. The second insulating layer 13 may also be sputter-etched to attain the layer as illustrated in FIG. 4B. Dry-etching or sputter-etching results in the second insulating layer 13 so etched to have an uneven thickness, so that a plurality of first holes 14 is formed into the thickness of the second insulating layer 13. And when the second insulating layer 13 which has been unevenly etched, is etched again, each hole of the plurality of first holes 14 is additionally etched, so that a plurality of pin holes 15 is formed to expose a portion of the first silicon layer 12 through the first remaining layer 13A of the second insulating layer 13.
The exposed first silicon layer 12 and the first remaining layer 13A of the second insulating layer 13, FIG. 4B, are sequentially etched to form a plurality of cavities 14A into the first silicon layer 12 and to further etch the remaining 13A second insulating layer 13 to a second remaining layer 13B, as illustrated at FIG. 4C. In this etching step, the etching selectivity of the first silicon layer 12 has a ratio greater than that of the first remaining layer 13A of the second insulating layer 13. In this embodiment, anisotropic etching having the etching selectivity as mentioned above is performed utilizing a gas selected from either Cl 2 or SF 6 , under the condition that the ratio of the etching selectivity of the first silicon layer 12 to the remaining layer 13A of the second insulating layer 13 is over 5:1. As a result, the exposed first silicon layer 12 and the first remaining layer 13A of the second insulating layer 13 are etched as described above to form each cavity 14A of the plurality of cavities into the first silicon layer 12 and to further etch the remaining layer 13A of the second insulating layer 13 to the remaining layer 13B, as shown in FIG. 4C. It is noted that since the etching rate of the first silicon layer 12 is faster than that of the first remaining layer 13A of the second insulating layer 13, the plurality of cavities are formed both at the plurality of pin holes 15, where the first silicon layer 12 is exposed, and at those portions of the first silicon layer 12 which are beneath each first hole of the plurality of the first holes 14 where the first remaining layer 13A of the second insulating layer 13 is very thin.
Referring to FIG. 4D, each cavity 14A of the plurality of cavities is deepened to result in a cavity 14B by successive etching of the exposed first silicon layer 12 into which the plurality of the cavities 14A are formed, until the remaining layer 13B of the second insulating 13 is completely etched away. The extent of the depth of each cavity 14B of the plurality of cavities is determined depending upon both the irregularity of the thickness of the first remaining layer 13A of the second insulating layer 13 as shown in FIG. 4B and the etching selectivity of the first silicon layer 12 and the first remaining layer 13A of the second insulating layer 13.
Referring to FIG. 4E, in order to completely remove the second remaining layer 13B of the second insulating layer 13, in the event some remains after the etching process, wet-etching is performed by dipping the resulting structure, as shown in FIG. 4D, into HF solution. During this step since there is a difference in etching selectivity between the first silicon layer 12 and the first remaining layer 13A of the second insulating layer 13, the surface of the first silicon layer 2 may be undesirably damaged by the wet-etching process. In order to recover or guard against the problem of a damaged surface, a second silicon layer 16 is deposited to a predetermined thickness on the entire surface of the resulting structure as shown in FIG. 4E. As described above, a silicon layer having increased surface area 17 can be obtained by granulating the surface according to the process of the invention.
The use of the silicon layer obtained by the first and second embodiments of the invention in a charged storage electrode for stacked capacitor of the semiconductor device increases the capacitance of the stacked capacitor by increasing the effective surface area of the silicon layer for charge storage electrode within the same surface area.
The resulting silicon layer with the highly granulated surface for use in a semiconductor device as illustrated at FIGS. 3D and 4D comprises a first insulating layer 2, 11 formed on the device for electrical insulation of the highly granulated surface silicon layer. The first silicon layer formed on the first insulating layer 2, 11 includes a plurality of deepened cavities 6B,14B formed in the first silicon layer. The resulting increased granulation of the silicon surface forms the highly granulated surfaced silicon layer with an increased surface area. To form a damage protected and highly granulated surfaced silicon layer with an increased surface area, a third silicon layer 7, 16 is formed on the first silicon layer as illustrated at FIGS. 3E and 4E. FIG. 1 is the actual electron microscope illustration according to the present invention, absent the third silicon layer 7, 16 which distinguishes the surface topography of the present invention from that of the prior art surface topography as shown in FIG. 2.
Although this invention has been described in its preferred form with a certain degree of particularity, it is appreciated by those skilled in the art that the present disclosure of the preferred form has been made only by way of example and that numerous changes in the details of the construction, combination and arrangement of parts may be resorted to without departing from the spirit and scope of the invention. | A silicon layer having an increased surface area by providing a highly granulated surface area, and a method for manufacturing the same are disclosed. The highly granulated surface of the silicon layer of the present invention provides greater surface area relative to the surface area of the present silicon layer where both layers have the same (length and width) dimensions. The present invention provides a silicon layer for a charge storage electrode having an increased surface area by forming the surface of the silicon layer into a highly granulated topography, which is used as a charge storage electrode, to enable the capacitance of the stacked capacitor to be increased relative to a prior art stacked capacitor having the same area of the silicon layer but with less granulated topography, and provides a process of making a highly granulated silicon layer having an increased surface area relative to the existing methods of making a silicon layer and its associated surface area. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to orthopedic braces. More particularly, the present application describes a hinge for an orthopedic brace having a condyle pad that is adjustable toward and away from a joint.
2. Description of the Related Art
Orthopedic knee braces are typically worn either to support a healthy knee joint and prevent injury, or to stabilize a knee joint that has been destabilized by an injury or other condition. These braces generally include rigid structural components that support or stabilize the knee joint. The rigid structural components are dynamically linked together by one or more hinges that enable controlled pivotal movement of the knee joint during user activity or rehabilitative therapy. The brace is positioned on the leg such that the hinges traverse the knee joint, while the rigid components are secured to the leg above and below the knee joint.
Osteoarthritis is a degenerative disease that destabilizes the knee joint. The disease commonly results from aging, knee joint overuse, or injury. A person afflicted with osteoarthritis suffers chronic pain when his or her knee joint is statically or dynamically loaded. The pain is caused by an unbalanced loading on the knee joint. The unbalanced loading often closes a compartment between the condyles of the femur and tibia. When these condyles contact one another, their contacting surfaces develop painful abrasions.
Wearing an orthopedic knee brace on the affected leg is one common noninvasive method of treating osteoarthritis pain. These braces apply a force to a medial or lateral side of the knee in order to unload the affected compartment of the knee joint and eliminate contact between the femur and tibia. U.S. Pat. No. 5,277,698 discloses an example of such a brace. This brace applies a force to the knee on that side of the knee remote from the compartment having osteoarthritis as the knee moves to extension. Preferably, the force is applied at a point about 10° to 15° posterior of the normal axis of rotation of the knee.
U.S. Pat. No. 5,586,970 discloses a knee brace having a medial condylar pad 34 and a lateral condylar pad 36 that are each independently adjustable in side-to-side motion. This independent adjustment permits either medial condylar pad 34 or lateral condylar pad 36 to have variable pressure with respect to a user's knee 26 .
U.S. Pat. No. 5,807,294 discloses a hinge assembly 14 for an orthopedic knee brace 10 that pivotally couples an upper arm 34 and a lower arm 46 . The hinge assembly includes a pad assembly 24 , 26 , a hinge 22 , and upper and lower adjustment members 74 , 88 enabling adjustment of the normal force applied by the hinge assembly to the knee joint for the treatment of osteoarthritis. The hinge includes an end of the upper arm, an end of the lower arm, outer and inner hinge plates 58 , 60 positioned on opposite sides of the ends, and upper and lower hinge fasteners 68 , 82 . The upper and lower hinge fasteners each have a bore therethrough that is internally threaded. The upper hinge fastener rotatably connects the end of the upper arm to the outer and inner hinge plates and the lower hinge fastener rotatably connects the end of the lower arm to the outer and inner hinge plates. The upper adjustment member has external threads that are received by the internal threads of the upper hinge fastener to telescopically couple the upper adjustment member to the upper hinge fastener. The lower adjustment member likewise has external threads that are received by the internal threads of the lower hinge fastener to telescopically couple the lower adjustment member to the lower hinge fastener. Both the upper and lower adjustment members have ends that are substantially fixedly coupled to the pad holder. As a result, the pad assembly is selectively displaceable toward or away from the hinge when the user selectively displaces the upper and lower adjustment members through the upper and lower bores of the upper and lower hinge fasteners.
No current brace allows a wearer to provide greater pressure on an anterior portion of his or her knee as compared to a posterior portion. Such a brace would be advantageous for both treating and preventing certain types of injuries.
SUMMARY OF THE INVENTION
The preferred embodiments of the brace hinge with telescoping condyle pad have several features, no single one of which is solely responsible for their desirable attributes. Without limiting the scope of this brace hinge with telescoping condyle pad as expressed by the claims that follow, its more prominent features will now be discussed briefly. After considering this discussion, and particularly after reading the section entitled “Detailed Description of the Preferred Embodiments,” one will understand how the features of the preferred embodiments provide advantages, which include the capability to apply greater pressure to an anterior portion of a joint than to a posterior portion of the joint, and vice versa.
A preferred embodiment of the brace hinge comprises a first hinge plate including an anterior aperture and a posterior aperture. A lateral/medial force application assembly is attached to the first hinge plate by an anterior adjustment member and a posterior adjustment member. The adjustment members are connected at a medial end of each to the force application assembly, and the anterior adjustment member telescopingly engages the anterior aperture and the posterior adjustment member telescopingly engages the posterior aperture, such that manipulation of the adjustment members enables adjustment of a distance between the first hinge plate and the force application assembly.
Another preferred embodiment comprises a method of treating a knee. The method comprises the steps of applying a brace to a leg including the knee, and applying pressure to a medial or lateral side of the knee. The pressure is applied to the knee such that an anterior portion of the knee is under greater pressure than a posterior portion of the knee, or vice versa.
BRIEF DESCRIPTION OF THE DRAWINGS
The preferred embodiments of the brace hinge with telescoping condyle pad, illustrating its features, will now be discussed in detail. These embodiments depict the novel and non-obvious brace hinge with telescoping condyle pad shown in the accompanying drawings, which are for illustrative purposes only. These drawings include the following figures, in which like numerals indicate like parts:
FIG. 1 is a perspective view of a preferred embodiment of the hinge with telescoping condyle pad according to the present invention;
FIG. 2 is an exploded perspective view of the hinge of FIG. 1;
FIG. 3 is a front elevation view of the hinge of FIG. 1;
FIG. 4 is a right-side elevation view of the hinge of FIG. 1;
FIG. 5 is a right-side section view of the hinge of FIG. 1 taken along the line 5 — 5 of FIG. 3;
FIG. 6 is a perspective view of a loading screw of the hinge of FIG. 1;
FIG. 7A is a top section view of the hinge of FIG. 1 taken along the line 7 — 7 of FIG. 4, illustrating the medial/lateral force application assembly at a minimum extension from the hinge;
FIG. 7B is a top section view of the hinge of FIG. 1 taken along the line 7 — 7 of FIG. 4, illustrating the medial/lateral force application assembly at a maximum extension from the hinge; and
FIG. 7C is a top section view of the hinge of FIG. 1 taken along the line 7 — 7 of FIG. 4, illustrating the medial/lateral force application assembly in an orientation for applying greater force to a posterior portion than to an anterior portion of a wearer's knee.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 illustrates a preferred embodiment of the brace hinge with telescoping condyle pad. The hinge 20 is preferably a component of a knee brace (not shown) that is designed to treat osteoarthritis. Those of skill in the art will appreciate, however, that the hinge 20 is adapted for use in a variety of braces, including prophylactic knee braces worn about healthy knees, and braces for parts of the body other than the knee. For simplicity, the construction and function of the hinge 20 will be described with reference to a knee brace.
The illustrated hinge 20 is adapted for use on a lateral side of a right leg, or a medial side of a left leg. Those of skill in the art will appreciate that a substantially identical hinge having a mirror image configuration would be adapted for use on a medial side of a right leg, or a lateral side of a left leg. For simplicity, the present hinge 20 will be described with reference to a lateral side of a right leg. The scope of the present hinge 20 is not, however, limited to an application to a lateral side of a right leg.
The hinge 20 comprises a proximal arm 22 and a distal arm 24 pivotably engaging a hinge assembly. The hinge assembly comprises a lateral hinge plate 26 and a medial hinge plate 28 , as shown in the exploded view of FIG. 2 . Each of the hinge plates 26 , 28 is substantially oval in front elevation aspect (FIG. 3 ), and each includes a proximal aperture 30 and a distal aperture 32 (FIG. 2 ). The proximal aperture 30 is located substantially in the center of a proximal half of each hinge plate 26 , 28 , and the distal aperture 32 is located substantially in the center of a distal half of each hinge plate 26 , 28 .
Each of the hinge plates 26 , 28 also includes an anterior aperture 34 and a posterior aperture 36 . Each anterior aperture 34 is located near a center of an anterior edge 38 of its respective plate, and each posterior aperture 36 is located near a center of a posterior edge 40 of its respective plate. Those of skill in the art will appreciate that the apertures 34 , 36 need not be arranged in the fashion illustrated. Both could for example, be located toward one side of the hinge plates, or be spaced from a proximal/distal axis of the hinge plates. The anterior and posterior apertures 34 , 36 include internal threads that cooperate with an anterior loading screw 44 and a posterior loading screw 46 , respectively, to adjust an amount of pressure exerted on a lateral side of the wearer's knee, as explained below.
The proximal arm 22 is a substantially flat plate having a hinge-engaging portion 48 at a distal end, and an upright-engaging portion 50 at a proximal end. The upright-engaging portion 50 is substantially rectangular, while the hinge-engaging portion 48 has a complex perimeter, including an anterior shoulder 52 , a posterior shoulder 54 , and a plurality of gear teeth 56 along proximal and posterior edges. The proximal arm 22 includes a pivot aperture 58 near the distal end. The distal arm 24 is substantially identical to the proximal arm 22 , but is a substantial mirror image of the proximal arm 22 about a line that passes through a center of the hinge 20 in an anterior/posterior direction.
In a knee brace, the proximal arm 22 preferably engages a rigid proximal upright (not shown), and the distal arm 24 preferably engages a rigid distal upright (not shown). The proximal and distal uprights are secured to the wearer's thigh and calf, respectively, with straps, cuffs or other suitable attachment devices. The uprights and their attachment devices thus anchor the brace to the wearer's leg and enable the brace to provide the advantages outlined below.
The proximal and distal arms 22 , 24 are sandwiched between the lateral and distal hinge plates 26 , 28 such that the pivot aperture 58 on the proximal arm 22 is coaxial with the proximal apertures 30 of the hinge plates 26 , 28 , and the pivot aperture on the distal arm 24 is coaxial with the distal apertures 32 of the hinge plates 26 , 28 . The arms 22 , 24 are preferably attached to the hinge plates 26 , 28 with rivets or other suitable attachment members that allow the arms to pivot with respect to the hinge plates 26 , 28 . In the embodiment of FIG. 5, a pair of lateral rivets 60 pass through the proximal and distal apertures 30 , 32 of the lateral hinge plate 26 , through the pivot apertures of the proximal and distal arms 22 , 24 , and through the proximal and distal apertures 30 , 32 of the medial hinge plate 28 . Those of skill in the art will appreciate that other attachment devices and methods could be used instead of the attachment configuration shown.
An optional extension stop 62 (FIG. 2) is mounted to a lateral face 64 of the medial hinge plate 28 near a center of the anterior edge 38 . The anterior shoulder 52 of each arm 22 , 24 cooperates with the extension stop 62 to define a maximum extension angle for each arm 22 , 24 . An optional flexion stop (not shown) is securable to the medial hinge plate 28 near a center of the posterior edge 40 . The posterior shoulder 54 of each arm cooperates with the flexion stop to define a maximum flexion angle for each arm 22 , 24 .
In the illustrated embodiment, the extension stop 62 includes proximal and distal apertures 66 , 68 that align with corresponding apertures 70 , 72 adjacent the anterior edge 38 of the medial hinge plate 28 . The extension stop 62 is secured to the medial hinge plate 28 with threaded fasteners, rivets, or other suitable attachment members that cooperate with the apertures 66 , 68 , 70 , 72 . The optional flexion stop, if one is provided, is secured to the medial hinge plate 28 in a similar fashion. Those of skill in the art will appreciate that the stops could be secured to the hinge plates 26 , 28 in a variety of alternate ways, such as with an adhesive. Those of skill in the art will further appreciate that neither the extension stop 62 nor the flexion stop is essential to achieving the advantages of the hinge 20 .
As illustrated in FIG. 2, an axis of rotation 74 of the proximal arm 22 is parallel to, but spaced from, an axis of rotation 76 of the distal arm 24 . Such a bicentric hinge assembly more closely approximates the bending dynamics of the human knee, as is well understood in the art of orthopedic bracing. Those of skill in the art will appreciate, however, that the features and advantages of the present hinge 20 may also be achieved with a monocentric hinge.
Preferably, a lateral spacer 78 separates the lateral hinge plate 26 from the arms 22 , 24 , and a medial spacer 80 separates the medial hinge plate 28 from the arms 22 , 24 . Each of the spacers 78 , 80 is shaped substantially the same as the hinge plates 26 , 28 , including a substantially oval-shaped perimeter and proximal and distal apertures 82 , 84 . The spacers 78 , 80 are oriented such that their proximal and distal apertures 82 , 84 align with the proximal and distal apertures 30 , 32 , respectively, of the hinge plates 26 , 28 . The spacers 78 , 80 are preferably constructed of a material having a low coefficient of friction, such as a plastic. The spacers 78 , 80 thus enable the arms 22 , 24 to rotate more easily within the hinge assembly. Those of skill in the art will appreciate that the spacers 78 , 80 could be shaped much differently, or could be eliminated entirely, without departing from the spirit of the hinge 20 .
A lateral/medial force application assembly 86 telescopingly engages the hinge assembly on a medial side, as shown in FIGS. 4, 5 and 7 A- 7 C. The assembly comprises a rigid loading plate 88 and a substantially rigid condyle shell 90 . For comfort, a resilient pad (not shown) may be attached to a medial surface of the shell 90 . Either the shell 90 or the optional pad applies selective pressure to the lateral side of the wearer's right knee in a manner described below.
The loading plate 88 is substantially oval shaped and includes a proximal aperture 92 (FIGS. 2 and 7A) and a distal aperture 94 corresponding to the proximal and distal apertures 30 , 32 , respectively, of the hinge plates 26 , 28 . The condyle shell 90 is also substantially oval shaped and includes proximal and distal apertures 96 , 98 (FIGS. 2 and 5) corresponding to the proximal and distal apertures 30 , 32 , respectively, of the loading plate 88 . A medial surface 100 of the loading plate 88 is secured to a lateral surface 102 of the condyle shell 90 , as shown in FIG. 5 . In the illustrated embodiment, the loading plate 88 is secured to the condyle shell 90 via a pair of medial rivets 104 that cooperate with the proximal and distal apertures 92 , 94 , 96 , 98 on the loading plate 88 and condyle shell 90 . Those of skill in the art will appreciate that the loading plate 88 and the condyle shell 90 could be secured to one another by other appropriate methods, such as by an adhesive.
Adjustment of the loading plate 88 and condyle shell 90 provides selective pressure on the wearer's knee, as described below. Thus, the loading plate 88 is preferably constructed of a rigid material such as a metal. In the illustrated embodiment, anterior and posterior edges 106 , 108 (FIGS. 2 and 7A) of the loading plate 88 are bent away from a plane of the plate 88 in a lateral direction. The bent edges 106 , 108 increase the bending strength of the plate 88 , enhancing the ability of the plate 88 to apply pressure to the wearer's knee. Those of skill in the art will appreciate that the bent edges 106 , 108 are not necessary to achieve the advantages of the hinge 20 .
The loading plate 88 includes an anterior slot 110 (FIGS. 2 and 7A) running in an anterior/posterior direction. The anterior slot 110 is located near a center of the loading plate 88 as measured in a proximal/distal direction. The anterior slot 110 includes a wide portion at a posterior end 114 , and a narrow portion at an anterior end 116 . The loading plate 88 also includes a posterior slot 112 that is substantially identical to the anterior slot 110 , but is a mirror image of the anterior slot 110 about a line bisecting the loading plate 88 in a proximal/distal direction.
The anterior slot 110 receives a medial end 118 of an anterior loading screw 44 , illustrated in FIGS. 6 and 7B. The posterior slot 112 receives a medial end 118 of a posterior loading screw 46 . The anterior and posterior loading screws 44 , 46 are substantially identical. As FIG. 6 illustrates, the screws 44 , 46 include a threaded lateral portion 120 having a drive tool engagement feature, such as a female hex key 122 , on a lateral face 124 . The threaded portion 120 terminates near a medial end of the screw 44 , 46 in a first coaxial disk 126 having a diameter larger than that of the threaded portion 120 . A second coaxial disk 128 is attached to the first disk 126 via a coaxial cylindrical portion 130 having a diameter substantially the same as the threaded portion 120 . A space between the two disks 126 , 128 thus defines an annular gap 132 .
The gap 132 on the anterior loading screw 44 engages the anterior slot 110 on the loading plate 88 , and the gap 132 on the posterior loading screw 46 engages the posterior slot 112 on the loading plate 88 , as shown in FIG. 7 B. The disks 126 , 128 at the medial ends 118 of the screws 44 , 46 each have a smaller diameter than a width of the wide portions of the anterior and posterior slots 110 , 112 . However, the disks 126 , 128 each have a larger diameter than a width of the narrow portions of the anterior and posterior slots 110 , 112 . Further, the cylindrical portions 130 of each screw 44 , 46 between the disks 126 , 128 have a smaller diameter than the width of the narrow portions of the anterior and posterior slots 110 , 112 . Thus, the anterior loading screw 44 is insertable within the wide portion of the anterior slot 110 and slidable into the narrow portion of the anterior slot 110 such that the sides of the narrow portion of the anterior slot 110 are disposed between the disks 126 , 128 . The anterior slot 110 thus fixes the anterior loading screw 44 against translation in a direction perpendicular to the loading plate 88 . The slot sides are, however, somewhat thinner than the distance between the disks 126 , 128 , such that there is a small amount of “play” between the loading plate 88 and the screws 44 , 46 , as shown in FIG. 7 B. The posterior loading screw 46 is engageable with the posterior slot 112 in the same manner that the anterior loading screw 44 is engageable with the anterior slot 110 .
The threaded portion 120 of the anterior loading screw 44 engages the anterior holes 34 in the hinge plates 26 , 28 , as shown in FIG. 7 C. The threaded portion 120 of the posterior loading screw 46 engages the posterior holes 36 in the hinge plates 26 , 28 . Thus, the screws 44 , 46 are selectively positionable with respect to the hinge plates 26 , 28 in a direction perpendicular to the hinge plates 26 , 28 . Because the screws 44 , 46 are fixed to the loading plate 88 , adjusting the position of the screws 44 , 46 within the apertures also adjusts the position and orientation of the loading plate 88 and condyle shell 90 with respect to the hinge plates 26 , 28 .
FIG. 7A illustrates the loading screws 44 , 46 adjusted such that both screws 44 , 46 extend a minimum distance in the medial direction from the hinge plates 26 , 28 . In this configuration, the loading plate 88 and condyle shell 90 are substantially parallel to the hinge plates 26 , 28 and spaced only slightly from the hinge plates 26 , 28 . The condyle shell 90 (or optional pad) thus applies little or no pressure to the wearer's knee, and any pressure is applied evenly across the knee in an anterior/posterior direction.
FIG. 7B illustrates the loading screws 44 , 46 adjusted such that both screws 44 , 46 extend a maximum distance in the medial direction from the hinge plates 26 , 28 . In this configuration, the loading plate 88 and condyle shell 90 are substantially parallel to the hinge plates 26 , 28 and spaced greatly from the hinge plates 26 , 28 . The condyle shell 90 (or optional pad) thus applies maximum pressure to the wearer's knee, and the pressure is applied evenly across the knee in an anterior/posterior direction.
FIG. 7C illustrates the loading screws 44 , 46 adjusted such that the posterior loading screw 46 extends from the hinge plates 26 , 28 in the medial direction a greater amount than the anterior loading screw 44 . In this configuration, the loading plate 88 and condyle shell 90 are oriented at an angle relative to the hinge plates 26 , 28 . The condyle shell 90 (or optional pad) thus applies greater pressure to a posterior portion of the wearer's knee than to an anterior portion of the wearer's knee.
Although not depicted, the lateral/medial force application assembly 86 is also configurable in a manner opposite from that of FIG. 7 C. In this configuration the anterior loading screw 44 extends from the hinge plates 26 , 28 in the medial direction a greater amount than the posterior loading screw 46 . The condyle shell 90 (or optional pad) thus applies greater pressure to an anterior portion of the wearer's knee than to a posterior portion of the wearer's knee.
The ability of a brace including the present hinge 20 to apply differing pressures to anterior and posterior portions of a wearer's knee enables such a brace to be adapted to a wide variety of treatment situations. Every human knee is unique, and there are a wide variety of knee injuries and knee injury prevention situations. In certain situations it is advantageous for a patient to have greater pressure applied to an anterior portion of his or her knee, and in certain other situations it is advantageous for a patient to have greater pressure applied to a posterior portion of his or her knee. Current braces do not allow for such adjustable application of pressure to anterior and posterior portions of a patient's knee as does a brace including the present hinge 20 .
Further, the configuration of the present hinge 20 spread loads over a greater area of the hinge plates 26 , 28 than other current designs. For example, in the hinge of U.S. Pat. No. 5,807,294, described above, the adjustment members 74 , 88 pass through the hinge fasteners 68 , 82 . Thus, all loads applied to the lateral pad 26 are transmitted to the hinge fasteners, and all loads applied to the arms 34 , 46 are also transmitted to the hinge fasteners. The hinge fasteners in turn transmit these loads to the areas of the hinge plates 58 , 60 in which they are disposed. This configuration concentrates tremendous loads on two small areas of the hinge plates 58 , 60 . These loads lead to rapid wear of the hinge plates 58 , 60 and eventually failure.
In the configuration of the present hinge 20 , however, loads applied to the condyle shell 90 are transmitted through the loading screws 44 , 46 to the anterior and posterior aperture 34 , 36 of the hinge plates 26 , 28 . Loads applied to the arms 22 , 24 are transmitted through the lateral rivets 60 to the proximal and distal aperture 30 , 32 of the hinge plates 26 , 28 . The loads are thus spread over a greater area of the hinge plates 26 , 28 . The hinge plates 26 , 28 are thus able to withstand more prolonged use without failure. Alternatively, the hinge plates 26 , 28 are able to be made using less material, which results in lighter hinge plates and an overall lighter brace.
SCOPE OF THE INVENTION
The above presents a description of the best mode contemplated for the present brace hinge with telescoping condyle pad, and of the manner and process of making and using it, in such full, clear, concise, and exact terms as to enable any person skilled in the art to which it pertains to make and use this brace hinge with telescoping condyle pad. This brace hinge with telescoping condyle pad is, however, susceptible to modifications and alternate constructions from that discussed above which are fully equivalent. Consequently, it is not the intention to limit this brace hinge with telescoping condyle pad to the particular embodiments disclosed. On the contrary, the intention is to cover all modifications and alternate constructions coming within the spirit and scope of the brace hinge with telescoping condyle pad as generally expressed by the following claims, which particularly point out and distinctly claim the subject matter of the brace hinge with telescoping condyle pad. | A brace hinge is provided having an adjustable pressure-applying assembly mounted to an inside of the hinge. A brace including the hinge can apply pressure to a joint in a medial or lateral direction. The hinge includes anterior and posterior apertures containing anterior and posterior adjustment members that control a position and orientation of the pressure-applying assembly relative to the hinge. Through selective adjustment of the adjustment members, the hinge can apply greater pressure to an anterior portion of the joint than to a posterior portion of the joint, and vice versa. A method of treating a joint using a brace including such a hinge is also provided. | 0 |
CROSS REFERENCE TO RELATED APPLICATIONS
Reference is made to commonly assigned U.S. Ser. No. 08/355,786, now abandoned, entitled "An Electroluminescent Device Having an Organic Electroluminescent Layer" by Tang et al and U.S. Ser. No. 08/355,940, now U.S. Pat. No. 5,550,066, entitled "A Method of Fabricating a TFT-EL Pixel" by Tang et al, both filed concurrently herewith, the disclosures of which are incorporated herein.
FIELD OF THE INVENTION
The present invention relates to an electroluminescent display panel employing thin-film-transistors (TFT) as active-matrix addressing elements, and organic electroluminescent thin films as the emissive medium.
INTRODUCTION
Rapid advances in flat-panel display (FPD) technologies have made high quality large-area, full-color, high-resolution displays possible. These displays have enabled novel applications in electronic products such as lap top computers and pocket-TVs. Among these FPD technologies, liquid crystal display (LCD) has emerged as the display of choice in the marketplace. It also sets the technological standard against which other FPD technologies are compared. Examples of LCD panels include: (1) 14", 16-color LCD panel for work stations (IBM and Toshiba, 1989) (see K. Ichikawa, S. Suzuki, H. Marino, T. Aoki, T. Higuchi and Y. Oano, SID Digest, 226 (1989)), (2) 6", full-color LCD-TV (Phillips, 1987) (see M. J. Powell, J. A. Chapman, A. G. Knapp, I. D. French, J. R. Hughes, A. D. Pearson, M. Allinson, M. J. Edwards, R. A. Ford, M. C. Hemmings, O. F. Hill, D. H. Nicholls and N. K. Wright, Proceeding, International Display Conference, 63, 1987), (3) 4" full-color LCD TV (model LQ424A01, Sharp, 1989) (see Sharp Corporation Technical Literature for model LQ424A01), and (4) 1 megapixel colored TFT-LCD (General Electric) (see D. E. Castleberry and G. E. Possin, SID Digest, 232 (1988)). All references, including patents and publications, are incorporated herein as if reproduced in full below.
A common feature in these LCD panels is the use of thin-film-transistors (TFT) in an active-addressing scheme, which relaxes the limitations in direct-addressing (see S. Morozumi, Advances in Electronics and Electron Physics, edited by P. W. Hawkes, Vol. 77, Academic Press 1990). The success of LCD technology is in large part due to the rapid progress in the fabrication of large-area TFT (primarily amorphous silicon TFT). The almost ideal match between TFT switching characteristics and electrooptic LCD display elements also plays a key role.
A major drawback of TFT-LCD panels is they require bright backlighting. This is because the transmission factor of the TFT-LCD is poor, particularly for colored panels. Typically the transmission factor is about 2-3 percent (see S. Morozumi, Advances in Electronics and, Electron Physics, edited by P. W. Hawkes, Vol. 77, Academic Press, 1990). Power consumption for backlighted TFT-LCD panels is considerable and adversely affects portable display applications requiring battery operation.
The need for backlighting also impairs miniaturization of the flat panel. For example, depth of the panel must be increased to accommodate the backlight unit. Using a typical tubular cold-cathode lamp, the additional depth is about 3/4 to 1 inch. Backlight also adds extra weight to the FPD.
An ideal solution to the foregoing limitation would be a low power emissive display that eliminates the need for backlighting. A particularly attractive candidate is thin-film-transistor-electroluminescent (TFT-EL) displays. In TFT-EL displays, the individual pixels can be addressed to emit light and auxiliary backlighting is not required. A TFT-EL scheme was proposed by Fischer in 1971 (see A. G. Fischer, IEEE Trans. Electron Devices, 802 (1971)). In Fischer's scheme powdered ZnS is used as the EL medium.
In 1975, a successful prototype TFT-EL panel (6") was reportedly made by Brody et al. using ZnS as the EL element and CdSe as the TFT material (see T. P. Brody, F. C. Luo, A. P. Szepesi and D. H. Davies, IEEE Trans. Electron Devices, 22, 739 (1975)). Because ZnS-EL required a high drive voltage of more than a hundred volts, the switching CdSe TFT element had to be designed to handle such a high voltage swing. The reliability of the high-voltage TFT then became suspect. Ultimately, ZnS-based TFT-EL failed to successfully compete with TFT-LCD. U.S. Patents describing TFT-EL technology include: U.S. Pat. Nos. 3,807,037; 3,885,196; 3,913,090; 4,006,383; 4,042,854; 4,523,189; and 4,602,192.
Recently, organic EL materials have been devised. These materials suggest themselves as candidates for display media in TFT-EL devices (see C. W. Tang and S. A. VanSlyke, Appl. Phys. Lett., 51, 913 (1987), C. W. Tang, S. A. VanSlyke and C. H. Chen, J. Appl. Phys., 65, 3610 (1989)). Organic EL media have two important advantages: they are highly efficient; and they have low voltage requirements. The latter characteristic distinguishes over other thin-film emissive devices. Disclosures of TFT-EL devices in which EL is an organic material include: U.S. Pat. Nos. 5,073,446; 5,047,687, 5,059,861; 5,294,870; 5,151,629; 5,276,380; 5,061,569; 4,720,432; 4,539,507; 5,150,006; 4,950,950; and 4,356,429.
The particular properties of organic EL material that make it ideal for TFT are summarized as follows:
1) Low-voltage drive. Typically, the organic EL cell requires a voltage in the range of 4 to 10 volts depending on the light output level and the cell impedance. The voltage required to produce a brightness of about 20 fL is about 5 V. This low voltage is highly attractive for a TFT-EL panel, as the need for the high-voltage TFT is eliminated. Furthermore, the organic EL cell can be driven by DC or AC. As a result the driver circuity is less complicated and less expensive.
2) High efficiency. The luminous efficiency of the organic EL cell is as high as 4 lumens per watt. The current density to drive the EL cell to produce a brightness of 20 fL is about 1 mA/cm 2 . Assuming a 100% duty excitation, the power needed to drive a 400 cm 2 full-page panel is only about 2.0 watts. The power need will certainly meet the portability criteria of the flat panel display.
3) Low temperature fabrication. Organic EL devices can be fabricated at about room temperature. This is a significant advantage compared with inorganic emissive devices, which require high-temperature (>300° C.) processing. The high-temperature processes required to make inorganic EL devices can be incompatible with the TFT.
The simplest drive scheme for an organic EL panel is to have the organic display medium sandwiched between two sets of orthogonal electrodes (rows and columns). Thus, in this two-terminal scheme, the EL element serves both the display and switching functions. The diode-like nonlinear current-voltage characteristic of the organic EL element should, in principle, permit a high degree of multiplexing in this mode of addressing. However, there are several major factors limiting usefulness of the two-terminal scheme in connection with organic EL:
1) Lack of memory. The rise and decay time of the organic EL is very fast, on the order of microseconds, and it does not have an intrinsic memory. Thus, using the direct addressing method, the EL elements in a selected row would have to be driven to produce an instantaneous brightness proportional to the number of scan rows in the panel. Depending on the size of the panel, this instantaneous brightness may be difficult to achieve. For example, consider a panel of 1000 scan rows operating at a frame rate of 1/60 seconds. The allowable dwell time per row is 17 μs. In order to obtain a time-averaged brightness of, for example, 20 Fl, the instantaneous brightness during the row dwell time would have to be a thousand times higher, i.e., 20,000 Fl, an extreme brightness that can only be obtained by operating the organic EL cell at a high current density of about 1 A/cm 2 and a voltage of about 15-20 volts. The long-term reliability of a cell operating under these extreme drive conditions is doubtful.
2) Uniformity. The current demanded by the EL elements is supplied via the row and column buses. Because of the instantaneous high current, the IR potential drops along these buses are not insignificant compared with the EL drive voltage. Since the brightness-voltage characteristic of the EL is nonlinear, any variation in the potential along the buses will result in a non-uniform light output.
Consider a panel with 1000 rows by 1000 columns with a pixel pitch of 200μ×200μ and an active/actual area ratio of 0.5. Assuming the column electrode is indium tin oxide (ITO) of 10 ohms/square sheet (Ω/□) resistance, the resistance of the entire ITO bus line is at least 10,000 ohms. The IR drop along this bus line for an instantaneous pixel current of 800 μA (2 A/cm 2 ) is more than 8 volts. Unless a constant current source is implemented in the drive scheme, such a large potential drop along the ITO bus will cause unacceptable non-uniform light emission in the panel. In any case, the resistive power loss in the bus is wasteful. A similar analysis can be performed for the row electrode bus that has the additional burden of carrying the total current delivered to the entire row of pixels during the dwell time, i.e., 0.8 A for the 1000-column panel. Assuming a 1 μm thick aluminum bus bar of sheet resistance about 0.028 ohms/square the resultant IR drop is about 11 volts, which is also unacceptable.
3) Electrode patterning. One set of the orthogonal electrodes, the anode--indium tin oxide, can be patterned by a conventional photolithographic method. The patterning of the other set of electrodes however, presents a major difficulty peculiar to the organic EL device. The cathode should be made of a metal having a work function lower than 4 eV, and preferably magnesium alloyed with another metal such as silver or aluminum (see Tang et al., U.S. Pat. No. 4,885,432). The magnesium-based alloy cathode deposited on top of the organic layers cannot be easily patterned by any conventional means involving photoresists. The process of applying the photoresist from an organic solvent on the EL cell deleteriously affects the soluble organic layer underneath the magnesium-based alloy layer. This causes delamination of the organic layers from the substrate.
Another difficulty is the extreme sensitivity of the cathode to moisture. Thus, even if the photoresist can be successfully applied and developed without perturbing the organic layers of the EL cell, the process of etching the magnesium-based alloy cathode in aqueous acidic solution is likely to oxidize the cathode and create dark spots.
SUMMARY OF THE INVENTION
The present invention provides an active matrix 4-terminal TFT-EL device in which organic material is used as the EL medium. The device comprises two TFTs, a storage capacitor and a light emitting organic EL pad arranged on a substrate. The EL pad is electrically connected to the drain of the second TFT. The first TFT is electrically connected to the gate electrode of the second TFT which in turn is electrically connected to the capacitor so that following an excitation signal the second TFT is able to supply a nearly constant current to the EL pad between signals. The TFT-EL devices of the present invention are typically pixels that are formed into a flat panel display, preferably a display in which the EL cathode is a continuous layer across all of the pixels.
The TFT-organic EL device of the present invention are formed in a multi-step process as described below:
A first thin-film-transistor (TFT1) is disposed over the top surface of the substrate. TFT1 comprises a source electrode, a drain electrode, a gate dielectric, and a gate electrode; and the gate electrode comprises a portion of a gate bus. The source electrode of TFT1 is electrically connected to a source bus.
A second thin-film-transistor (TFT2) is also disposed over the top surface of the substrate, and TFT2 also comprises a source electrode, a drain electrode, a gate dielectric, and a gate electrode. The gate electrode of TFT2 is electrically connected to the drain electrode of the first thin-film-transistor.
A storage capacitor is also disposed over the top surface of the substrate. During operation, this capacitor is charged from an excitation signal source through TFT1, and discharges during the dwell time to provide nearly constant potential to the gate electrode of TFT2.
An anode layer is electrically connected to the drain electrode of TFT2. In typical applications where light is emitted through the substrate, the display is a transparent material such as indium tin oxide.
A dielectric passivation layer is deposited over at least the source of TFT1, and preferably over the entire surface of the device. The dielectric passivation layer is etched to provide an opening over the display anode.
An organic electroluminescent layer is positioned directly on the top surface of the anode layer. Subsequently, a cathode layer is deposited directly on the top surface of the organic electroluminescent layer.
In preferred embodiments, the TFT-EL device of the present invention is made by a method using low pressure and plasma enhanced chemical vapor deposition combined with low temperature (i.e. less than 600° C.) crystallization and annealing steps, hydrogen passivation and conventional patterning techniques.
The thin-film-transistors are preferably formed simultaneously by a multi-step process involving:
the deposition of silicon that is patterned into polycrystalline silicon islands;
chemical vapor deposition of a silicon dioxide gate electrode; and
deposition of another polycrystalline silicon layer which is patterned to form a self-aligned gate electrode so that after ion-implantation a source, drain, and gate electrode are formed on each thin-film-transistor.
The construction of pixels having thin-film-transistors composed of polycrystalline silicon and silicon dioxide provides improvements in device performance, stability, reproducibility, and process efficiency over other TFTs. In comparison, TFTs composed of CdSe and amorphous silicon suffer from low mobility and threshold drift effect.
There are several important advantages in the actual panel construction and drive arrangement of a TFT-organic EL device of the present invention:
1) Since both the organic EL pad and the cathode are continuous layers, the pixel resolution is defined only by the feature size of the TFT and the associated display ITO pad and is independent of the organic component or the cathode of the EL cell.
2) The cathode is continuous and common to all pixels. It requires no patterning for pixel definition. The difficulty of patterning the cathode in the two-terminal scheme is therefore eliminated.
3) The number of scanning rows is no longer limited by the short row dwell time in a frame period, as the addressing and excitation signals are decoupled. Each scan row is operated at close to 100% duty factor. High resolution can be obtained since a large number of scan rows can be incorporated into a display panel while maintaining uniform intensity.
4) The reliability of the organic EL element is enhanced since it operates at a low current density (1 mA/cm 2 ) and voltage (5 V) in a 100% duty factor.
5) The IR potential drops along the buses are insignificant because of the use of a common cathode and the low current density required to drive the EL elements. Therefore the panel uniformity is not significantly affected by the size of the panel.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram of an active matrix 4-terminal TFT-EL device. T1 and T2 are thin-film-transistors, Cs is a capacitor and EL is an electroluminescent layer.
FIG. 2 is a diagrammatic plan view of the 4-terminal TFT-EL device of the present invention.
FIG. 3 is a cross-sectional view taken along the line A-A' in FIG. 2.
FIG. 4 is a cross-sectional view taken along the line A-A', illustrating the process of forming a self-aligned TFT structure for ion implantation.
FIG. 5 is a cross-sectional view taken along the line A-A', illustrating the processing steps of depositing a passivation oxide layer and opening contact cuts to the source and drain regions of the thin-film-transistor.
FIG. 6 is a cross-sectional view taken along line A-A', illustrating deposition of an aluminum electrode.
FIG. 7 is a cross-sectional view taken along line A-A', illustrating deposition of the display anode and a passivation layer that has been partially etched from the surface of the display anode.
FIG. 8 is a cross-sectional view taken along line A-A', illustrating the steps of depositing an electroluminescent layer and a cathode.
FIG. 9 is a cross-sectional view taken along line B-B' in FIG. 2.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows the schematic of an active matrix 4-terminal TFT-EL display device. Each pixel element includes two TFTs, a storage capacitor and an EL element. The major feature of the 4-terminal scheme is the ability to decouple the addressing signal from the EL excitation signal. The EL element is selected via the logic TFT (T1) and the excitation power to the EL element is controlled by the power TFT (T2). The storage capacitor enables the excitation power to an addressed EL element to stay on once it is selected. Thus, the circuit provides a memory that allows the EL element to operate at a duty cycle close to 100%, regardless of the time allotted for addressing.
The construction of the electroluminescent device of the present invention is illustrated in FIGS. 2 and 3. The substrate of this device is an insulating and preferably transparent material such as quartz or a low temperature glass. The term transparent, as it is used in the present disclosure, means that the component transmits sufficient light for practical use in a display device. For example, components transmitting 50% or more of light in a desired frequency range are considered transparent. The term low temperature glass refers to glasses that melt or warp at temperatures above about 600° C.
In the TFT-EL device illustrated in FIG. 2, TFT1 is the logic transistor with the source bus (column electrode) as the data line and the gate bus (row electrode) as the gate line. TFT2 is the EL power transistor in series with the EL element. The gate line of TFT2 is connected to the drain of TFT1. The storage capacitor is in series with TFT1. The anode of the EL element is connected to the drain of TFT2.
The construction of the TFT-EL of FIG. 2 is shown in cross-sectional view in FIGS. 3-9. The cross-sectional views shown in FIGS. 3-8 are taken along section line A-A' in FIG. 2. The cross-sectional view in FIG. 9 is taken along line B-B' in FIG. 2.
In the first processing step, a polysilicon layer is deposited over a transparent, insulating substrate 41 and the polysilicon layer is patterned into an island 48 (see FIG. 4) by photolithography. The substrate may be crystalline material such as quartz, but preferably is a less expensive material such as low temperature glass. When a glass substrate is utilized, it is preferable that the entire fabrication of the TFT-EL be carried out at low processing temperatures to prevent melting or warping of the glass and to prevent out-diffusion of dopants into the active region. Thus, for glass substrates, all fabrication steps should be conducted below 1000° C. and preferably below 600° C.
Next, an insulating gate material 42 is deposited over the polysilicon island and over the surface of the insulating substrate. Insulating material is preferably silicon dioxide that is deposited by a chemical vapor deposition (CVD) technique such as plasma enhanced CVD (PECVD) or low pressure CVD (LPCVD). Preferably, the gate oxide insulating layer is about 1000 Å in thickness.
In the next step, a layer of silicon 44 is deposited over the gate insulator layer and patterned by photolithography over the polysilicon island such that after ion implantation, source and drain regions are formed in the polysilicon island. The gate electrode material is preferably polysilicon formed from amorphous silicon. Ion implantation is conducted with N-type dopants, preferably arsenic. The polysilicon gate electrode also serves as the bottom electrode of the capacitor (see FIG. 9).
In a preferred embodiment of the present invention, the thin film transistors do not utilize a double gate structure. Thus manufacturing is made less complex and less expensive.
A gate bus 46 is applied and patterned on the insulating layer. The gate bus is preferably a metal silicide such as tungsten silicide (WSi 2 ).
In the next step, an insulating layer, preferably silicon dioxide, 52 is applied over the entire surface of the device.
Contact holes 54 and 56 are cut in the second insulating layer (see FIG. 5) and electrode materials are applied to form contacts with the thin-film-transistors (see FIGS. 6 and 7). The electrode material 62 attached to the source region of TFT2 also forms the top electrode of the capacitor (see FIG. 9). A source bus and ground bus are also formed over the second insulating layer (see FIG. 2). In contact with the drain region of TFT2 is a transparent electrode material 72, preferably ITO, which serves as the anode for the organic electroluminescent material.
In the next step, a passivating layer 74 of an insulating material, preferably silicon dioxide, is deposited over the surface of the device. The passivation layer is etched from the ITO anode leaving a tapered edge 76 which serves to improve the adhesion of the subsequently applied organic electroluminescent layer. A tapered edge is necessary to produce reliable devices because the present invention utilizes relatively thin organic EL layers, typically 150 to 200 nm thick. The passivation layer is typically about 0.5 to about 1 micron thick. Thus, if the edge of the passivation layer forms a perpendicular or sharp angle with respect to the anode layer, defects are likely to occur due to discontinuities in the organic EL layer. To prevent defects the passivation layer should have a tapered edge. Preferably the passivation layer is tapered at an angle of 10 to 30 degrees with respect to the anode layer.
The organic electroluminescent layer 82 is then deposited over the passivation layer and the EL anode layer. The materials of the organic EL devices of this invention can take any of the forms of conventional organic EL devices, such as those of Scozzafava EPA 349,265 (1990); Tang U.S. Pat. No. 4,356,429; VanSlyke et at. U.S. Pat. No. 4,539,507; VanSlyke et at. U.S. Pat. No. 4,720,432; Tang et al. U.S. Pat. No. 4,769,292; Tang et al. U.S. Pat. No. 4,885,211; Perry et al. U.S. Pat. No. 4,950,950; Littman et al. U.S. Pat. No. 5,059,861; VanSlyke U.S. Pat. No. 5,047,687; Scozzafava et al. U.S. Pat. No. 5,073,446; VanSlyke et al. U.S. Pat. No. 5,059,862; VanSlyke et al. U.S. Pat. No. 5,061,617; VanSlyke U.S. Pat. No. 5,151,629; Tang et al. U.S. Pat. No. 5,294,869; and Tang et al. U.S. Pat. No. 5,294,870, the disclosures of which are incorporated by reference. The EL layer is comprised of an organic hole injecting and transporting zone in contact with the anode, and an electron injecting and transporting zone forming a junction with the organic hole injecting and transporting zone. The hole injecting and transporting zone can be formed of a single material or multiple materials, and comprises a hole injecting layer in contact with the anode and a contiguous hole transporting layer interposed between the hole injecting layer and the electron injecting and transporting zone. Similarly, the electron injecting and transporting zone can be formed of a single material or multiple materials, and comprises an electron injecting layer in contact with the cathode and a contiguous electron transporting layer that is interposed between the electron injecting layer and the hole injecting and transporting zone. Recombination of the holes and electrons, and luminescence, occurs within the electron injecting and transporting zone adjacent the junction of the electron injecting and transporting zone and the hole injecting and transporting zone. The components making up the organic EL layer are typically deposited by vapor deposition, but may also be deposited by other conventional techniques.
In a preferred embodiment the organic material comprising the hole injecting layer has the general formula: ##STR1## wherein: Q is N or C(R)
M is a metal, metal oxide or metal halide
R is hydrogen, alkyl, aralkyl, aryl or alkaryl, and
T, and T 2 represent hydrogen or together complete an unsaturated six membered ring that can include substituents such as alkyl or halogen. Prefred alkyl moieties contain from about 1 to 6 carbon atoms while phenyl constitutes a preferred aryl moiety.
In a preferred embodiment the hole transporting layer is an aromatic tertiary amine. A preferred subclass of aromatic tertiary amines include tetraaryldiamines having the formula: ##STR2## wherein Are is an arylene-group,
n is an integer from 1 to 4, and
Ar, R 7 , R 8 and R 9 are independently selected aryl groups.
In a preferred embodiment, the luminescent, electron injecting and transporting zone contains a metal oxinoid compound. A preferred example of a metal oxinoid compound has the general formula: ##STR3## wherein R 2 -R 7 represent substitutional possibilities. In another preferred embodiment, the metal oxinoid compound has the formula: ##STR4## wherein R 2 -R 7 are as defined above and L 1 -L 5 collectively contain twelve or fewer carbon atoms and each independently represent hydrogen or hydrocarbon groups of from 1 to 12 carbon atoms, provided that L 1 and L 2 together or L 2 and L 3 together can form a fused benzo ring. In another preferred embodiment, the metal oxinoid compound has the formula: ##STR5## wherein R 2 -R 6 represent hydrogen or other substitutional possibilities.
The foregoing examples merely represent some preferred organic materials used in the electroluminescent layer. They are not intended to limit the scope of the invention, which is directed to organic electroluminescent layers generally. As can be seen from the foregoing examples, the organic EL material includes coordination compounds having organic ligands. The TFT-EL device of the present invention does not include purely inorganic materials such as ZnS.
In the next processing step, the EL cathode 84 is deposited over the surface of the device. The EL cathode may be any electronically conducting material, however it is preferable that the EL cathode be made of a material having a work function of less than 4 eV (see Tang et al. U.S. Pat. No. 4,885,211). Low work function metals are preferred for the cathode since they readily release electrons into the electron transporting layer. The lowest work function metals are the alkali metals; however, their instability in air render their use impractical in some situations. The cathode material is typically deposited by physical vapor deposition, but other suitable deposition techniques are applicable. A particularly desirable material for the EL cathode has been found to be a 10:1 (atomic ratio) magnesium:silver alloy. Preferably, the cathode is applied as a continuous layer over the entire surface of the display panel. In another embodiment, the EL cathode is a bilayer composed of a lower layer of a low work function metal adjacent to the organic electron injecting and transporting zone and, overlying the low work function metal, a protecting layer that protects the low work function metal from oxygen and humidity. Optionally, a passivation layer may be applied over the EL cathode layer.
Typically, the anode material is transparent and the cathode material opaque so that light is transmitted through the anode material. However, in an alternative embodiment, light is emitted through the cathode rather than the anode. In this case the cathode must be light transmissive and the anode may be opaque. A practical balance light transmission and technical conductance is typically in the thickness range of 5-25 nm.
A preferred method of making a thin-film-transistor according to the present invention is described below. In a first step, an amorphous silicon film of 2000±20 Å thickness is deposited at 550° C. in an LPCVD system with silane as the reactant gas at a process pressure of 1023 mTorr. This is followed by a low temperature anneal at 550° C. for 72 hours in vacuum to crystallize the amorphous silicon film into a polycrystalline film. Then a polysilicon island is formed by etching with a mixture of SF 6 and Freon 12 in a plasma reactor. Onto the polysilicon island active layer is deposited a 1000±20 Å PECVD SiO 2 gate dielectric layer. The gate dielectric layer is deposited from a 5/4 ratio of N 2 O/SiH 4 in a plasma reactor at a pressure of 0.8 Torr with a power level of 200 W and a frequency of 450 KHz at 350° C. for 18 minutes.
In the next step an amorphous silicon layer is deposited over the PECVD gate insulating layer and converted to polycrystalline silicon using the same conditions as described above for the first step. A photoresist is applied and the second polysilicon layer is etched to form a self-aligned structure for the subsequent ion implantation step. The second polysilicon layer is preferably about 3000 Å thick.
Ion implantation is conducted by doping with arsenic at 120 KeV at a dose of 2×10 15 /cm 2 to simultaneously dope the source, drain and gate regions. Dopant activation is carried out at 600° C. for two hours in a nitrogen atmosphere.
In the next step, a 5000 Å thick silicon dioxide layer is deposited by conventional low temperature methods. Aluminum contacts are formed by a physical vapor deposition and sintered in forming gas (10% H 2 , 90% N 2 ) for thirty minutes at 400° C.
Finally, hydrogen passivation of the thin-film-transistor is carried out in an electron cyclotron resonance reactor (ECR). ECR hydrogen plasma exposure is conducted at a pressure of 1.2×10 -4 Torr with a microwave power level of 900 W and a frequency of 3.5 GHz. Hydrogen passivation is performed for fifteen minutes at a substrate temperature of 300° C. This procedure results in a thin-film-transistor device having a low threshold voltage, a high effective carrier mobility and an excellent on/off ratio.
As an example of characteristics of the present invention, consider the drive requirements for the following TFT-EL panel:
______________________________________Number of rows = 1000Number of columns = 1000Pixel dimension = 200 μm × 200 μmEL fill-factor = 50%frame time = 17 msrow dwell time = 17 μsAvg brightness = 20 fLEL pixel current = 0.8 μADuty cycle = 100%EL power source = 10 v rms______________________________________
These drive requirements are met by the following specifications for the TFTs and the storage capacitor:
______________________________________TFT1Gate voltage = 10 VSource voltage = 10 VOn-current = 2 μAOff-current = 10.sup.-11 A TFT2Gate voltage = 10 VSource voltage = 5 VOn-current = 2 × EL pixel current = 1.6 μAOff-current = 1 nAStorage capacitor:Size = 1 pf______________________________________
The on-current requirement for TFT1 is such that it is large enough to charge up the storage capacitor during the row dwell time (17 μs) to an adequate voltage (10 V) in order to turn on the TFT2. The off-current requirement for TFT1 is such that it is small enough that the voltage drop on the capacitor (and TFT2 gate) during the frame period (17 ms) is less than 2%.
The on-current requirement for TFT2 is (designed to be) about 2 times the EL pixel current, 1.6 μA. This factor of two allows for adequate drive current to compensate for the gradual degradation of the organic EL element with operation. The off-current of TFT2 affects the contrast of the panel. An off-current of 1 nA should provide an on/off contrast ratio greater than 500 between a lit and an unlit EL element. The actual contrast ratio of the panel may be lower, depending on the ambient lighting factor.
For a full page panel of 400 cm 2 the power required by the EL elements alone is about 4 watts. ##EQU1## This power consumption excludes the power consumed by the TFTs. Since TFT2 is in series with the EL element, any source-drain voltage drop across TFT2 will result in substantial power loss in the TFT2. Assuming a source-drain voltage of 5 volts, the total power loss on TFT2 is 2 watts. The power consumption for TFT1 is estimated to be no greater than 1 watt for the 1000×1000 panel. The power needed for the row (gate) drivers is negligible, on the order of a few tens of milliwatts, and the power for the column (source) drivers is on the order of 0.5 watt (see S. Morozumi, Advances in Electronics and Electron Physics, edited by P. W. Hawkes, Vol. 77, Academic Press, 1990). Thus, the total power consumption for a full page TFT-EL panel is about 7 watts. Realistically, the average power consumption would be much less since the EL screen is not 100% on in average usage.
The TFT-EL panel of the present invention has two important advantages in terms of power requirements over TFT-LCD panels. First, the TFT-EL power need is relatively independent of whether the panel is monochrome or multi-color, provided that the color materials have a similar luminescent efficiency. In contrast, the TFT-LCD colored panel requires a much higher power than the monochrome panel because the transmission factor is greatly reduced in the colored panel by the color filter arrays. Second, the LCD backlight has to stay on regardless of the screen usage factor. In contrast, the TFT-EL power consumption is highly dependent on this usage factor. The average power consumption is much less since less than 100% of the EL screen is emitting at any given time in typical applications.
The invention has been described in detail with particular reference to preferred embodiments thereof, but it will be understood that variations and modifications can be effected within the spirit and scope of the invention.
______________________________________Parts List______________________________________ 42 gate material 44 silicon layer 46 gate bus 52 insulating layer 54 contact hole 56 contact hole 62 electrode material 72 electrode material 74 passivating layer 76 tapered edge 82 EL layer 84 EL cathode______________________________________ | A flat panel display comprising thin-film-transistor-electroluminescent (TFT-EL) pixels is described. An addressing scheme incorporating two TFTs and a storage capacitor is used to enable the EL pixels on the panel to operate at a duty factor close to 100%. This TFT-EL device eliminates the need to pattern the EL cathode, thus greatly simplifying the procedure to delineate the EL pixels as well as ensuring high resolution. The TFT-EL panel consumes less power than conventional TFT-LCD panels, especially when the usage factor of the screen is less than unity. | 7 |
FIELD OF THE INVENTION
This invention relates to portable and collapsible shelters for the use by sportsmen and more particularly relates to portable and collapsible blinds for use by hunters and photographers.
BACKGROUND OF THE INVENTION
Hunters, photographers, bird watchers, etc. often desire or have a need to remain hidden from view of wildlife they are observing or pursuing. Although permanent blinds or shelters have been used for this purpose, the lack of adjustability of the structures is a significant disadvantage.
The blinds are often placed on rough terrain. The manufacturer does not know whether the occupant will be looking up a hill or down in a valley from inside the blind. The manufacturer does not know the height of the occupants chair or if they are even using one. Moreover, the blind may be placed on ground so rough that the blind rests at an angle. All these factors impact the proper location of the window(s). That is, the location of the occupants eyes inside the blind and the area to be observed outside the blind need to be in a direct line passing through the window.
In the past, windows have been made large, which has an additional drawback. Game can generally see in the window that the occupant looks out. For the occupant to be truly hidden, the window gap needs to be able to remain small, while in position for observation.
Game typically moves on game trails. The game tends to follow a known path and crosses expected locations. Not all of these locations are ideal for shooting either a camera or a weapon. The hunter may not need or want windows in locations from which the game is unreachable. In some locations, the game may come from any direction and other times not. However, present blinds lack the ability to laterally enlarge or shrink the window such that it can circumscribe the blind or only provide one small peak hole.
An example of the shortcomings in the prior art can be found in U.S. Pat. No. 4,819,680, which describes a ground tent having four sides and a top, with a plurality of poles having a spring-biased foot subassembly supporting a fabric cover. Such a structure is not practical for use as a blind and it is time-consuming to set up when needed. This tent does not have a variable slot for observation of game through which the hunter may extend a rifle and shoot the game.
U.S. Pat. No. 3,105,505 describes a portable and collapsible tent having four walls, a floor and a dome ceiling. This structure is not suitable for use as a blind. This tent does not have a variable slot for observation of game through which the hunter may extend a rifle and shoot the game.
U.S. Pat. Nos. 4,026,312 and 3,941,140 describes a foldable free-standing tent having end walls, a floor and side walls which slope upwardly to a peak. This structure is cumbersome to set up and is not suitable as a blind. This tent does not have a variable slot for observation of game through which the hunter may extend a rifle and shoot the game.
U.S. Pat. No. 3,625,235 describes a portable shelter which is sphere-shaped and requires several supporting poles or rods. It is cumbersome to set up and take down and would not be suitable for use as a blind in the field. This portable shelter does not have a variable slot for observation of game through which the hunter may extend a rifle and shoot the game.
U.S. Pat. No. 3,968,809 describes a van tent, i.e., a tent-like extension for attachment to the rear of a van. This structure is useful as a shelter for workmen who require easy access to their van for tools and materials and who do not desire to go out into the elements while working. This structure is not at all suitable as a temporary blind in the field because it requires a van to support it. This tent does not have a variable slot for observation of game through which the hunter may extend a rifle and shoot the game.
U.S. Pat. No. 5,628,338 describes a portable blind including an integral fabric forming four walls and top in what is typically referred as a pop-up construction. This blind has four resilient and flexible legs. The blind has at least one window including a flap movable between an open and a closed position. The blind also has a door that may be moved between an open and a closed position. This blind does not have a variable slot for observation of game through which the hunter may extend a rifle and shoot the game.
There has not heretofore been provided a light-weight, portable, easily collapsible blind or shelter having the combined features of the present invention. What is needed is a portable blind designed for easy set-up with variable windows that may be adjusted to the desired height at the bottom edge and desired height at the upper edge, thus allowing the window itself to be vertically moved to a preferred location with adjustability of the size of the window gap. Desirably, the window should be adapted to circumscribe the blind and be openable in any select portions thereof, while allowing other portions to remain closed.
SUMMARY OF THE PRESENT INVENTION
The present invention is a portable and collapsible blind. A flexible cover may be mounted on a support structure. The cover may have at least one side wall, e.g. perhaps conical, and a top with at least a portion of at least one side wall including first and second opposite edges. The opposite edges desirably cooperatively define a window. An elongated member, perhaps a strap or frame portion, extends across the opposite edges and a selective fastener joins to one edge and adjustably joins to the elongated member. The fastener selectively being fixedly joinable to the elongated member.
Advantageously, the present invention allows the window to be opened in a parallel or a skewed manner.
Also advantageously, the present invention allows the opening to be moved up or down the wall.
As yet another advantage, the present invention allows the window to bend around corners and curves.
As an even further advantage, the window of the present invention can be opened a user determined amount, in a user determined location, and in a user determined configuration.
These and other advantages will become clear from reading the below description with reference to the appended drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an interior view of the side wall showing the straps and fasteners disposed across the opposing edges together with the structure supporting the cover.
FIG. 2 is a perspective view showing the front and side of the blind with the window positioned low and partially shown in phantom.
FIG. 3 is a perspective view showing the front and side of the blind with the window at medium height and partially shown in phantom.
FIG. 4 is a perspective view showing the front and side of the blind with the window positioned at an elevated height and partially shown in phantom.
FIG. 5 is a perspective view showing the front and side of the blind with the window with parallel edges and partially shown in phantom.
FIG. 6 is a perspective view showing the front and side of the blind with the window positioned with skewed edges and partially shown in phantom.
DETAILED DESCRIPTION OF THE INVENTION
The present portable and collapsible blind 10 may include a cover 12 , at least one elongated member 40 , and a fastener 50 . The components through interconnections hereinafter described, provides a window that may extend around the blind 10 and is adjustable in a variety of unique manners. Each component will be discussed in serial fashion.
The flexible cover 12 , which may be made of flexible materials, can be mounted on a support structure 14 . The cover 12 may have at least one side wall 16 , 18 , 20 , and 22 together with a top 24 . A single side wall configuration can be used if desired, perhaps in a cylinder shape, which while commonly viewed as one side wall is technically an infinite number of side walls, or as a single flat surface wall. At least one side wall 16 , 18 , 20 and/or 22 may include a top edge 26 and a bottom edge 28 , with the top and bottom edges 26 , 28 cooperatively defining a window 30 . The top edge 26 and bottom edge 28 are terms used relative to the window 30 and not the side walls 16 , 18 , 20 , 22 . Side walls 16 , 18 , 20 , 22 may cooperatively provide the top edge 26 and 28 such that the window extends across a plurality of the sides.
At least one, but preferably a plurality of elongated members 40 , which may be straps, poles, cords or other similarly functional structures, extend across/adjacent the top and bottom edges 26 , 28 . The elongated members 40 may be vertical, perpendicular to the edges 26 , 28 or in any other functional orientation. The elongated members 40 at each end 42 , 44 may be secured a distance above the top edge 26 and below the bottom edge 28 of the side walls. The portion of the side walls 16 , 18 , 20 , and 22 that is between the ends 42 , 44 desirably has a surplus of fabric such that the bottom edge 28 may be lifted well beyond the point at which the top edge 26 may reach down. The overlap may appear to be structured as one or more flaps if the window is such that it cannot circumscribe the blind 10 . The elongated member 40 is desirably positioned to be taut and is fastened at fastening point 46 perhaps with stitching to the side walls.
One may determine the height of the bottom edge 28 of the window 30 or the top edge 26 of the window 30 as shown in FIGS. 2-5 . The gap 32 of the window 30 may then be determined via adjustment of the opposing edge 26 or 28 . Multiple elongated members 40 allow the user to adjust the window position 34 and gap 32 at varying points along the length of the window 30 , creating either a parallel, skewed or irregular relationship between the top and bottom edges 26 , 28 of the window 30 as shown in FIG. 6 .
A plurality of selective fasteners 50 can be independently and fixedly joined to the top and bottom edges 26 , 28 of the window 30 . Such fasteners 50 may join to the elongated members 40 , allowing the fastener 50 to selectively secure the top or bottom edges 26 , 28 at the desired location relative to the elongated member 40 . The preferred fastener is a clip 52 that permanently or fixedly secures to the top or bottom edge 26 , 28 and slidably engages the elongated member 40 such that it may selectively lock to the elongated member 40 at any desired point. Other fasteners such as ties, hook and loop fabric, snaps, buttons or other suitably arranged fasteners are equivalents. The clips 52 allow independent adjustment of one of the edges 26 , 28 at a point along the length thereof and securement of that edge at a fixed location relative to the blind 10 at that point.
The blind 10 has been described with the window 30 oriented a preferred direction, e.g. horizontally. One skilled in the art will realize that orienting the top and bottom edges 26 , 28 such that they are side edge or angled edges with a corresponding movement of the elongated members 40 allow one to orient the window in any desired direction.
In operation, the user constructs the blind 10 . The fasteners 50 secured to the bottom edge 28 are fastened to the elongated member 40 at a level where the user would prefer the bottom edge of the window 30 . The user then secures the fasteners 50 joined to the upper edge 26 at a point along the elongated member 40 where the user would prefer to have the top edge of the window 30 . The window 30 maybe lowered via lowering the lower edge 28 and the window may be raised via raising the upper edge 26 . In either case the opposing edge 26 or 28 may be used a corresponding amount to maintain size of the gap 32 . Since each fastener 50 can be moved independently, the user can determine whether the edges 26 , 28 are parallel, skewed or other arrangement.
Although the present invention has been described with reference to preferred embodiments, workers skilled in the art will recognize changes may be made in form and detail without departing from the spirit and scope of the invention. | A portable and collapsible blind including a flexible cover mounted on a support structure having a plurality of side walls and a top; wherein at least one side wall includes first and second opposite edges, and the opposite edges cooperatively defining a window; an elongated member extending across the opposite edges; and a selective fastener joined to one edge and adjustably joined to the strap, the fastener selectively being fixedly joinable to the elongated member. | 4 |
BACKGROUND OF THE INVENTION
This invention relates generally to logic circuits and more particularly to logic circuits adapted for very large scale integrated (VLSI) circuit layouts.
As is known in the art, CMOS (complementary metal oxide semiconductor) transmission-gate based logic circuits have been used as efficient solutions for generating specific logic functions. Such CMOS transmission-gate circuits typically includes a P-channel and an N-channel MOS transistor having gates fed by a complementary logic signal. The source electrodes are connected together to form a common input fed by a second logic signal and the drains are connected together to form a common output. Thus, when the first logic signal is at a first logic state, the second logic signal is coupled through the gate and appears at the output, and conversely, when the first logic signal is at a second, complementary logic state, the second logic signal is inhibited (i.e. decoupled) from passing to the output. One logic function implemented with such CMOS transmission-gates is an Exclusive-OR gate such as is shown in the High-Speed CMOS Logic Data Book published by Texas Instruments, 1984 on page 7-4. Here, a pair of CMOS transmission-gates are provided with the outputs thereof connected in common to provide the output for the Exclusive-OR gate. The true and complement of the second logic signal are fed to the input of a corresponding one of the transmission-gates. The true and complement of the first logic signal are fed to the transmission-gates such that when the first logic signal is in a first logic state (say true), the complement of the second logic signal passes through one of the transmission-gates to the output of the Exclusive-OR gate and conversely, when the first logic signal is in the second state (i.e. complement), the true of the second logic signal passes the other one of the transmission-gates to the output of the Exclusive-OR qate. A further "ad hoc" simplification of a CMOS Exclusive-OR gate is shown and described in U.S. Pat. No. 4,417,161 to Masaru Uya and assigned to Matsushita Electric Industrial Co., Ltd. Thus, CMOS transmission-gates have been shown to minimize area and delay when implemented on a CMOS based VLSI chip. However, there does not appear to be a uniform approach to the creation of these special circuit solutions. For example, Boolean functions (i.e. OR, AND, NOR and NAND) are typically realized using conventional state CMOS logic technology by combining ordered arrangements of NAND and NOR gates.
A conventional CMOS NOR gate typically includes a plurality of N-channel MOS transistors, one for each input to the gate and a like plurality of P-channel MOS transistors. The sources-drains of the N-channel transistors are coupled in shunt between ground and the output; each gate is fed by a corresponding logic signal. The sources-drains of the P-channel transistors are serially connected between +V DD and the output; each gate also being fed by a corresponding one of the logic signals. Hence, if any one of the logic signals is "high", the N-channel transistor fed by such signal conducts bringing the output towards ground. However, if all logic signals are "low", the N-channel devices are non-conducting and the P-channel devices turn on pulling the output up to +V DD . Thus, the series connection of the P-transistors result in a long delay time when responding to all "high" input signals unless their W/L ratios are increased in proportion to the number of serial transistors. In fact, when the serial chain exceeds five, distribution effects are similar to an R-C delay line.
For the NAND gate, a similar, yet complementary, effect exists. In this case, the N-channel transistors are serially coupled between the output and ground; each one having its gate coupled to a corresponding one of the input signals. The P-channel transistors are coupled in parallel between +V DD and the output; each one having its gate coupled to a corresponding one of the inputs. Thus, if any one of the inputs is "low", the P-channel transistors fed by it conducts and the output is at +V DD ; however, when all of the inputs go "high", all of the N-channel transistors go towards conduction driving the output towards ground. Thus, in this case, the W/L ratios of the N-channel transistors must be increased in proportion to the number of those in series. Further, with the NOR gate, since the carrier (hole) mobility of the P-channel transistors is lower than that of the carrier (electron) mobility of the N-channel transistor, the W/L ratio of the P-channel transistor must be typically larger than that of the N-channel transistor in order to obtain balanced dynamic performance. This, however, results in a very large area consumption for multi-input NOR gates in order to preserve logic "1" output speed. In order to overcome these problems, a number of other circuit forms have been developed. Among these are pre-charge logic, programmable logic arrays, domino-logic, etc. These are typically "dynamic" in form and impose additional constraints on system timing (as well as logic structuring).
SUMMARY OF THE INVENTION
In accordance with the present invention, a logic circuit is provided for providing an output logic signal at an output port having a logic state representative of a predetermined combination of the logic states of a pair of input logic signals, such circuit comprising: means, responsive to a first one of the pair of logic signals, for coupling either a second one of the pair of input logic signals to the output port while decoupling from the output port a signal having a predetermined fixed potential representative of one of the logic states of the output signal in response to a first logic state of the first one of the pair of input logic signals, or, alternatively, coupling the fixed potential signal to the output port while decoupling the second one of the pair of input logic signals from the output port in response to a second logic state of the first one of the pair of input logic signals.
In a preferred embodiment, the coupling means includes an n-channel MOS transistor and a p-channel MOS transistor, such transistors having sources and drains serially coupled between a source of the second inout logic signal and the source of the fixed potential signal at the output port. The gate of the transistors are fed by the first input logic signal. The predetermined fixed reference potential is either ground or +V DD . Thus, with such an arrangement, this structure may be configured as a static OR or AND gate by the simple interchange of the reference potential, ground and one input logic signal and requiring no dynamic precharge operation. Further, since it is CMOS, it consumes nanowatt static power. Further, it is modular and flexible, adapting itself to simple, yet efficient VLSI layouts. It can be configured to optimize area and speed for many higher order combinational logic functions and can be simply extended to create logic derivatives in a very structured format.
In accordance with the present invention, a plurality of input logic signals may be converted into an output logic signal representative of a predetermined logical combination of the plurality of input logic signals by replicating a basic 2-input AND gate or a 2-input OR gate in a cascaded manner wherein an output from one cascaded stage is coupled to an input of the next cascaded stage, and a first one and a second one of the input logic signals is fed to a first one of the plurality of cascaded stages and each successive one of the plurality of cascaded stages is fed by an output logic signal from a preceeding stage and another one of the input logic signals. Each of the cascaded stages comprises a pair of electronic switch means, each switch means having an input terminal, a control terminal and an output terminal for coupling or decoupling the input terminal on the output terminal selectively in accordance with the logic state of a signal fed to the control terminal. The first one of the plurality of input logic signals is fed to the input terminal of a first one of the pair of switch means; the second one of the plurality of input signals is fed to the control terminals of the pair of switch means; the first and second electronic switch means of a last stage have the output terminals thereof connected to an output of the logic circuit; and the input of the second electronic switch means in each stage is coupled to a signal having a predetermined reference potential representative of one of the logic states of the input logic signals. The electronic switch means comprises a CMOS transmission-gate.
A further feature of the invention includes a method of converting with a logic circuit a plurality of input logic signals into an output logic signal representative of a predetermined logical combination of the plurality of input logic signals comprising the steps of providing a pair of electronic switch means, each one thereof having an input terminal, a control terminal and an output terminal, coupling or decoupling the input terminal and the output terminal selectively of each of said electronic switch means in accordance with the logic state of a signal fed to the control terminal, feeding a first one of the plurality of input logic signals to the input terminal of a first one of the pair of switch means, feeding a second one of the plurality of input signals to the control terminals of the pair of switch means, connecting the output terminals of such first and second electronic switch means to an output of the logic circuit, and coupling the input of the second electronic switch means to a signal having a predetermined reference potential represenatative of one of the logic states of the input logic signal.
BRIEF DESCRIPTION OF THE DRAWINGS
Other and further features and advantages of the invention will become apparent in connection with the accompanying drawings wherein:
FIGS. 1A and 1B are circuit diagrams of the invention showing structured CMOS transmission-gates for performing an AND logic function.
FIGS. 1C and 1D show reduced circuit embodiments of the invention for performing an AND logic function based on structured CMOS transmission-gates.
FIGS. 2A and 2B are circuit diagrams of the invention showing structured CMOS transmission-gates for performing an OR logic funtion.
FIGS. 2C and 2D show reduced circuit forms of the invention for performing an OR logic function based on structured CMOS transmission-gates.
FIGS. 3A and 3B show cascaded AND gates of the invention and a reduced circuit form based on FIGS. 1A and 1D, respectively, for performing a logical AND function on three input signals.
FIGS. 4A and 4B show cascaded OR gates of the invention and a reduced circuit form based on FIGS. 2A and 2D, respectively, for performing a logical OR function on three input signals.
FIGS. 5A and 5B show the logic symbols for embodiments of the invention shown in FIGS. 1C and 2C, respectively.
FIG. 6 is a circuit diagram showing an alternate embodiment of the invention for performing a logical AND function on three input signals.
FIG. 7 is a circuit diagram showing an alternate embodiment of the invention for performing a logical OR function on three input signals.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIGS. 1A TO 1D, four embodiments of an AND gate are shown. Thus, in FIG. 1A four MOS transistors 10, 12, 14 and 16 are interconnected as shown, transistors 10 and 16 being N-channel enhancement mode MOS transistors and transistors 12 and 14 being P-channel enhancement mode MOS transistors. The gates of transistors 10, 14 are fed by a B logic signal. An A logic signal is fed to the drains of transistors 10 and 12. The sources of transistors 14 and 16 are at ground potential. The complement of the B logic signal, i.e. B is fed to the gates of transistors 12 and 16. The sources of transistor 10, 12 and the drains of transistors 14, 16 are connected to output 18 port. Thus, if the B logic signal is "high", i.e. logic 1, transistors 10 and 12 are driven to conduction while transistors 14 and 16 are driven to non-conduction with the result that the A logic signal is coupled to output port 18 while electrically decoupling the ground potential from the output port 18. Therefore, the output signal at the output 18 will be a logic 1 if the A logic signal is a logic "1" and the output signal of the output 18 will be a logic "0" if the A logic signal is a logic "0". Further, if the B logic signal is "low" (i.e. logic 0), transistors 14 and 16 are driven to conduction while transistors 10 and 12 are driven to non-conduction with the result that the A logic signal is electrically decoupled from output 18 and the fixed reference potential, here ground, is coupled to output 18. Consequently, under such condition, the output signal at output 18 is a "low" (i.e. ground) logic 0 signal. The operation of the logic AND gate in FIG. 1A may thus be summarized by the following truth table:
TABLE 1______________________________________Logic Signal Output SignalA B Output______________________________________0 0 00 1 01 0 01 1 1______________________________________
Referring now to FIG. 1B there is shown an embodiment of the invention wherein the P-channel MOS transistor 14 has been removed from the circuit shown in FIG. 1A resulting in a three transistor circuit that performs the AND gate logic function shown in Table 1. Similarly, FIG. 1C shows another embodiment which is a further simplification of FIG. 1A by the additional removal of N-channel MOS transistor 10 resulting in a two transistor circuit that performs the same AND gate function shown in Table 1. For example, when the A logic signal is A logic 1 and the B is asserted or at a logic 0 (hence B is a logic 1) then transistor 16 will be OFF and transistor 12 will be switched ON, thereby coupling the A logic signal level 1 to the output 18. When the A logic signal is a logic 0 and B is a logic 0 (and B=1), then transistor 16 is OFF and transistor 12 is switched ON, thereby coupling the A logic signal level 0 to the output 18. When B logic signal is a logic 1 (B=0), and the A logic signal is either 0 or 1, then transistor 12 is OFF and transistor 16 is switched ON and the output 18 is at logic 0 as a result of the ground reference being coupled through transistor 16 to the output 18. In FIG. 1D the P-channel and the N-channel MOS transistors have been interchanged with respect to the ground reference in the embodiment of FIG. 1C and it also performs the AND gate logic function. Here the A logic signal is fed to the drain of transistor 16 and the B logic signal is fed to the gates of transistors 12 and 16. The source of transistor 12 is at ground potential. The source of transistor 16 and the drain of transistor 12 are connected to output 18. The embodiments shown in FIGS. 1C and 1D may result in some sacrifice of both noise immunity and soeed, but such limitations do not outweigh the advantages of reduced transistors for implementing various logic functions. FIG. 5A shows a logic symbol equivalent for the circuit in FIG. 1C.
Referring now to FIGS. 2A to 2D, four embodiments of an OR gate are shown. In FIG. 2A four MOS transistors 20, 22, 24, 26 are interconnected as shown, transistors 20 and 26 being N-channel enhancement mode MOS transistors and transistors 22 and 24 being P-channel enhancement mode MOS transistors. The gates of transistors 20 and 24 are fed by a B logic signal. An A logic signal is fed to the sources of transistors 24 and 26. The complement of the B logic signal, B, is fed to the gates of transistors 22 and 26. The drains of transistors 20 and 22 are connected to a V DD voltage reference. The sources of transistors 20 and 22 and the drains of transistors 24 and 26 are connected to an output 28.
Thus, if logic signal B is 0 (and B=1) and logic signal A is 0, transistors 20 and 22 will be OFF and transistors 24 and 26 will be switched ON and the A logic signal 0 will be coupled to output 28 thereby providing a logic 0 output. Then if logic signal B becomes a logic 1 while A remains at logic 0, transistors 24 and 26 switch OFF and transistor 20 and 22 switch ON resulting in the V DD reference level being coupled to output 28 providing a logic 1 output. If logic signal A is a logic 1 and logic signal B is a logic 1, then transistors 24 and 26 are OFF and transistors 20 and 22 are ON thereby providing V DD or a logic 1 to output 18. If logic signal A is a logic 1 and logic signal B is a logic 0, then transistors 20 and 22 are OFF and transistors 24 and 26 are switched ON thereby providing the logic signal A logic 1 to output 28. The operation of the logic OR gate in FIG. 2A may thus be summarized by the following truth table:
TABLE 2______________________________________Logic Signal Output SignalA B Output______________________________________0 0 00 1 11 0 11 1 1______________________________________
Referring now to FIG. 2B there is shown an embodiment of the invention wherein the N-channel MOS transistor 20 has been removed from the circuit resulting in a three transistor circuit that still performs the OR gate logic function shown in Table 2. Similarly FIG. 2C shows another embodiment which is a further simplification of FIG. 1A by the additional removal of P-channel MOS transistor 24 resulting in a two transistor circuit that performs the same AND gate function shown in Table 2. For example, when the A logic signal is 0 and the B logic signal is 0 (hence, B=1), transistor 22 is OFF and transistor 26 is switched ON and the A logic signal (which is a logic 0) is coupled to the output 28 thereby providing a logic 0 output. If logic signal B becomes a logic 1 (B=0) and logic signal A remains a logic 0, then transistor 22 is switched ON and transistor 26 is OFF thereby providing the V DD reference or a logic 1 to output 28. If logic signal A is 1 and logic signal B is 1, transistor 22 is ON and transistor 26 is OFF thereby providing the V DD reference or a logic 1 to the output 28. Finally, if logic signal A is 1 and logic signal B is 0 (B=1), then transistor 22 is OFF and transistor 26 is ON, thereby coupling the logic signal A (which is a logic 1) to the output 28. Again the truth table for an OR gate shown in Table 2 is produced.
In FIG. 2D the P-channel and N-channel MOS transistors have been interchanged with respect to the V DD reference and the embodiment of FIG. 2C, and this rearranged 2 transistor circuit also performs the OR gate logic function shown in Table 2. Here the B logic signal is fed to the gates of transistors 22 and 26 and the A logic signal is fed to the source of P-channel transistor 22. The source of transistor 26 and the drain of transistor 22 are connected to the output 28 port. The drain of N-channel transistor 26 is connected to the V DD reference. The embodiments shown in FIGS. 2C and 2D may result in some sacrifice of both noise immunity and speed, but as stated previously for the AND gate configuration, such limitations do not outweight the advantages of reduced transistors for implementing logic functions. FIG. 5B shows a logic symbol equivalent for the circuit in FIG. 2C.
Referring now to FIGS. 3A and 3B an embodiment of the invention is shown wherein a replication of the basic 2-input AND gate circuit is employed in a cascaded manner to perform higher order logic functions. A 3 variable AND function is accomplished by the embodiment shown in FIG. 3A and also by the simplified embodiment shown in FIG. 3B. The logic circuit shown in FIG. 3A performs a 3 variable AND gate function and comprises AND gate 40 and AND cate 42. Each of the AND gates 40 and 42 is equivalent to the 2 variable AND gate shown in FIG. 1A and the simplified AND gates 60 and 62 are each equivalent to the simplified AND gates shown in FIG. 1D. The cascaded AND gates 40 and 42 in FIG. 3A and AND gates 60 and 62 in FIG. 3B both perform the AND logic function according to the following truth table:
TABLE 3______________________________________A B C OUTPUT______________________________________0 0 0 00 0 1 00 1 0 00 1 1 01 0 1 01 1 0 01 1 1 1______________________________________
The circuit in FIG. 3A requires as inputs not only the three logic signals A, B and C but also B and C. Logic signal A is fed to the drains of MOS transistors 43 and 44, logic signal B is fed to the gates of MOS transistors 43 and 45 and the complement, B, of logic signal B is fed to the gates of MOS transistors 44 and 46. The source of MOS transistors 45 and 46 are coupled to a ground reference. The output 47 of AND GATE 40 which is coupled to the source of MOS transistor 44 and the drain of MOS transistor 46 is fed forward to an input of the next cascaded 2 variable AND gate stage, AND GATE 42; output 47 is coupled to AND gate 42 and particularly to the drains of MOS transistors 50 and 51. A logic signal C is fed to the gates of MOS transistors 50 and 52 and a logic signal C (the complement of C) is fed to the gates of MOS transistors 51 and 53 in AND gate 42. The sources of MOS transistors 52 and 53 are coupled to the ground reference. The output 54 is coupled to the drains of MOS transistor 52 and 53 and the sources of MOS transistors 50 and 51. Additional stages of AND gates identical to AND gate 40 or AND gate 42 are cascaded in a similar manner to perform the logical AND function for additional logic signals.
Referring now to FIG. 3B, the simplified AND gate 60 and AND gate 62 are cascaded for handling the three logic signals A, B and C and in this embodiment it is unnecessary to provide the complement of these logic signals in order to perform an AND gate logic function. The A logic signal is fed to the drain of MOS transistor 63 in AND gate 60 and the B logic signal is fed to the gates of MOS transistors 63 and 64. The source of MOS transistor 64 is coupled to the ground reference. The output 65 of AND gate 60 is fed to the next stage which comprises AND gate 62 and in particular to the drain of MOS transistor 66. A logic signal C is fed to the gates of MOS transistors 66 and 67. The logic output 68 is coupled to the drain of MOS transistor 67 and the source of MOS transistor 66. For each additional logic signal, an additional AND gate stage may be coupled in a cascaded manner to the output of the previous AND gate stage such as AND gate 62.
Referring now to FIGS. 4A and 4B an embodiment of the invention is shown wherein a replication of the basic 2 variable OR circuit is employed in a cascaded manner to perform higher order logic functions. A three variable OR function is accomplished by the embodiment shown in FIG. 4A and also by the simplified embodiment shown in FIG. 4B. The logic circuit shown in FIG. 4A performs a three variable OR gate function and comprises OR gate 70 and OR gate 72. Each OR gate 70 and 72 is equivalent to the 2 variable OR gate shown in FIG. 2A and the simplified OR gates 90 and 92 are each equivalent to the simplified OR gate shown in FIG. 2D. The cascaded OR gates 70 and 72 in FIG. 4A and the OR gates 90 and 92 in FIG. 4B perform the logic function according to the following truth table:
TABLE 4______________________________________A B C OUTPUT______________________________________0 0 0 00 0 1 10 1 0 10 1 1 11 0 1 11 1 0 11 1 1 1______________________________________
The circuit in FIG. 4A requires as inputs not only the three logic signals A, B and C but also the complements B and C. Logic signal A is fed to the drains of MOS transistors 75 and 76 of OR gate 70, logic signal B is fed to the gates of MOS transistors 73 and 75 and B is fed to the gates of MOS transistors 74 and 76. The drains of MOS transistors 73 and 74 are connected to a V DD reference and the output 77 of OR gate 70 is coupled to the sources of MOS transistors 73 and 74 and the drains of MOS transistors 75 and 76. Output 77 is fed to OR gate 72 and in particular to the sources of MOS transistors 82 and 83. In addition, logic signal C is fed to the gates of MOS transistors 80 and 82 and the comolement of logic signal C, C is fed to the gates of MOS transistors 81 and 83. An output 84 of the 2-stage OR gate of FIG. 4A is coupled to the sources of MOS transistors 80 and 81 and the drains of MOS transistors 82 and 83. Additional stages of OR gates identical to OR gate 70 and OR gate 72 are cascaded in a similar manner to perform the logical OR function for additional logic signals.
Referring now to FIG. 4B, the simplified OR gate 90 and OR gate 92 are cascaded for handling the three logic signals A, B and C and in this embodiment it is unnecessary to provide the complement of these logic signals in order to perform an OR gate logic function. The A logic signal is fed to the drain of MOS transistor 94 in OR gate 90 and the B logic signal is fed to the gates of MOS transistors 93 and 94. The drain of MOS transistor 93 is coupled to a V DD reference. The output 95 of OR gate 90 is fed to the next stage which comprises OR gate 92 and the logic signal C is fed to the gates of MOS transistors 96 and 97. The output 98 of OR gate 92 is coupled to the source of MOS transistor 96 and the drain of MOS transistor 97. Therefore, it can be readily seen that for each additional logic signal, an additional OR gate stage may be added in a cascaded manner to the output of the previous OR gate stage such as OR gate 92.
Referring now to FIG. 6 there is shown an alternate embodiment of the invention for a 3-input (A,B,C) AND gate 100 logic circuit implemented with CMOS transmission gates 103, 107, 111 and 115, each of which comprises a pair of P-channel and N-channel MOS transistors having their gates fed by complementary logic signals. For example, transmission gate (T-gate) 103 comprises P-channel MOS transistor 102 and N-channel MOS transistor 104 and the gate of transistor 102 is fed by a B logic signal whereas the gate of transistor 104 is fed by a B logic signal. The other transmission gates 107, 111, 115 are similarly configured. An A logic signal is fed to an input of T-gate 103 and an output of T-gate 103 is coupled to an input of T-gate 107. The control gates of T-gate 107 are fed by logic signals C and C and the output of T-gate 107 is coupled to the output 118 of the AND gate 100. For each of the B and C input logic signals, T-gates 111 and 115 are connected in parallel between output 118 and a fixed reference potential which is ground for said AND gate 100. The B and B logic signals are fed to the control gates of T-gate 111 and the C and C logic signals are fed to the control gates of T-gate 115 shown in FIG. 6. AND gate 100 may be expanded to handle additional logic signal inputs by simply inserting for each additional input signal a T-gate in series with T-gate 107 and output 118 and another T-gate in parallel with T-gate 115 and coupled between output 118 and the ground reference potential. Simplifications of T-gates may be performed in AND gate 100 as was similarly done for a two-input AND as shown in FIGS. 1A to 1D depending on integrated circuit layouts and the particular circuit characteristics desired for an application.
Referring now to FIG. 7, there is shown an alternate embodiment of the invention for a 3-input (A,B,C) OR gate 120 logic circuit implemented with CMOS transmission gates (T-gates) 123, 127, 131 and 135 each of which comprises a pair of P-channel and N-channel MOS transistors having their gates fed by complementary logic signals. For example, transmission gate 123 comprises P-channel MOS transistor 122 and N-channel MOS transistor 126 and the control gate of transistor 122 is fed by a B logic sicnal whereas the gate of transistor 124 is fed by a B logic signal. The other transmission gates 127, 131 and 135 are similarly configured. An A logic signal is fed to an input of T-gate 123 and an output of T-gate 123 is coupled to an input of T-gate 127. The control gates of T-gate 127 are fed by logic signals C and C and the output of T-gate 127 is coupled to the output 138 of the OR gate 120. For each of the B and C input locic signals, T-gates 131 and 135 are connected in parallel between output 138 and a fixed reference potential which is V DD in said OR gate 120. The B and B logic signals are fed to the control gates of T-gate 131 and the C and C logic signals are fed to the control gates of T-gate 135 as shown in FIG. 7. OR gate 120 may be expanded to handle additional logic signal inputs by simply inserting for each additional input signal a T-gate in series with T-gate 127 and output 138 and another T-gate in parallel with T-gate 135 and coupled between output 138 and the V DD reference potential. Simplification of the T-gates may be performed in OR gate 120 as was similarly done for a two-input OR gate as shown in FIGS. 2A to 2D depending on integrated circuit layouts and the particular circuit characteristics desired for an application.
This concludes the description of the preferred embodiments. However, many modifications and alterations will be obvious to one of ordinary skill in the art without departing from the spirit and scope of the inventive concept. For example, the AND gate embodiments of the invention shown in FIG. 1B and FIG. 1C may be cascaded in a similar manner as the AND gate of FIG. 1D is shown cascaded in FIG. 3B; and likewise, the OR gate embodiments of the invention shown in FIG. 2B and FIG. 2C may be cascaded in a similar manner as the OR gate of FIG. 2D is shown cascaded in FIG. 4B. Therefore, it is intended that the scope of this invention be limited only by the appended claims. | Unified CMOS logic circuits are based on a structured implementation of transmission-gates. The basic logic building blocks for AND and OR circuits comprise a plurality of transmission-gates some of which may be simplified to a reduced form of a single pass transistor resulting in fewer transistors for implementing logic functions without loss of logic circuit performance characteristics. Three variable logic functions and higher order logic functions are easily implemented. Generally, the required VLSI chip area is minimized as a result of this structured transmission-gate approach. | 7 |
FIELD OF THE INVENTION
[0001] The present invention relates to a laser direct imaging (LDI) apparatus and an imaging method for moving a workpiece in a sub-scanning direction while deflecting a laser beam, which has been modulated based on raster data, toward a main scanning direction so as to image a desired pattern on the workpiece.
BACKGROUND OF THE INVENTION
[0002] In an LDI apparatus, CAD data used for designing a circuit pattern are converted into vector data format, and then contours are calculated from the vector data. After that, the contours are further converted into raster data for imaging. From the raster data, ON and OFF pixels for a laser beam are obtained. The ON pixels are irradiated with the laser beam.
[0003] FIG. 7 is a view showing a configuration of background-art LDI apparatus.
[0004] A laser source 1 is mounted on an optical table 16 . The optical table 16 is disposed on a column 17 on a bed 18 . A laser beam 5 emitted from the laser source 1 enters an acousto-optic modulator (hereinafter referred to as “AOM”) 4 reflected by mirrors 2 and an expander 3 . A laser beam 5 a modulated by the AOM 4 is deflected by a polygon mirror 6 and enters an fθ lens 7 . The laser beam 5 a emerged from the fθ lens 7 is deflected toward the downward direction of FIG. 7 by a reflection mirror 8 , and enters a cylindrical lens 9 . The laser beam 5 a emerged from the cylindrical lens 9 is incident on a workpiece 10 . A dry film resist (hereinafter referred to as “DFR”), a photo-resist or the like on the workpiece 10 is exposed to the laser beam 5 a . On this occasion, a table 12 where the workpiece 10 is mounted moves in a sub-scanning direction (Y-axis direction in FIG. 7 ) at a constant speed. A linear motor 14 moves the table 12 . A pair of guides 13 guide the table 12 . A camera 60 is disposed above the table 12 . The camera 60 is mounted on a not-shown shifter by which the camera 60 can be positioned desirably in the X-axis direction. The camera 60 is connected to a not-shown image processor. For example, in order to determine an imaging position, the camera 60 is used for picking up images of alignment marks disposed in the surface of the workpiece 10 (Patent Document 1).
[0005] FIGS. 8A and 8B are views showing the position of a start sensor. FIG. 8A is a view in the X-axis direction of FIG. 7 , and FIG. 8B is a view in the Y-axis direction of FIG. 7 .
[0006] A mirror 11 is disposed under the left end portion of the cylindrical lens 9 in FIG. 7 . A start sensor 15 is disposed in the direction of reflected laser beam from the mirror 11 . In order to align the scanning start points of rows, which mean the rows of the exposed pixels by the main scanning (X-axis direction), imaging in each scan in the main scanning direction is started when a predetermined time has passed after the start sensor 15 has detected the laser beam 5 a reflected by the mirror 11 (the distance between the detection position and the imaging start position is 10 mm in the illustrated case). Thus, the scanning start points of rows are aligned.
[0007] To machine a printed circuit board, xy coordinate axes are determined with reference to alignment marks provided in the surface of the printed circuit board (workpiece) in advance before machining. It is difficult to fix the printed circuit board onto the table so that the xy coordinate axes are set in parallel with the XY coordinate axes of the driving system of the LDI apparatus. Therefore, a not-shown rotating mechanism is provided in the table 12 . By the rotating mechanism, the workpiece 10 is rotated so that the xy coordinate axes of the workpiece 10 can be set in parallel with the XY coordinate axes of the driving system of the LDI apparatus.
[0008] There are various methods for manufacturing so-called multilayer boards. In a pin lamination method or a mass lamination method, double-sided boards each having conductor layers disposed on the both sides of an insulating layer are laminated to one another with insulating layers interposed. In order to improve the reliability of such a multilayer board as a product, it is necessary to precisely position patterns to be disposed on front and back surfaces of each double-sided board.
[0009] When a photosensitive material such as resist is applied to surfaces of conductor layers of each double-sided board, the following technique can be used (Patent Document 1). That is, an exposure unit is provided on the back surface side. When the front surface side is being exposed to light, exposure is performed on the back surface side so as to form an alignment mark thereon. When the back surface side is exposed to light, the back surface side is machined based on the position of the alignment mark formed by the exposure in advance, as described above. According to this technique, a pattern to be disposed on the back surface side can be determined precisely with respect to a pattern disposed on the front surface side.
[0010] Patent Document 1: WO 02/39794
[0011] However, exposure is merely performed but development is not performed in the above-mentioned technique, that is, a latent image is used. Therefore, when some kind of photosensitive material is used, there is a case where the alignment mark cannot be identified. Development on printed circuit boards or partial development only near portions exposed to light in order to identify the alignment mark increases the number of processes of operation. Therefore such a solution cannot be employed.
SUMMARY OF THE INVENTION
[0012] An object of the present invention is to solve the foregoing problem. Another object of the present invention is to provide a laser direct imaging apparatus and an imaging method in which a position on the back surface side can be determined precisely with respect to the front surface side even if any kind of photosensitive material is used.
[0013] In order to attain the foregoing objects, a first configuration of the present invention provides a laser direct imaging apparatus for deflecting a laser beam toward a main scanning direction while moving a workpiece, which is mounted on a table, in a sub-scanning direction so as to image a pattern in a front surface of the workpiece. The laser direct imaging apparatus is characterized in that indentations forming unit is provided in the table and for forming indentations with a bottom in a back surface of the workpiece.
[0014] A second configuration of the present invention provides an imaging method for deflecting a laser beam toward a main scanning direction while moving a workpiece, which is mounted on a table, in a sub-scanning direction so as to image patterns in front and back surfaces of the workpiece. The imaging method is characterized in that patterns are imaged by the following steps a to e.
[0000] a. Step of mounting the workpiece on the table.
b. Step of imaging a pattern in the front surface of the workpiece while forming indentations with a bottom in predetermined positions of the back surface of the workpiece.
c. Step of turning over the workpiece, and mounting the workpiece on the table.
d. Step of determining a coordinate system of the front surface of the workpiece based on the positions of the indentations, and imaging a pattern in the back surface of the workpiece.
e. Step of removing the workpiece from the table.
[0015] The positions of the alignment marks can be known even if any kind of photosensitive material is used. Accordingly, a position on the back surface side can be determined precisely with respect to the front surface side. As a result, it is possible to improve the reliability of a multilayer board as a product and the yield of the product.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIGS. 1A-1C are views showing a configuration of a table of a laser direct imaging apparatus according to an embodiment of the present invention;
[0017] FIG. 2 is a view for explaining the configuration of a dry film;
[0018] FIGS. 3A-3C are diagrams for explaining the layout of a workpiece with respect to the table according to the embodiment of the present invention;
[0019] FIGS. 4A and 4B are views showing another embodiment of the present invention;
[0020] FIGS. 5A-5D are views showing examples of modified hollow pins;
[0021] FIG. 6 is a plan view of a table showing further another embodiment of the present invention;
[0022] FIG. 7 is a view showing a configuration of background-art laser direct imaging apparatus; and
[0023] FIGS. 8A and 8B are views showing the position of a start sensor.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0024] The present invention will be described below with reference to the drawings.
[0025] FIGS. 1A-1C are views showing a configuration of a table of a laser direct imaging apparatus according to the present invention. FIG. 1A is a plan view, FIG. 1B is a side sectional view, and FIG. 1C is an enlarged fragmentary sectional view of a portion S in FIG. 1B . Parts the same as or having the same functions as those in FIG. 7 are designated with the same reference numeral and a description thereof is omitted.
[0026] A large number of suction holes 22 connected to an internal hollow portion 18 are disposed like a lattice in the surface of a table 12 . The hollow portion 18 is connected to a not-shown vacuum system through joints 45 . The hollow portion 18 is divided into three blocks by not-shown partitions. The joints 45 are provided for the blocks respectively so that negative pressure can be applied to the blocks individually. Three positioning pins 21 a to 21 c for positioning the workpiece 10 are disposed on the surface of the table 12 . The positioning pins 21 a to 21 c are circular in section, and the tangent line to the positioning pins 21 a and 21 c are parallel to the Y axis.
[0027] Four hollow pins 20 ( 20 a - 20 d ) are fixed onto the table 12 . Each hollow pin 20 is annular in section. The center of each hollow pin 20 is aligned in parallel to the X axis. Each inside of the hollow pins 20 communicates with the hollow portion 18 . As shown in FIG. 1C , the inner edge of the tip of each hollow pin 20 is beveled to sharpen the outer edge. The hollow pins 20 a - 20 d project over the surface of the table 12 by a distance g (here 10-50 μm). The hollow pins 20 a - 20 d are placed out of an area where the workpiece 10 will be patterned.
[0028] Here, description will be made about the workpiece 10 . The workpiece 10 is constituted by a double-sided board 50 , photosensitive resists 51 and carrier films 52 . The photosensitive resist 51 is disposed (pasted) on each side of the double-sided board 50 . The carrier film 52 is disposed (pasted) outside each photosensitive resist 51 . As shown in FIG. 2 , the photosensitive resist 51 is kept as a dry film in which the carrier-film 52 whose material is, for example, polyester is disposed on one outer surface of the photosensitive resist 51 and a cover film 53 whose material is polyethylene is disposed on the other outer surface of the photosensitive resist 51 . The cover film 53 is removed (separated) when the photosensitive resist 51 is disposed on the double-sided board 50 .
[0029] Next, description will be made about the procedure of the present invention.
[0030] Here, assume that the outer shape of the workpiece is rectangular.
[0000] Step 1: The workpiece 10 is mounted on the table 12 . On this occasion, the workpiece 10 is disposed so that two adjacent sides of the workpiece 10 touch the positioning pins 21 a - 21 c.
Step 2: The vacuum system is operated to suck the workpiece 10 onto the table 12 . By the suction, the workpiece 10 is pressed onto the table 12 so that indentations (which are annular in plan view and V-shaped in thickness direction here. In accordance with the suction force of the vacuum system, the indentions may be formed only in the carrier film 52 or may extend to the photosensitive resist 51 .) are formed in the surface of the carrier film 52 (or the surfaces of the carrier film 52 and the photosensitive resist 51 ) by the hollow pins 20 a - 20 d.
Step 3: The front side surface (The illustrated surface will be referred to as “surface F”. The back side surface will be referred to as “surface B.”.) is exposed to light. The photosensitive resist is exposed to a laser beam transmitted through the carrier film (16-25 μm thick).
Step 4: When the exposure of the surface F is terminated, the vacuum system is suspended. The workpiece 10 is turned over around the Y axis and mounted on the table 12 . On this occasion, two adjacent sides of the workpiece 10 are made to touch the positioning pins 21 a to 21 c.
[0031] Step 5: The vacuum system is operated to suck the workpiece 10 onto the table 12 .
[0000] Step 6: Any two out of the indentations formed by the hollow pins 20 a to 20 d (here, we select an indentation 20 A formed by the hollow pin 20 a and an indentation 20 D formed by the hollow pin 20 d ) are observed by the camera 60 , and the coordinates of the centers of the indentations are obtained by image processing.
Step 7: The table 12 is rotated based on the coordinates of the centers of the indentations 20 A and 20 D so that the xy axes of the pattern machined in the surface F which is now on the back side are brought into parallelism (here line) with the XY coordinate axes of the driving system of the laser direct imaging apparatus. The detail will be described later.
Step 8: The surface B is exposed.
Step 9: The workpiece 10 is removed from the table 12 .
[0032] The carrier film on each side is removed prior to a development step which is an after process. When the photosensitive material is a negative type material, the photosensitive resist which was not irradiated with (exposed to) the laser beam is removed by developer, and the portion which has been exposed forms the pattern. On the other hand, when the photosensitive material is a positive type material, the portion which was irradiated by the laser beam forms the pattern.
[0033] Next, the aforementioned Step 7 will be described further in detail.
[0034] FIGS. 3A-3C are diagrams showing the procedure for positioning the back surface B. FIG. 3A shows the case of the aforementioned Step 2. FIG. 3B shows the case of the aforementioned Step 5, where the surface F has been exposed. FIG. 3C shows the result of the aforementioned Step 7.
[0035] Here, assume that the origin O of the XY coordinate axes of the driving system of the laser direct imaging apparatus is on the optical axis of the camera 60 . The reference sign P designates the rotation center of the table 12 . The hollow pin 20 d and the indentation 20 D are depicted as shaded portions.
[0036] Here, assume that the indentations 20 A and 20 D formed in the surface B by the hollow pins 20 a and 20 d respectively are used.
[0037] When Qa, Qd and QC designate the center of the hollow pin 20 a , the center of the hollow pin 20 d and the midpoint of the segment QaQd respectively, the coordinates of the center Qa, the center Qd, the midpoint QC and the rotation center P are expressed by (X1R, Y1R), (X2R, Y2R), (Xcr, Ycr) and (Xt, Yt) respectively. Since the segment QaQd is parallel to the X axis, there is a relation of the form Y1R=Y2R=Ycr.
[0038] As shown in FIG. 3A , in Step 2, the indentations 20 A and 20 D are formed in the surface B by the hollow pins 20 a and 20 d respectively.
[0039] Now assume that the coordinates of the central positions Qab and Qdb of the indentations 20 A and 20 D and the midpoint QCb (expressed with a suffix b because they are on the surface B side) measured in Step 6 are (X1, Y1), (X2, Y2) and (XC, YC) respectively as shown in FIG. 3B .
[0040] In this case, XC, YC and the tilt angle θ can be obtained by Equations 1 to 3 respectively.
[0000] XC =( X 1+ X 2)/2 (Equation 1)
[0000] YC =( Y 1+ Y 2)/2 (Equation 2)
[0000] Δθ=tan −1 {( X 2 −X 1)/( Y 2 −Y 1)} (Equation 3)
[0041] Displacements ΔX1 and ΔY1 of the midpoint QCb from the midpoint QC in the X-axis and Y-axis directions can be obtained by Equations 4 and 5 respectively.
[0000] Δ X 1= Xcr−XC (Equation 4)
[0000] Δ Y 1= Ycr−YC (Equation 5)
[0042] Here, when L designates the distance between the midpoint QCb and the rotation center P, the distance L can be obtained from Equation 6, and the tilt Δθ of the segment QCbP can be obtained from Equation 7.
[0000] L =√{( Xt−XC ) 2 +( Yt−YC ) 2 } (Equation 6)
[0000] Δθ=tan −1 {( XC−Xt )/( YC−Yt )} (Equation 7)
[0043] When the table 12 is rotated by −Δθ, the center coordinates (Xch, Ych) of the corrected midpoint QCb can be expressed by Equations 8 and 9 respectively.
[0000] Xch=L ×cos(θ+Δθ) (Equation 8)
[0000] Ych=L ×sin(θ+Δθ) (Equation 9)
[0044] Here, when Xg and Yg designate X-axis-direction and Y-axis-direction distances of the rotation center of the midpoint QCb from a reference point respectively, Xg and Yg can be expressed by Equations 10 and 11 respectively.
[0000] Xg=XC−Xt (Equation 10)
[0000] Yg=YC−Yt (Equation 11)
[0045] The X-axis-direction and Y-axis-direction displacements of the midpoint QCb caused by the Δθ rotation can be obtained from Equations 12 and 13 respectively.
[0000] Δ Xch=Xch−Xg (Equation 12)
[0000] Δ Ych=Ych−Yg (Equation 13)
[0046] Accordingly, when the table is moved in the X-axis and Y-axis directions by ΔX and ΔY expressed by Equations 14 and 15 respectively, the midpoint QCb can be brought into line with the midpoint QC as shown in FIG. 3C .
[0000] Δ X=ΔX 1+Δ Xch (Equation 14)
[0000] Δ Y=ΔY 1+Δ Ych (Equation 15)
[0047] In the aforementioned description, the indentations 20 A and 20 D were used. However, any two of the indentations 20 A- 20 D may be used.
[0048] FIGS. 4A and 4B are views showing another embodiment of the present invention. FIG. 4A is a plan view of a table end portion, and FIG. 4B is a side sectional view thereof.
[0049] A pair of guide pins 24 are disposed in opposite ends of an end portion of a table 12 . An L-shaped support 27 is fixed to a side of the table 12 . A cylinder 25 is supported in a central portion of the support 27 . A piston rod 25 a of the cylinder 25 passes through a not-shown hole formed in the support 27 and projects over the front surface of the table 12 . A plate 26 is supported on the tip of the piston rod 25 a . The plate 26 is large enough to face hollow pins 20 a - 20 d . When the piston rod 25 a is at a standby position (at the position shown by the real line in FIG. 4B ), a lower surface 26 b of the plate 26 keeps away from the surface of a workpiece 10 mounted on the table 12 . When the piston rod 25 a is at its operating position, the lower surface 26 b is positioned rather on the front surface of the table 12 , than on the surface of the workpiece 10 .
[0050] In this embodiment, the cylinder 25 may be operated at a desired time after the workpiece 10 is sucked onto the table 12 and before the workpiece 10 is released from the suction. For example, assume that each hollow pin 20 is 3 mm in its outer diameter, and a carrier sheet is 8 μm thick. In this case, when pressure of 1 kgf/cm 2 is applied, enough time for which the pressure should be applied is about 0.2 seconds.
[0051] Though not shown, the hollow pins 20 a - 20 d may be supported movably axially and designed to be able to be projected over the surface of the table 12 by a driving unit.
[0052] When each hollow pins 20 are pressed to the workpiece 10 , the carrier sheet may be cracked around the portions pressed by the hollow pins 20 . When the carrier sheet is warped due to the cracks, the imaging accuracy may deteriorate. Therefore, the occurrence of cracks is undesirable.
[0053] FIGS. 5A-5D are views showing examples of modified hollow pins 20 . FIG. 5A shows the case where a hollow pin 20 has a rounded edge in its tip. FIG. 5B shows the case where the hollow pin 20 shown in FIG. 5A is made solid. FIG. 5C shows the case where the hollow pin 20 shown in FIG. 5B is shaped into a truncated cone. FIG. 5D shows the above-mentioned hollow pin 20 shown in FIGS. 3A-3C .
[0054] In the case of FIG. 5A , due to the hollow pin 20 whose tip is rounded, it is possible to prevent the carrier sheet form being cracked around the portion pressed by the hollow pin 20 . In the case of FIG. 5B , due to the hollow pin 20 which is solid, not only is it possible to prevent the carrier sheet form being cracked around the portion pressed by the hollow pin 20 in the same manner as in the case of FIG. 5A , but it is also possible to make the maintenance easier because the tip of the hollow pin 20 does not wear down so quickly.
[0055] Any one of the hollow pins shaped thus can be used. One which can form a clearer indentation may be used selectively in accordance with the thickness or material of the carrier sheet.
[0056] When the carrier sheet in a indentation is cut off, the cut-off portion becomes waste. It is therefore practical to adjust the pressing force of the cylinder 25 to a value which is low enough to prevent the carrier sheet from being cut off in a circle.
[0057] FIG. 6 is a plan view of a table showing further another embodiment of the present invention.
[0058] Hollow pins 20 a to 20 d are disposed in a diagonal line on the surface where the workpiece 10 is mounted. If indentations can be controlled to be shallow, the hollow pins 20 can be disposed thus in an area where a pattern will be formed. In this manner, the layout of the hollow pins 20 can be less restricted. It is therefore possible to expand the intervals with which the hollow pins 20 are disposed. Thus, the positioning accuracy of the back surface can be improved further.
[0059] The present invention can be also applied to a laser direct imaging apparatus which uses a laser diode as a light source and turns on/off the laser diode directly.
[0060] The present invention can be also applied to a laser direct imaging apparatus which uses a spatial light modulator (DMD). | A laser beam direct imaging apparatus and an imaging method which can precisely determine a back-surface-side position with respect to a front-surface-side position even if any kind of photosensitive material is used. In the laser direct imaging apparatus, a laser beam is deflected toward a main scanning direction (X-axis direction) while a workpiece mounted on a table is moved in a sub-scanning direction (Y-axis direction) so that a pattern is imaged on the surface of the workpiece. Hollow pins are disposed on the table so that the tips of the hollow pins 20 project over the surface of the table by a predetermined distance. The workpiece is sucked onto the table so that indentations (indentations by the tips of the hollow pins) are formed on the back surface of the workpiece. When a pattern is imaged on the back surface, imaging is performed with reference to the indentations. | 6 |
BACKGROUND OF THE INVENTION
The present invention relates to optical communications, in general, and more particularly to apparatus and method of providing an optical connection between printed circuit (PC) boards for optical communication there-between.
Greater demands for increased bandwidth are being made on data communication between electrical data processing units or subunits, like printed circuit (PC) boards, for example. Communication rates of tens of gigabits per second are exemplary of such demands. These demands can not be met by traditional metal electrical connections, like those found on mother boards and back plane connections, for example. One solution to meet these demands is to create optical communication channels for board-to-board communication using light coupling between an array of light emitters of one PC board and an array of light detectors of another PC board.
A drawback to this solution is that a mechanical light coupling interconnection between parallel PC boards is no simple task. Thus, a simple and automatic interconnection of the light coupling between PC boards is desirable to render optical communication between PC boards a commercially viable reality. The present invention intends to satisfy this desire through suitable interconnection apparatus.
SUMMARY
In accordance with one aspect of the present invention, apparatus for connecting an interconnecting cable between first and second printed circuit (PC) boards comprises: a base member disposed on a side of the first PC board for fixedly attaching one end of the interconnecting cable to the first PC board; a first connector attached to the other end of the interconnecting cable; a second connector disposed on a side of the second PC board; and a spring member attached to the base member for supporting the first connector away from the side of the first PC board, the spring member operative to force the first connector against the side of the second PC board to cause slidable engagement of the first and second connectors when one of the first and second PC boards is slid past the other of the first and second PC boards.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view illustration of optical fiber interconnection apparatus suitable for embodying the principles of the present invention.
FIG. 1A is a cross-sectional sketch illustrating an exemplary optical interface at one end of an optical fiber cable suitable for use in an embodiment of the present invention.
FIG. 1B is a cross-sectional sketch illustrating an exemplary optical interface at the other end of the optical fiber cable suitable for use in an embodiment of the present invention.
FIG. 2 is an illustration of a pivot pin suitable for use in the embodiment of FIG. 1 .
FIG. 3 is a top view illustration of an exemplary arm suitable for use in the embodiment of FIG. 1 .
FIGS. 4A and 4B are side and top view illustrations, respectively, of a spring mechanism suitable for use in the embodiment of FIG. 1 .
FIGS. 5A , 5 B and 5 C are top, bottom and end view illustrations, respectively, of a fiber connector suitable for use in the embodiment of FIG. 1 .
FIG. 6 is a side view illustration showing one mode of operation of the embodiment of FIG. 1 .
FIG. 7 is a side view illustration showing another mode of operation of the embodiment of FIG. 1 .
FIGS. 8 and 9 are side and end view illustrations, respectively, of an alternate embodiment of the present invention.
FIG. 10 is a side view illustration of an alternate optical interconnection apparatus suitable for embodying the principles of the present invention.
FIG. 10A is a cross-sectional sketch illustrating an exemplary optical interface of optical arrays between two connectors suitable for use in an embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 is a side view illustration of optical fiber cable interconnection apparatus suitable for embodying the principles of the present invention. In the present embodiment, two PC boards 10 and 12 of a data processing system, for example, are disposed in a parallel side-by-side configuration. The PC boards 10 and 12 of the present embodiment may be fixed in place in the parallel configuration through board connectors of a backplane or a motherboard (not shown). Apparatus is provided to support optical communication between an array of light emitters on one board and an array of light detectors on the other board through a cable of optical fibers. This apparatus permits an automatic mechanical interconnect of the cable of optical fibers between PC boards 10 and 12 as one board is slid into its connector with the other board fixed in place as will become more evident from the following description.
Referring to FIG. 1 , a platform or base 14 which may be molded plastic, for example, is fixedly disposed over a side 16 of PC board 10 . One end of a cable of optical fibers 18 is aligned in cross-section with an array of emitters or detectors 20 disposed on side 16 of board 10 . The end of cable 18 is held in alignment with and in proximity to the array 20 by the base 14 as shown by way of example in the cross-sectional sketch of FIG. 1A . The base 14 includes a pivot structure 22 at a distance from the cable 18 , preferably close to an end 24 . Pivotally coupled to the pivot structure 22 is one end of an arm 26 which is forced away from the base 14 by a spring mechanism 28 attached to both the base 14 and arm 26 . A suitable spring mechanism 28 for the present embodiment is shown in the side and top view sketches of FIGS. 4A and 4B , respectively.
The arm 26 which is exemplified in structure by the top view sketch of FIG. 3 may be stamped metal or molded plastic, for example. In the present embodiment, a pivot pin, which may be either plastic or metal, is disposed through an aperture 30 in the pivot structure 22 and through co-aligned apertures at the one end of the arm 26 to provide the pivotal coupling therebetween. An example of a pivot pin for use in the present embodiment is shown in FIG. 2 . In the present embodiment, the pivot pin may be also inserted through a loop 31 in the spring mechanism 28 to provide a fulcrum for the spring 28 as well as retain the spring 28 in position. Once inserted though the corresponding apertures of the pivot structure 22 and arm 26 , and the loop 31 of spring mechanism 28 , the plain end of the pivot pin may be headed to retain it in place.
The other end of arm 26 is pivotally coupled to a connector 32 including a female interconnecting structure which is slidably engagable with a male interconnecting structure of a connector 34 which is shown in greater detail in the side view sketches of FIGS. 6 and 7 . A suitable female connector 32 for use in the embodiment of FIG. 1 is shown in top, bottom and end views in FIGS. 5A , 5 B and 5 C, respectively. Referring to FIGS. 5A–5C , the female connector 32 includes pivot structures 36 at opposite sides of the top thereof. Each pivot structure 36 includes an aperture 38 . Apertures at other end of the arm 26 are co-aligned with the apertures 38 of the pivot structure 36 and another pivot pin may be inserted through the corresponding apertures of the connector 32 and arm 26 to render the pivotal coupling in the present embodiment. This pivot pin may be headed after insertion to hold it in place.
Also, at opposite sides of the bottom of the female connector 32 are wrap-around winged female interconnecting structures 40 which accommodate the slidable engagement and mating with the male interconnecting structure of connector 34 as shown in FIG. 1 . In addition, the female connector 32 includes an aperture 42 through the body thereof which is aligned over an array of emitters or detectors 44 in the male connector 34 in the mated state. The other end of the cable of optical fibers 18 may be attached to the aperture 42 so that when the female connector 32 is mated with the male connector 34 as shown in FIG. 1 , the other end of the cable 18 will be aligned in cross-section over the array 44 as shown by way of example in the cross-sectional sketch of FIG. 1B . In the present embodiment, a ramp like structure 46 is disposed on a side 48 of board 12 and the male connector 34 containing the array 44 is fixedly disposed in the vicinity of the peak of ramp structure 46 . The ramp structure 46 may be stamped metal or molded plastic, for example. Wiring 49 from the array 44 may pass through the connector 34 and ramp section 46 to circuitry on the PC board 12 .
Moreover, the length of the cable 18 may be made greater then the distance between boards 10 and 12 so that when connectors 32 and 34 are mated, the cable 18 will flex and bend slightly. Structural features of the combination of components including the base 14 , arm 26 , the pivot structures 22 and 36 and the female connector 32 serve to limit the possible rotation of the arm/connector assembly and maintain the female connector 32 within a few degrees of parallel to the board 10 . Thus, in the fully extended position, very little, if any, force is exerted on the cable 18 . In the present embodiment, the extended position of the arm/connector assembly is controlled in order to provide accurate initial engagement of the connector 32 with the ramp 46 without stubbing into the leading edge of the other board 12 as will become more evident from the following description. Accordingly, the length of cable 18 may be made commensurate with a desired distance that the arm 26 is permitted to rotate or move when unmated.
FIG. 6 is a side view illustration of the present embodiment showing a slidable engagement of the female connector 32 of board 10 with the male connector 34 of board 12 . In the illustration of FIG. 6 , board 12 is connected in place and board 10 is being moved in the direction of arrow 50 in parallel with board 12 for connection. In this state, due to the controlled extension of the arm/connector assembly as described above, female connector 32 makes initial contact with side 48 of board 10 and then, traverses up the ramp structure 46 . The spring mechanism 28 maintains a force on arm 26 to keep the connector 32 pressed against the surface of ramp 46 . Eventually, the female connector 32 will slidably engage the male connector 34 in the vicinity of the peak of the ramp 46 and will be fully engaged with the connector 34 when the board 10 is connected in place as shown by the illustration of FIG. 1 . Note that when board 10 is connected and the connectors 32 and 34 are fully engaged, the cross-section of the other end of cable 18 will be aligned with the array 44 as shown in FIG. 1B . Note that board 10 may be withdrawn from its connection and the connectors 32 and 34 disengaged in a reverse process to that of the foregoing.
FIG. 7 is a side view illustration of the present embodiment showing a slidable engagement of the female connector 32 of board 10 which is connected in place with the male connector 34 of board 12 which is being moved in the direction of arrow 52 in parallel with board 10 for connection. In this state, due to the controlled extension of the arm/connector assembly as described above, female connector 32 makes initial contact with side 48 of board 12 and then, traverses up the ramp structure 46 . The spring mechanism 28 maintains a force on arm 26 to keep the connector 32 pressed against the surface of ramp 46 from the opposite side. Eventually, the female connector 32 will slidably engage the male connector 34 in the vicinity of the peak of the ramp 46 and will be fully engaged with the connector 34 when the board 12 is connected in place as shown by the illustration of FIG. 1 . Note that when board 12 is connected and the connectors 32 and 34 are fully engaged, the cross-section of the other end of cable 18 will be aligned with the array 44 as shown in FIG. 1B . Note that board 12 may be withdrawn from its connection and the connectors 32 and 34 disengaged in a reverse process to that of the foregoing.
While the foregoing described embodiment uses a female interconnection structure for connector 32 and a male interconnection structure for connector 34 , it is understood that connector 32 may include a male interconnection structure and connector 34 a female interconnection structure to afford the same slidable engagement therebetween without deviating from the broad principles of the present invention. Alternatively, the interconnection structures for connectors 32 and 34 may be hermaphroditic.
FIGS. 8 and 9 are illustrations of side and end views, respectively, of an alternate embodiment of the present invention. FIGS. 8 and 9 show the alternate embodiment in mated alignment with boards 10 and 12 connected in their parallel configuration. All of the components of the embodiment of FIG. 1 may remain as described except for the springed and pivoted arm assembly which is being replaced in the alternate embodiment by a hollow plastic tubular spring member 60 which may be formed by molding, for example. The spring member 60 is fixedly attached at one end to the base 14 and the female connector 32 is attached at the other end thereof. One end of the cable 18 is attached to the base 14 through one end of the spring member 60 so that it is aligned in cross-section with the array 20 on the board 10 as shown in FIG. 1A and the other end of cable 18 is attached to the connector 32 through the other end of the spring member 60 so that it may be aligned in cross-section with the array 44 at the male connector 34 when the connectors are engaged as shown in FIG. 1B . Also, the connectors 32 and 34 are slidably engagable and disengagable in a similar manner as described for the embodiment of FIG. 1 .
The spring member 60 provides support for and controls the extension of female connector 32 in an unmated state. It also provides a spring force for the female connector 32 when engaged with side 48 of board 12 and alignment of connector 32 for slidable engagement with connector 34 . Accordingly, when one board is connected in place and the other board is slid in parallel configuration with the one board into its connector, the female connector 32 is forced against the side 48 and ramp 46 by a compression of the spring member 60 and slidably engages male connector 34 with movement of the sliding board. As with the embodiment of FIG. 1 , when the sliding board is connected, the connectors 32 and 34 will be fully engaged. Thus, the alternate embodiment of FIGS. 8 and 9 allows either board 10 or 12 to be inserted into its connector with an automatic mechanical slidable engagement of the connectors 32 and 34 . Once both boards 10 and 12 are connected in parallel configuration, the cable of optical fibers will be automatically aligned with the arrays 20 and 44 and optical communication between boards may commence.
Either of the foregoing described embodiments may include a low-force plastic detent, which may be formed by molding, to provide coarse alignment in the axis in the direction of slide. Also, the cable fibers and/or arrays may be attached to the slidable male and female connectors using several techniques comprising: (a) potting with an epoxy compound, (b) over-molding the fibers into an array that may be laser trimmed to effect and even mating cross-section surface, (c) looming individual fibers of the cable into an array that may be attached with an epoxy compound to provide retention and an even mating surface, (d) looming individual fibers of the cable into an array that uses “hose barb” features to retain the individual fibers, and may be laser trimmed to provide retention and an even mating surface, and (e) molding, potting, sliding or snapping an entire array assembly of emitters or detectors, including a small printed wiring board (PWB), into either connector, for example.
FIG. 10 is a side view illustration of yet another embodiment of the present invention in which the optical fiber cable 18 is eliminated and the optical array 20 is moved from the PC board 10 as shown in FIG. 1 to the connector 32 so that when the connectors 32 and 34 are mated, the optical arrays 20 and 44 will be in close proximity and aligned with one another. Referring to FIG. 10 , the optical array 20 is disposed in the connector 32 and electrically connected to circuitry on PC board 10 through a wiring cable 70 which is held in place at the PC board end by an aperture in the base 14 , for example. The cross-sectional sketch of FIG. 10A illustrates an exemplary optical interface between connectors 32 and 34 .
Referring to FIG. 10A , as described herein above, the aperture 42 of connector 32 is positioned to be aligned with the array 44 when the connectors 32 and 34 are mated (see FIG. 1B ). In the present embodiment, instead of the optical fiber cable 18 , the optical array 20 itself is disposed at the aperture 42 of connector 32 and oriented to face the optical array 44 . Accordingly, when the connectors 32 and 34 are mated as shown in FIG. 10A , the arrays 20 and 44 will be aligned with one another. Wiring cables 70 and 49 will connect the elements of their respective optical arrays 20 and 44 to the respective PC boards 10 and 12 . The array 20 and wiring cable 70 may be affixed to the connector 32 at the aperture 42 by an adhesive material or potting compound 72 , for example.
While this alternate embodiment has been described in connection with the pivoted arm interconnection apparatus of FIG. 1 , it is understood that it may be applied just as well to the tubular spring member apparatus of FIGS. 8 and 9 by moving the array 20 to the connector 32 and replacing the optical fiber cable 18 with the wiring cable 70 as shown in FIG. 10A , for example.
While the present invention has been described herein above in connection with a plurality of embodiments, it is understood that this presentation was made entirely by way of example. Accordingly, the present invention should not be limited to any particular embodiment, but rather construed in breadth and broad scope in accordance with the recitation of the claims appended hereto. | Apparatus for connecting an interconnecting cable between first and second printed circuit (PC) boards comprises: a base member disposed on a side of the first PC board for fixedly attaching one end of the interconnecting cable to the first PC board; a first connector attached to the other end of the interconnecting cable; a second connector disposed on a side of the second PC board; and a spring member attached to the base member for supporting the first connector away from the side of the first PC board, the spring member operative to force the first connector against the side of the second PC board to cause slidable engagement of the first and second connectors when one of the first and second PC boards is slid past the other of the first and second PC boards. Apparatus and method of providing optical connection between a first optical array electrically coupled to a first printed circuit (PC) board and a second optical array electrically coupled to a second PC board for providing optical communication between the first and second optical arrays are also disclosed. | 6 |
This application is a National Stage completion of PCT/EP2008/063438 filed Oct. 8, 2008, which claims priority from German patent application serial no. 10 2007 049 266.0 filed Oct. 15, 2007.
FIELD OF THE INVENTION
The present invention relates to a double clutch transmission for a motor vehicle.
BACKGROUND OF THE INVENTION
Known from the publication DE 103 05 241 A1 is a 6-speed or 7-speed dual clutch transmission. The dual clutch transmission comprises two clutches, each connected with their inputs to the drive shaft and with their output to one of the two transmission input shafts. The two transmission input shafts are coaxially positioned each other. In addition, two countershafts are arranged to be axially parallel to the transmission input shafts, their idle gears mesh with the fixed gear wheels of the transmission input shafts. Furthermore, coupling devices that are axially movable and arranged on the countershaft in a rotationally fixed manner to shift the respective gear wheels. Each selected ratio is transferred by the drive gear wheels to a differential transmission. To achieve the desired gear ratio steps in this known double clutch transmission, a vast number of gear planes are required, so that a significant amount of installation space is needed.
In addition, a spur gear change speed transmission is known through the publication DE 38 22 330 A1. The spur gear change speed transmission comprises a double clutch, that is shiftable under power, where one part is connected with a drive shaft and the other part with a hollow drive shaft, rotatably supported on the drive shaft. For certain gear ratios, the drive shaft can be coupled with the hollow drive shaft via a shifting device.
Known from the publication DE 10 2004 001 961 A1 is a power transmission with two clutches, each of which are assigned to a partial transmission. The transmission input shafts of the two partial transmissions are positioned coaxial to each other and mesh, via fixed gear wheels, with idle gears of the designated countershaft. The respective idle gears of the countershafts can be connected, in a rotationally fixed manner, with the respective countershaft via designated shifting devices. The particular idle wheels of the countershaft can be connected via the assigned shifting devices with the associated countershaft in a rotationally fixed manner. A double clutch transmission is known from this publication, which absolutely requires at least six gear planes. Hence, the needed spatial installation requirement, in axial direction, increases with such transmission, so that the installation options are significantly limited with such known transmission.
SUMMARY OF THE INVENTION
It is the task of this present invention, to propose a double clutch transmission as in the previously described type, in which the power shiftable gear ratio steps are realized with the least spatial installation requirement, secondly, the transmission shall need only few component parts, hereby keeping the manufacturing cost for the transmission low.
Thus, a double clutch transmission with just five gear planes in the partial transmissions is realized, whereby the two partial transmissions can be coupled via at least one additional shifting device, to enable winding-path gears. Hereby, the proposed double clutch transmission realizes as few gear planes as possible, but providing a maximum number of transmission ratios, whereby preferably all forward gears and reverse gears are power shiftable in sequential mode.
The gear wheels of both partial transmissions are coupled with each other as a winding-path gear, to enable a flow of force through both partial transmissions. The respective shifting device which is used serves to couple idle gears and establish a dependency between transmission input shafts. Independently of the particular embodiment of the double clutch transmission, the configuration of the shifting devices for the coupling of two particular idle gears can be varied, so that the shifting element does not need to be positioned necessarily between the idle gears which need to be coupled.
Because of the low number of required gear planes, a short, axial configuration length is required for the proposed transmission, which enables also a front-transversal implementation into motor vehicles. Due to the fact that the inventive double clutch transmission also provides winding-path gears, and because of the three-shaft configuration, the multi-use of particular gear pairs or gear wheels, respectively, is enabled, which leads to a reduction of parts of the transmission.
In the proposed double clutch transmission, in accordance with the invention, gear planes can be provided, as a so-called dual gear plane and/or single gear plane. In a dual gear plane, an idle gear on the countershafts is each assigned to a fixed gear wheel of a transmission input shaft. To the contrary, in a single gear plane, just one idle gear on a countershaft is assigned to a fixed gear wheel of a transmission input shaft. Due to the fact that, in each dual gear plane, one idle gear can be used for at least two gears, the possible multi-use idle gears enables the realization of a certain number of gear ratios with less gear planes. Hence, the physical length of the transmission can be reduced.
For the use of single gear planes, in which just one idle gear on a countershaft is assigned to the fixed gear wheel of a transmission input shaft, a free range of the transmission ratios is possible.
The winding-path gears can be realized through several gear pairs or gear planes, respectively, so that additional gears can be shifted via the particular gear pairs or gear planes, respectively of the winding-path gears.
The proposed gear planes, in accordance with the inventive double clutch transmission, provide a gear set configuration to obtain at least seven forward gears and at least one reverse gear ratio, whereby at least one winding-path gear can be realized in the first gear step and/or can be shifted in one of the reverse gears can. Also additional winding-path gears can be shifted as the second up to the seventh gear, or also as reverse gear, whereby the seventh gear, depending on the sixth gear, can be power shifted. All forward gears and reverse gears should be, in sequential design, power shiftable. Non-power shiftable winding-path gears can be configured as intermediate gears, in which the transmission takes place between the ratios of two main drive gears, as overdrive gears or speed gears in which the gear ratio is smaller then the smallest gear ratio of the main drive gear (6 th gear), as an off-road gear or low speed gear in which the gear ratio in each case is larger than the gear ratio of the first gear, and/or as additional reverse gears.
The power shiftable reverse gears, in the inventive double clutch transmission, are realized through just one additional arrangement or through just one additional gear wheel whereby and at least, through the additional gear plane, which reverses the rotation, a reverse gear can be realized as winding-path gear, and another reverse gear can be realize directly via the gear plane. The gear ratios of the reverse gears can, for instance, be varied by adding an additional step gear or similar.
Within the scope of an embodiment variation of the present invention, it can be provided that the four gear planes are realized through maximal two fixed gear wheels on each transmission input shaft, which mesh, for instance, with a maximum of four or less idle gears on the countershafts. Other constructions of embodiments are possible to realize the four gear planes.
In this embodiment variation, at least seven power shift forward gear and several reverse gear ratios can be realized, whereby at least the first gear can be configured as a winding-path gear and one of the reverse gears can be configured as a winding-path gear. The additional shifting device which is realized as the winding-path gears, is positioned in this embodiment variation on the first countershaft, between the second and the third gear plane. Other configuration options are also possible and additional shifting devices can be applied. The first reverse gear can be realized, as a winding-path gear, via the same clutch as the first gear. The second reverse gear can be arranged on the other clutch to be power shfited.
Another variation of the invention can provide that at least seven power shift forward gears and two reverse gear ratios can be realized, whereby at least a first gear is configured as a winding-path gear and the second reverse gear is configured as a winding-path gear.
Within the scope of and additional embodiment variation of the present invention and contrary to the previously described embodiment variation, an additional shifting device is provided to couple the partial transmissions on the second countershaft between the second and third gear planes. In this embodiment variation, at least seven power shift forward gears and one reverse gear are realized. The reverse gear is preferably configured as a winding-path gear.
To connect the idle gears in a rotationally fixed manner, for the individual gear ratio steps with the respective countershaft, dual action coupling devices are provided, for instance, between the third gear plane and the fourth gear plane on at least one of the countershafts. In addition, a single action coupling device can be positioned at least on one of the countershafts. The coupling devices can comprise, for instance, hydraulic actuated clutches or also interlocking claw clutches, as well as any kind of synchronization device. It is also possible to replace a dual action coupling device by two single action coupling devices and, vice versa.
It is possible to vary the presented configuration options, and also the number of the gear wheels as well as the number of the coupling devices can be altered, to realize further load or non-load shiftable gears, to realize installation space savings and the use of lesser parts in the proposed double clutch transmission. In addition, the respective configuration positioned of the coupling devices in the gear plane can be varied. Furthermore, also the operating direction of the coupling devices can be altered or extended, respectively.
Independent of the particular embodiment variation of the double clutch transmission, the drive shaft and the output shaft, preferably, do not need to be positioned coaxially to each other, which realizes especially an installation space saving configuration. For instance, shafts, which are spatial positioned one after the other, can also have a slight offset to each other. In that configuration, a direct gear with the transmission ratio one can be realized via gear meshing, and can, in an advantageous way, can be freely shifted to the fifth, the sixth, or the seventh gear. Other configuration options of the drive shaft and the output shaft are also possible.
The proposed double clutch transmission is preferably equipped with an integrated output stage. The output stage can comprise an output gear, a fixed gear wheel on the output shaft, which mesh is with a fixed gear wheel on the first countershaft, as well as with a fixed gear wheel on the second countershaft.
Advantageously, the lower forward gears and the reverse gears can be activated through a starting, or shifting clutch, to hereby concentrate higher loads on this clutch and to construct the second clutch with less need for installation space and as more cost-effective. Especially, the gear planes in the proposed double clutch transmission can be positioned in a way that one can start, through the inner transmission input shaft or through the outer transmission input shaft, hereby always a starting through the more appropriate clutch, which is also possible in a concentrically positioned, radial interlaced construction of the double clutch. Hereby and accordingly, the gear planes can be positioned as mirror-symmetric, or swapped, respectively. It is also possible to swap the countershafts or positioned them in a mirroring way.
BRIEF DESCRIPTION OF THE DRAWINGS
Following, the present invention is further explained based on the drawings. It shows:
FIGS. 1 and 1A a schematic view of the first embodiment of a 7-gear double clutch transmission with an exemplary shifting scheme;
FIGS. 2 and 2A a schematic view of a second embodiment variation of the inventive 7-gear double clutch transmission with an exemplary shifting scheme; and
FIGS. 3 and 3A a schematic view of a third embodiment variation of the inventive 7-gear double clutch transmission with an exemplary shifting scheme.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
An inventive 7-gear double clutch transmission comprises two clutches K 1 , K 2 , the input sides of which are connected to a drive shaft w_an. Also, a torsion vibration damper 16 can be mounted on the drive shaft w_an. The output sides of the clutches K 1 , K 2 are each connected with one of two transmission input shafts w_K 1 , w_K 2 , which are arranged coaxial to each other. The first transmission input shaft w_K 1 is designed as a solid shaft and the second transmission input shaft w_K 2 is designed as hollow shaft. In addition, countershafts w_vorlege 1 , w_vorgelege 2 are provided which are positioned to be axial-parallel to each other. The coupling of the two transmission input shaft w_K 1 and w_K 2 takes place by way of a shifting device H via tooth meshing, so that the transmission input shafts w_K 1 and w_K 2 are coupled together.
Only four gear planes are provided in the 7-gear dual clutch transmission. In the first embodiment variation, in accordance with FIG. 1 , the four gear planes 01 - 05 , 02 - 13 , 03 - 06 , 04 - 07 are each realized via the fixed gear wheels 12 , 13 ; 14 , 15 of the two transmission input shafts w_K 1 , w_K 2 and by way of the four idle gears 01 , 02 , 03 , 04 on the first countershaft w_vorgelege 1 , as well as through the idle gears 05 , 06 , 07 on the second countershaft w_vorgelege 2 .
In the embodiment variation, in accordance with FIG. 1 , the first gear plane 01 - 05 and the third gear plane 03 - 06 , as well as the fourth gear plane 04 - 07 are each designed as dual gear plane. The second gear plane 02 - 13 , however, is designed as single gear plane.
In the first gear plane 01 - 05 , the fixed gear wheel 12 on the second transmission input shaft w_K 2 meshes with the idle gear 01 on the first countershaft w_vorgelege 1 , and with the idle gear 05 on the second countershaft w_vorgelege 2 . The second gear plane 02 - 13 comprises the fixed gear wheel 13 on the second transmission input shaft w_K 2 , which only meshes with the idle gear 02 on the first countershaft w_vorgelege 1 . Hence, the fixed gear wheel 13 on the second transmission input shaft w_K 2 meshes in the second gear plane 02 - 13 only with the idle gear 02 . Hereby, the advantage of a more free transmission gear selection arises, in contrast to gear planes with dual side engagement of the fixed gear wheel.
The third gear plane 03 - 06 comprises the fixed gear wheel 14 on the first transmission input shaft w_K 1 which meshes with the idle gear 03 on the first countershaft w_vorgelege 1 , and with the idle gear 06 on the second countershaft w_vorgelege 2 .
Finally, in the fourth gear plane 04 - 07 , the fixed gear wheel 15 on the first transmission input shaft w_K 1 meshes with the idle gear 07 on the second countershaft w_vorgelege 2 , also with an idle gear 17 on an intermediate shaft w_zw, the fixed gear wheel 15 on the first transmission input shaft w_K 1 and also the idle gear 04 on the first countershaft w_vorgelege 1 . Hereby, a reversal of rotation can be achieved to realize the reverse gears RA 1 , RA 2 , RB 1 . It is also possible to design the idle gear 17 as a step gear. For the reversal of rotation, the idle gear 04 on the first countershaft w_vorgelege 1 can also mesh with the idle gear 07 on the second countershaft w_vorgelege 1 , so that the idle gear 17 can be omitted.
In this proposed gear set configuration, on the first countershaft w_vorgelege 1 , dual action coupling devices A-B, C-D are each provided between the first gear plane 01 - 05 and the second gear plane 02 - 13 , between the third gear plane 03 - 06 and the fourth gear plane 04 - 07 . Also on the second countershaft w_vorgelege 2 , a dual action coupling device F-G is positioned, between the third gear plane 03 - 06 and the fourth gear plane 04 - 07 . In addition, a single action coupling device E is positioned on the second countershaftw_vorgelege 2 , on the side which is facing away from the clutch K 1 , K 2 .
To realize winding-path gears, meaning to enable coupling of both partial transmissions, the additional shifting device H is positioned on the first countershaft w_vorgelege 1 , between the second gear plane 02 - 10 and the third gear plane 03 - 06 .
The table, which is presented in FIG. 1A , shows an exemplary shifting scheme for the first embodiment variation of the 7-gear dual clutch transmission.
In accordance with the shifting schemes in FIG. 1A , the first forward gear 1 is shifted via the first clutch K 2 and via the coupling device F-G, shifted the direction G, as well as via the activated shifting device H, as a winding-path gear. The second forward gear 2 is realized via the first clutch K 1 and via the coupling device F-G, shifted in the direction G, the third forward gear 3 is shifted via the second clutch K 2 and via the coupling device A-B, shifted in the direction B. The fourth forward gear for is again shifted via the clutch K 1 and via the coupling device C-D, shifted in the direction C, whereby the fifth gear 5 is realize via the second clutch K 2 and via the coupling device A-B, shifted in the direction A. Finally, the sixth forward gear 6 is shifted via the first clutch K 1 and via the coupling device F-G, shifted in the direction F, whereby the seventh forward gear 7 is shifted via the second clutch K 2 and via the coupling device E on the second countershaft w_vorgelege 2 . The first reverse gear RA 1 is shifted via the second clutch K 2 and via the coupling device C-D, shifted in the direction D. the second reverse gear RA 2 and the alternative first reverse gear RB 1 are each shifted via the first clutch K 1 and via the coupling device C-D, shifted in the direction D.
Thus, the first forward gear 1 arranged as a winding-path gear, using the gear wheels 13 , 02 , 03 , 14 , 07 , and 10 . The second forward gear 2 uses the gear wheels 15 , 07 , and 10 , whereby the gear wheels 13 , 02 , and 09 are used to realize the third forward gear 3 . The fourth forward gear 4 uses the gear wheels 14 , 03 , and 09 , whereby the fifth forward gear 5 uses the gear wheels 12 , 01 , and 09 , whereby the sixth forward gear 6 uses the gear wheels 14 , 06 , and 10 . Finally the seventh forward gear 7 uses the gear wheels 12 , 05 , and 10 . For the first reverse gear RA 1 engaged as a winding-path gear, the gear wheels 13 , 02 , 03 , 14 , 15 , 17 , 04 , and 09 are used. For the second reverse gear RA 2 , the gear wheels 15 , 17 , 04 , and 09 are used, whereby the same gear wheels are used for the alternative first reverse gear RB 1
Other assignment configurations of the particular gear steps in this embodiment variation, in regard to the clutches, are also possible. Especially with mirror image, for instance, a reversed assignment configuration can easily be realized.
In the second embodiment variation, in accordance with FIG. 2 , the four gear planes 01 - 05 , 02 - 06 , 03 - 07 , 04 - 15 are each realized through two fixed gear wheels 12 , 13 ; 14 , 15 on the two transmission input shafts w_K 1 , w_K 2 and through four idle gears 01 , 02 , 03 , 04 on the first countershaft w_vorgelege 1 , three idle gears 05 , 06 , 07 on the second countershaft w_vorgelege 2 .
In the embodiment variation, in accordance with FIG. 2 , the first gear plane 01 - 05 and the second gear plane 02 - 06 , as well as the third gear plane 03 - 07 are each designed as dual gear planes. In contrary, the fourth gear plane 04 - 15 is designed as a single gear plane.
In the first gear plane 01 - 05 , the fixed gear wheel 12 of the second transmission input shaft w_K 2 meshes with the idle gear 01 on the first countershaft w_vorgelege 1 , and with the idle gear 05 on the second countershaft w_vorgelege 2 , as it is provided in the first embodiment variation.
Contrary to the first embodiment variation, the second gear plane 02 - 06 comprises the fixed gear wheel 13 on the second transmission input shaft w_K 2 , which meshes with the idle gear 02 on the first countershaft w_vorgelege 1 . Also, the idle gear 17 on an intermediate shaft w_zw meshes with the fixed gear wheels 13 on the second transmission input shaft w_K 2 , and with the idle gear 06 on the second countershaft w_vorgelege 2 . Hereby, a reversal of rotation can be achieved to realize the reverse gears R 1 and R 2 . It is also possible to design the idle gear 17 as a step gear. For the reversal of rotation, the idle gear 06 on the second countershaft w_vorglege 2 can also mesh with the idle gear 02 on the first countershaft w_vorgelege 1 , so that the idle gear 17 can be omitted.
The third gear plane 03 - 07 comprises the fixed gear wheels 14 on the first transmission input shaft w_K 1 , which meshes with the idle gear 03 on the first countershaft w_vorgelege 1 , with the idle gear 07 on the second countershaft w_vorgelege 2 .
Finally, in the fourth gear plane 04 - 15 , the fixed gear wheels 15 on the first transmission input shaft w_K 1 only meshes with the idle gear 04 on the first countershaft w_vorgelege 1 . Hereby, the advantage of a more free transmission gear selection arises, in contrast to gear planes with dual side arrangement of the fixed gear wheel.
In this proposed gear set configuration, a dual action coupling devices A-B, C-D are each provided, on the first countershaft w_vorgelege 1 , between the first gear plane 01 - 05 and the second gear plane 02 - 06 , and between the third gear plane 03 - 07 and the fourth gear plane 04 - 15 . On the second countershaft w_vorgelege 2 , a dual action coupling device E-F is positioned between the first gear plane 01 - 05 and the second gear plane 02 - 06 . In addition, a single action coupling device G is positioned on the second countershaft w_vorgelege 2 , on the side which is facing away from the clutches K 1 , K 2 , of the third gear plane 03 - 07 .
The table, which is presented in FIG. 2A , shows an exemplary shifting scheme for the first embodiment variation of the 7-gear dual clutch transmission.
In accordance with the shifting schemes in FIG. 2A , the first forward gear 1 is shifted via the second clutch K 2 and via the coupling device G on the second countershaft w_vorgelege 2 , shifted in the direction G, and via the activated shifting device H, as a winding-path gear. The second forward gear 2 is realized via the first clutch K 1 and via the coupling device G on the second countershaft w_vorgelege 2 , shifted in the direction G, the third forward gear 3 is shifted via the second clutch K 2 and via the coupling device A-B, shifted in the direction B. The fourth forward gear for is again shifted via the first clutch K 1 and via the coupling device C-D, shifted in the direction C, whereby the fifth forward gear 5 is realized via the second clutch K 2 and via the coupling device E-F, shifted in the direction E. Finally, the sixth forward gear 6 is shifted via the first clutch K 1 and the coupling device-D, shifted in the direction D, whereby the seventh forward gear 7 is again shifted via the second clutch K 2 and via the coupling device A-B, shifted in the direction A. The first reverse gear R 1 is shifted via the second clutch K 2 and via the coupling device E-F, shifted in the direction F. The second reverse gear R 2 is shifted via the first clutch K 1 and via the coupling device E-F, shifted in the direction F, as well as via the activated shifting device H as a winding-path gear.
Thus, the first forward gear 1 is engaged, as a winding-path gear using the gear wheels 13 , 02 , 03 , 14 , 07 , and 10 . In the second forward gear 2 , the gear wheels 14 , 07 , and 10 are used, the gear wheels 13 , 02 , and 09 are used to realize the third forward gear 3 . In the fourth forward gear 4 , the gear wheels 14 , 03 , and 09 are used, in the fifth forward gear 5 the gear wheels 12 , 05 , in 10 are used, the sixth forward gear 6 uses the gear wheels 15 , 04 , and 09 . Finally, the seventh forward gear 7 uses the gear wheels 12 , 01 , and 09 . The first reverse gear R 1 uses the gear wheels 13 , 17 , 06 , and 10 , the second reverse gear R 2 is engaged as a winding-path gear, using the gear wheels 14 , 03 , 02 , 13 , 17 , 06 , and 10 .
Other assignment configurations of the particular gear steps in this embodiment variation, in regard to the clutches, are also possible. Especially through mirroring, for instance, a reversed assignment configuration can easily be realized.
In contrast to the first and the second embodiments variation, the additional shifting device H, in the third embodiment variation in accordance with FIG. 3 , is provided on the second countershaft w_vorgelege 2 for the coupling of the two partial transmissions, between the second gear plane 02 - 06 and the third gear plane 03 - 07 . Another difference is an additional idle gear 08 which is positioned on the second countershaft w_vorgelege 2 . This idle gear 08 expands the fourth gear plane 04 - 08 in a way, that the fixed gear wheels 15 on the first transmission input shaft w_K 1 meshes with the idle gear 04 on the first countershaft w_vorgelege 1 as well as with the idle gear 08 on the second countershaft w_vorgelege 2 . Contrary the second embodiment variation, the single action coupling device G, in the third embodiment variation, is positioned on the second countershaft w_vorgelege 2 , on the side which is facing away from the clutches of the fourth gear plane 04 - 08 .
The third gear plane 03 - 07 also provides that the fixed gear wheels 14 and the idle gear 07 on the second countershaft w_vorgelege 2 , and also an idle gear 17 on an intermediate shaft w_zw, mesh with, the fixed gear wheel 14 with the idle gear 07 on the second countershaft w_vorgelege 2 , as well as with idle gear 03 of the first countershaft w_vorgelege 1 . In this case, a rotation reversal can be provided to realize the reverse gear R 1 . It is also possible, that the idle gear 17 is designed as a step gear. The provide the rotation reversal, the idle gear 07 on the second countershaft w_vorgelege 2 meshes with the idle gear 03 on the first countershaft w_vorgelege 1 , so that the idle gear 17 can be omitted.
In the embodiment variation, in accordance with FIG. 3 , all gear planes 01 - 05 , 02 - 06 , 03 - 07 , and 04 - 08 are designed as dual gear planes.
The table, which is presented in FIG. 3A , shows an exemplary shifting scheme for the first embodiment variation of the 7-gear dual clutch transmission.
In accordance with the shifting schemes in FIG. 3A , the first forward gear 1 is shifted via the second clutch K 2 and via the coupling device A-B, shifted in the direction B. The second forward gear 2 is realized via the first clutch K 1 and via the coupling device C-D, shifted into the direction C, the third forward gear 3 is shifted via the second clutch K 2 and via the coupling device E-F, shifted in the direction F. The fourth forward gear 4 is again shifted via the first clutch L 1 and via the coupling device C-D, shifted in the direction D, whereby the fifth forward gear 5 is realized via the second clutch K 2 and via the coupling device A-B, shifted in the direction A. Finally, the sixth forward gear 6 is shifted via the first clutch K 1 and via the coupling device G on the second countershaft w_vorgelege 2 , whereby the seventh forward gear 7 is again shifted via the second clutch K 2 and via the coupling device E-F, shifted in the direction E. The reverse gear R 1 is shifted via the second clutch K 2 and via the, shifted into the direction C, coupling device C-D, as well as via the shifting device H as a winding-path gear.
Thus, the first forward gear 1 uses the gear wheels 13 , 02 , and 09 . The second forward gear 2 uses the gear wheels 14 , 03 , and 09 , the gear wheels 13 , 0 , and 10 are used to realize the third forward gear 3 . For the fourth forward gear 4 , the gear wheels 15 , 04 , and 09 are used, the fifth forward gear 5 uses the gear wheels 12 , 01 , and 09 , the sixth forward gear 6 uses the gear wheels 15 , 08 , and 10 . Finally, the seventh forward gear 7 uses the gear wheels 12 , 05 , and 10 . The reverse gear R 1 uses, as a winding-path gear, the gear wheels 13 , 06 , 07 , 14 , 17 , 03 , and 09 .
Other assignments for the particular gear steps, in regard to clutches, are also possible in this embodiment variation. Especially, and for instance through mirroring, a reversed assignment can easily be realized.
In the above described embodiment variations, the direction into which the coupling devices are shifted, to connect a particular idler gear wheel with the respective countershaft, can be altered by a modifying the coupling devices, for instance, through particular deflection devices.
REFERENCE CHARACTERS
01 Idler gear wheel on the first Countershaft
02 Idler gear wheel on the first Countershaft
03 Idler gear wheel on the first Countershaft
04 Idler gear wheel on the first Countershaft
05 Idler gear wheel on the second Countershaft
06 Idler gear wheel on the second Countershaft
07 Idler gear wheel on the second Countershaft
08 Idler gear wheel on the second Countershaft
09 Fixed gear wheel on the first Countershaft as Output Stage
10 Fixed gear wheel on the second Countershaft as Output Stage
11 Fixed gear wheel on the Output Shaft
12 Fixed gear wheel on the second Transmission Input Shaft
13 Fixed gear wheel on the second Transmission Input Shaft
14 Fixed gear wheel on the first Transmission Input Shaft
15 Fixed gear wheel on the first Transmission Input Shaft
16 Torsion Vibration Damper
K 1 First Clutch
K 2 Second Clutch
w_an Drive Shaft
w_ab Output Shaft
w_vorgelege 1 first Countershaft
w_vorgelege 2 second Countershaft
A-B dual action Coupling Device
C-D dual action Coupling Device
E single action Coupling Device
E-F dual action Coupling Device
F-G dual action Coupling Device
G single action Coupling Device
H additional Shifting Device
i Gear Transmission Ratio
phi Transmission Ratio Spread
1 First Forward Gear
2 Second Forward Gear
3 Third Forward Gear
4 Fourth Forward Gear
5 Fifth Forward gear
6 Sixth Forward Gear
7 Seventh Forward Gear
RA 1 First Reverse Gear
RA 2 Second Reverse Gear
RB 1 alternative first Reverse Gear
R 1 first Reverse Gear
R 2 second Reverse Gear
w_zw Intermediate Shaft
17 Idler gear wheel on the Intermediate Shaft | A double clutch transmission with two clutches connected to a drive shaft and to one of two transmission input shafts. Fixed gears are coupled to the input shafts and engage idler gears. Several coupling devices connect the idler gears to a countershaft which have an output gear that couple gears of an output shaft such that at least seven power shift forward gears and at least one reverse gear can be shifted, and four gear wheel planes are positioned in a way that at least one power shift winding-path gear can be shifted via the shifting device. | 5 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This patent application claims priority as a continuation-in-part of U.S. patent application Ser. No. 12/790,262, filed on May 28, 2010, titled “METHOD FOR ASSESSMENT AND TREATMENT OF DEPRESSION VIA UTILIZATION OF SINGLE. NUCLEOTIDE POLYMORPHISMS ANALYSIS,” which claims priority to U.S. Provisional Patent Application No. 61/217,338, filed on May 29, 2009, titled “SYSTEM AND METHOD FOR DIAGNOSIS AND TREATMENT OF COMMON MENTAL HEALTH COMPLAINTS,” and U.S. Provisional Patent Application 61/325,098, filed on Apr. 16, 2010, titled “MODULATION OF SEROTONIN REUPTAKE BASED ON GENOTYPE TO TREAT DEPRESSION,”
[0002] This patent application also claims priority to U.S. Provisional Patent Application Nos. 61/410,523, filed on Nov. 5, 2010, titled “TREATMENT RESISTANT DEPRESSION DIAGNOSTIC TEST REPORT;” 61/321,065, filed on Apr. 5, 2010, titled “MEDICAL FOODS FOR THE TREATMENT OF DEPRESSION AND NEURODEGENERATIVE DISORDERS;” and 61/321,281, filed on Apr. 6, 2010, titled “TREATMENT OF ALZHEIMERS DISEASE BY MODULATION OF ANTIMICROBIAL PEPTIDES.” All of the patent applications mentioned above are herein incorporated by reference in their entirety.
INCORPORATION BY REFERENCE
[0003] All publications and patent applications mentioned in this specification are herein incorporated by reference in their entirety to the same extent as if each individual publication or patent application was specifically and individually indicated to be incorporated by reference.
FIELD OF THE INVENTION
[0004] The devices, methods, and systems described herein relate to the diagnosis and treatment of mood disorders, and particularly to the treatment of depression based on the determination of genetic predispositions related to common neurotransmitter pathway based polymorphisms, including serotonin, glutamate and dopamine. The screens described herein are gathered into a screen based on a clinically and therapeutically relevant nexus.
BACKGROUND OF THE INVENTION
[0005] Between 5-10% of adults worldwide suffer from depression.
[0006] The economic costs to society and the personal costs to individuals and families, associated with depression are enormous. Within a 15-month period after having been diagnosed with depression, sufferers are four times more likely to die as those who do not have depression. Almost 60% of suicides have their roots in major depression, and 15% of those admitted to a psychiatric hospital for depression eventually kill themselves. In the U.S. alone, the estimated economic costs for depression in 1990 exceeded $44 billion. The World Health Organization estimates that major depression is the fourth most important cause worldwide of loss in disability-adjusted life years, and will be the second most important cause by 2020.
[0007] A variety of pharmacologic agents are available for the treatment of depression. Significant success has been achieved through the use of serotonin reuptake inhibitors (SRIs), norepinephrine reuptake inhibitors (NERIs), combined serotonin-norepinephrine reuptake inhibitors (SNRIs), monoamine oxidase inhibitors (NERIs), phosphodiesterase-4 (PDE4) inhibitors or other compounds. However, even with these options available, many patients fail to respond, or respond only partially to treatment. Additionally, many of these agents show delayed onset of activity, so that patients are required to undergo treatment for weeks or months before receiving benefits. Most currently available antidepressants take 2-3 weeks or more to elicit a response.
[0008] Traditional therapies can also have significant side effects. For example, more than a third of patients taking SRIs experience sexual dysfunction. Other problematic side effects include gastrointestinal disturbances, often manifested as nausea and occasional vomiting, agitation, insomnia, weight gain, onset of diabetes.
[0009] Thus, there remains a need for the development of improved therapies for the treatment of depression and/or other mood disorders.
[0010] In the clinic, 40-50% of depressed patients who are initially prescribed antidepressant therapy do not experience a timely remission of depression symptoms. This group typifies treatment-refractory depression, that is, a failure to demonstrate an “adequate” response to an “adequate” treatment trial (sufficient intensity of treatment for sufficient duration). Moreover, about 20-30% of depressed patients remain partially or totally resistant to pharmacological treatment.
[0011] This is increasing evidence implicating the role of neurotransmitters depression, in particular the monoamines serotonin, noradrenaline, dopamine, as well as the excitatory amino acid glutamate. Many of the tricylic antidepressants (TCAs), selective serotonin re-uptake inhibitors (SSRIs) and monoamine oxidase inhibitors (MAOIs) effective in the treatment of depression increase the availability of the catecholamines (noradrenaline and dopamine) and indolamines (serotonin) in the central nervous system (CNS). The clinical efficacy of these agents has given rise to the catecholamine-indolamine hypothesis of depression. This theory postulates that a certain level of amines and/or receptor sensitivity to catecholamines functions to generate a normal mood. Receptor insensitivity, a depletion of monoamines, or a decrease in their release, synthesis or storage has been postulated to lead to depression. Other agents are also increasingly being used to treat depression, including mood stabilizers and anti psychotics. The increasing choices and complexity of decision making when treating depression is reinforced by the differences in activity on neurotransmitter systems these class agents have.
[0012] Although previous work has suggested the use of certain SNPs to diagnose depression (see, for example, US 2008/0299125 to Hinds et al., US 2008/0199866 to Akil et al., US 2008/0268436 to Duan et al., US 2006/0160119 to Turner et al., US 2008/018076 to Chissoe, and US 2008/0118918 to Licinio et al.), the systems, assays and methods described herein are based on the discovery that the behavioral phenotypes of gene expression can be understood and interpreted in terms of the net effect of these particular genes on specific neurotransmitter based brain synaptic pathways. Specifically, the inventor has recognized that genotyping relevant neurotransmitter based pathways will further instruct on choosing between agents with distinct and divergent pharmacological activity.
SUMMARY OF THE INVENTION
[0013] We herein postulate herein that depression subtypes are based upon imbalances of specific neurotransmitter pathways in the brain. Certain subtypes of depression are associated with predominant neurotransmitter imbalances, leading to specific phenomenological behavioral states. Thus, a clinician will be able to ascertain a specific subtype of depression by analyzing both the behavioral and genetic patterns of individuals with a mood disorder. The primary neurotransmitter based genes include serotonin pathway related genes, calcium mediated glutamate related genes, dopamine pathway related genes and methylation and metabolism genes.
[0014] As used herein, the term “mood disorder” may include any number of disorders, including, but not limited to: major depression, bipolar disease, psychotic disorders, childhood disorders, geriatric disorders, anxiety disorders, PTSD, and the like.
[0015] A screen for a cluster of genes is claimed which may include examining for polymorphisms of: CACNA1C, FKBP5, SERT, DRD2, BDNF, MTHF and COMT. Treatments are also claimed based upon identification of these polymorphisms.
[0016] In general, an SNP indicator indicates the presence or absence of an SNP from a tissue sample. The SNP indicator may be based on (or part of) a screening test, such as a genetic screen (e.g., using a PCR-based test) to determine if the SNP is present within the DNA of a particular patient's tissue sample being examined. Any appropriate test for the individual SNP or a pooled test for multiple SNPs may be used as part of the methods, kits, assays and systems described herein. As mentioned, the SNP indicators comprise one or more PCR-based assays. An SNP indicator may include a report (e.g., visual, oral, printed, electronic, or the like), and may indicate the presence or absence of the particular SNP. The SNP indicator may indicate if the SNP is homozygous or heterozygous.
[0017] For example, in some variations, the SNP indicator indicates an SNP that alters the function or expression of the Serotonin transporter genes in the serotonin metabolism pathway. In some variations, the SNP indicator indicates an SNP that alters the function or expression of the MTHF, COMT pathways or DRD2 genes in the dopamine metabolism pathway. In some variations, the SNP indicator indicates an SNP that alters the function or expression of the CACNA1C genes in the glutamate metabolism pathway. In some variations, the SNP indicator indicates an SNP that alters the function of FKBP5 genes in the hypothalamic pituitary adrenal axis.
[0018] The panel assay may include: a plurality of SNP indicators that collectively indicate the presence or absence of one or more SNP that alters the function or expression of a gene from each of the serotonin metabolism pathway, the dopamine metabolism pathway, the glutamate metabolism pathway, and the hypothalamic pituitary adrenal axis; and an interpretive comment indicating the effect of any identified SNPs.
[0019] For example, described herein are panel assays to determine the presence of SNPs that alter the function or expression of a gene from each of the serotonin metabolism pathway, the dopamine metabolism pathway, the glutamate metabolism pathway, and the drug metabolism pathway, in some variations, the panel assay also includes a report with one or more interpretive comments indicating the effect of any identified SNPs on the regulation of these pathways. The panel assay may also include an interpretive comment suggesting a treatment based on identified SNPs.
[0020] The SNP indicator may indicate an SNP that alters the function or expression of the SERT gene in the serotonin metabolism pathway; the DRD2 genes in the dopamine metabolism pathway; the CACNA1C gene in the glutamate metabolism pathway; genes that regulate methylatoin and/or drug metabolism, including: MTHFR, COMT and/or CYP2D6. Any appropriate method for testing for the SNP indicators described herein may be used, including PCR-based assays.
[0021] The assay may also include one or more an interpretive comment suggesting a treatment based on identified SNPs. For example, the SNP indicator may indicate an SNP that alters the function or expression of the SERT related genes in the serotonin metabolism pathway. The SNP indicator may indicate an SNP that alters the function or expression of the MTHF, or COMT genes in the methylation pathway; the SNP indicator may indicate an SNP that alters the function or expression of the CACNA1C genes in the glutamate metabolism pathway. The SNP indicator may indicate an SNP that alters the function or expression of the FKBP5 genes or BDNF in the hypothalamic pituitary adrenal axis.
[0022] Also described herein are mood disorder panel assays to guide therapeutic treatment by determining the presence of SNPs that alter the function or expression of: the SERT gene; one or more of: DRD2, MTHF, COMT genes; one or more of: CACNA1C; and one or more of: MTHFR, COMT and/or CYP2D6.
[0023] In some variations the mood disorder panel assay to determine the presence of SINPs that contribute to a mood disorder comprises: a plurality of SNP Indicators that collectively indicate the presence or absence of one or more SNP that alters the function or expression of a gene from each of the serotonin metabolism pathway, the dopamine metabolism pathway, the glutamate metabolism pathway, and the hypothalamic pituitary adrenal axis; and an interpretive comment suggesting a treatment based on the identified SNPs.
[0024] Also described herein are methods of treating a patient for a mood disorder comprising: determining the genotype of a polymorphism in each of the SERT, BDNF, CACNA1C, MTHFR/COMT and DRD2 genes; advising a treatment based upon the results of said testing.
[0025] In some variations a method of treating a patient for a mood disorder comprise: determining the genotype of a polymorphism in each of the SERT, BDNF, CACNA1C, MTHFR/COMT and DRD2 genes; advising a treatment based upon the results of said testing wherein the treatment comprises: prescribing at least one of tianeptine and other SSRE for patients having a SERT short allele; prescribing at least one of Aniracetam and Nefiracetam for patients having the Val66Met form of BDNF; prescribing at least one of a calcium channel antagonists, an L-type voltage gated calcium channel agonist, and a member of the ARB class of drugs, and Candesartan for patients having either the rs1006737 or the rs1006737 variant of CACNA1C; prescribing at least one of a methylating agent, MTHF, S adenosylmethionine, a dopamine agonists, a MAO inhibitor, and a stimulant, for patients having either the C677T MTHFR variant or the 158val/val allele of the COMT gene; and prescribing at least one of an atypical neuroleptics which preferentially inhibits 5HT2A over DRD2 and Clozaril for patients having the −141C Ins/Del.
[0026] In some variations the method of treating a patient for a mood disorder comprises: determining the genotype of a polymorphism in each of the SERT, BDNF, CACNA1C, MTHFR/COMT and DRD2 genes; providing a treatment based upon the results of said testing, wherein the treatment comprises: prescribing at least one of tianeptine and other SSRE for patients having a SERT short allele; prescribing at least one of Aniracetam and Nefiracetam for patients having the Val66Met form of BDNF; prescribing at least one of a calcium channel antagonists, an L-type voltage gated calcium channel agonist, and a member of the ARB class of drugs, and Candesartan for patients having either the rs1006737 or the rs1006737 variant of CACNA1C; prescribing at least one of a methylating agent, MTHF, S adenosylmethionine, a dopamine agonists, a MAO inhibitor, and a stimulant, for patients having either the C677T MTHFR variant or the 158val/val allele of the COMT gene; and prescribing at least one of an atypical neuroleptics which preferentially inhibits 5HT2A over DRD2 and Clozaril for patients having the −141C Ins/Del.
[0027] As mentioned above, the assay may also include an interpretive comment suggesting a treatment based on identified SNPs.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] FIG. 1 is a flowchart illustrating one variation of a method for determining a net or predicted net effect of one or more SNPs.
[0029] FIG. 2 is a table listing the pathways (e.g., serotonin, dopamine, glutamate, drug metabolism), genes tested in each pathway for polymorphisms, possible results (polymorphisms), interpretive comments and examples of therapies that may be applied guided by these results.
[0030] FIG. 3 is a chart indicating exemplary therapeutics that may be advisable based on particular SNP results.
DETAILED DESCRIPTION OF THE INVENTION
[0031] Genes associated with neurotransmitter pathways are abnormal in patients with clinical depression. For instance, genes which regulate serotonin pathways, including genes coding for receptors, metabolism and reuptake mechanisms, are associated with depression. Furthermore, other genetic-neurotransmitter pathways, including dopamine, norepinephrine and glutamate are associated with depression. The heterogenous nature of these results suggests that depression as a disorder is itself heterogenous. By analyzing depression from a single nucleotide polymorphism based gene analysis, subtypes of depression can be differentiated and diagnosed. Accurate subtype depression based upon single nucleotide polymorphism is novel and previously undisclosed. Further, the employment of such analysis will allow mental health professionals who treat individuals with depression with more specific and targeted interventions.
[0032] Depression may be better dissected using paradigms that assess how specific genes associate with component features of depression. This approach reveals gene influences on trait components of depression and, may help identify depression subpopulations that can benefit from more targeted pharmacotherapy.
[0033] Many people complain of depressive symptoms, but despite the commonality of these complaints, there is significant biochemical heterogeneity regarding the etiology, phenomenology and treatment of mood disorders. This biochemical heterogeneity is evidenced by, inter alia, the occurrence of single nucleotide polymorphisms (SNPs) in genes involved with neurotransmitter activity related to depression. Subtle genomic variations create the chemistry that underlies subtypes of depression.
[0034] As an example, a single nucleotide polymorphism in the gene that regulates dopamine can be associated with altered neurotransmitter binding and differential drug effect in the brain. Patients with a dopamine based SNP thus differ not only in their symptoms but their response to therapies as well.
[0035] Based upon the recognition of SNP associated biochemical and symptomatic heterogeneity, a mood complaint such as depression can either be a consequence of a genetic defect that effects serotonin metabolism, but also can be a consequence of an SNP associated genetic defect in a gene that regulates dopamine, or some other neurotransmitter. As a similar example, depression can be etiologically associated with a SNP in glutamate in one individual, and with a SNP related to dopamine or norepinephrine in another.
[0036] The recognition of the distinction in the genetic and biochemical heterogeneity related to the expression of subtypes of depression has important therapeutic implications. Frequently, an individual with a mood disturbance does not respond favorably to a specific class of therapeutic agents but may respond to a different class of therapeutic agents. As an example, an individual who is experiencing depression due to a specific SNP related dopamine metabolism defect will not respond or respond less favorably to a serotonin modulating agent. In clinical practice, this can happen when a psychiatrist treats a patient with depression who possesses a SNP associated with a dopamine related defect with a serotonin modulating drug like sertraline paroxetine instead of a dopamine modulating drug such as buproprion or Aripirazole. In these instances, the drug may produce a worsening of symptoms instead of improving them.
[0037] Conversely, an individual with a SNP associated with serotonin metabolism may respond less favorably to a dopamine modulating agent. Unfortunately, psychiatrists administer medications for depression solely on a trial and error basis. The lack of diagnostic specificity frequently leads to ineffective treatments, substantial side effects or a delay in the proper treatment.
[0038] Thus, a common problem in the management of mood disorders is a lack of diagnostic specificity and/or treatments which are not coupled to the unique neurotransmitter disturbance related to depression. Provided herein is a method of using the analysis of an individual's SNPs related to neurotransmitter function as an aid to diagnosis and choice of therapeutic treatment. It is an object of this description to set forth the specific genomic sites that are causally associated with the biochemical and neurochemical abnormalities associated with depression. The ability to accurately identify SNPS related to neurotransmitter imbalances and depression subtypes represents an advance in the field of mental health.
[0039] The methods regarding the employment of genes related to neurochemical imbalances are broadly applied to the genes involved in at least the following pathways: Serotonin, dopamine, glutamate and the hypothalamic pituitary adrenal axis. Specific genes within these categories are described in the paragraphs herein but are not limited to this disclosure. Thus, while the present invention describes polymorphisms in specific serotonin pathways, it is recognized that other polymorphisms in the serotonin pathway are contemplated as within the scope of this disclosure.
[0040] Genomic polymorphisms in the following glutamate related pathways are associated with depression: CACNAC gene.
[0041] Genomic polymorphisms in the following dopamine related pathways are associated with depression: DRD2.
[0042] Genomic polymorphisms associated with methylation pathway: MTHFR gene and COMT gene.
[0043] Genomic polymorphisms in the following serotonin related pathways are associated with depression: the serotonin transporter gene.
[0044] The hypothalamic pituitary adrenal axis has been recognized as a critical region in the stress response as well as in the pathophysiology of depression.
[0045] The FKBP5 gene and BDNF gene are related to the stress response, and the hypothalamic pituitary adrenal pathway.
[0046] These gene categories are associated with depression subendophenotypes, the analysis of which through single nucleotide polymorphisms is applied to provide a more accurate and specific therapeutic intervention based upon the neurochemical consequences of these genetic polymorphisms.
[0047] A summary of the neurochemical assessment based upon the analysis of single nucleotide polymorphisms is subsequently provided below.
Glutamate Pathway Associated Genes
[0048] CACNA1C (rs1006737) G>A and (rs10848635) T>A
[0049] The calcium ion is one of the most versatile, ancient, and universal of biological signaling molecules, know o regulate physiological systems at every level from membrane potential and ion transporters to kinases and transcription factors. Disruptions of intracellular calcium homeostasis underlie a host of emerging diseases, the calciumopathies. Cytosolic calcium signals originate either as extracellular calcium enters through plasma membrane ion channels or from the release of an intracellular store in the endoplasmic reticulum (ER) via inositol triphosphate receptor and ryanodine receptor channels. Therefore, to a large extent, calciumopathies represent a subset of the channelopathies, but include regulatory pathways and the mitochondria, the major intracellular calcium repository that dynamically participates with the ER stores in calcium signaling, thereby integrating cellular energy metabolism into these pathways, a process of emerging importance in the analysis of the neurodegenerative and neuropsychiatric diseases.
[0050] Molecular genetic analysis offers opportunities to advance our understanding of the nosological relationship between psychiatric diagnostic categories in general, and the mood and psychotic disorders in particular. The CACNA1C (alpha 1C subunit of the L-type voltage-gated calcium channel; SNP example rs1006737) gene encodes one subunit of a calcium channel. Results suggest that ion channelopathies may be involved in the pathogenesis of bipolar disorder, schizophrenia and autism with an overlap in their pathogenesis based upon disturbances in brain calcium channels.
[0051] CACNA1C encodes for the voltage-dependent calcium channel L-type, alpha 1c subunit. Gene variants in CACNA1 are associated with altered calcium gating and excessive neuronal depolarization. CACNA1 polymorphisms such as rs 10848635 and 1006737 are associated with increased risk of bipolar disease, and risk of SSRI induced suicidal ideation and changes in baseline agitation. Significant effects have been found of the G to A variant on total gray matter volume.
[0052] Psychiatric disease phenotypes, such as schizophrenia, bipolar disease, recurrent depression and autism, produce a constitutionally hyperexcitable neuronal state that is susceptible to periodic decompensations. The gene families and genetic lesions underlying these disorders may converge on CACNA1C, which encodes the voltage gated calcium channel which can be diagnostically evaluated for its role in schizophrenia, autism and bipolar disease.
[0053] Recent genetic studies found the A allele of the variant rs1006737 in the alpha 1C subunit of the L-type voltage-gated calcium channel (CACNA1C) gene to be overrepresented in patients suffering from bipolar disorder, schizophrenia or major depression.
[0054] Strong evidence of association at the polymorphism rs1006737 (within CACNA1C, the gene encoding the alpha-1C subunit of the L-type voltage-gated calcium channel) with the risk of bipolardisorder (BD) has recently been reported in a meta-analysis of three genome-wide association studies of BD. The bipolar risk allele CACNA1C rs1006737 conferred increased risk for schizophrenia and recurrent major depression with similar effect sizes to those previously observed in BD. These findings suggest some degree of overlap in the biological underpinnings of susceptibility to mental illness across the clinical spectrum of mood and psychotic disorders, and show that at least some loci can have a relatively general effect on susceptibility to diagnostic categories based upon alterations in calcium signaling.
[0055] The A allele in the variant described is associated with higher rates of mood disorder recurrence, treatment resistance, and paroxysmal psychotic states.
[0056] Agents claimed as having application to treat neuropsychiatric disorders associated with altered calcium signaling detected by CACNA1C diagnostic testing include: Flunarazine, candesartan and Hydroxyfasudil, Nimodipine, other L type voltage gated calcium channel blockers, Lithium, and anti convulsants including Valproic acid, Lamotrogine, Carbamezepine,
[0057] For example, Hydroxyfasudil may affect a protein kinase that serve to catalyze the phosphorylation of an amino acid side chain in various proteins. These enzymes control the majority of the signaling processes inside cells, thereby governing cell function, growth, differentiation and destruction (apoptosis) through reversible phosphorylation of the hydroxyl groups of serine, threonine and tyrosine residues in proteins.
[0058] A major signal transduction system utilized by cells is the RhoA-signalling pathway. RhoA is a small GTP binding protein that can be activated by several extracellular stimuli such as growth factor, hormones, mechanic stress, or osmotic change as well as high concentration of metabolite like glucose. RhoA activation involves GTP binding, conformation alteration, post-translational modification and activation of its intrinsic GTPase activity. Activated RhoA is capable of interacting with several effector proteins including ROCKs (Rho kinase) and transmit signals into cellular cytoplasm and nucleus.
[0059] Injury to the brain and spinal cord activates ROCKs, thereby causing neurodegeneration and inhibition of neuroregeneration like neurite growth and sprouting Inhibition of ROCKs results in induction of new axonal growth, axonal rewiring across lesions within the CNS, accelerated regeneration and enhanced functional recovery after acute neuronal injury.
[0060] 1-(5-Isoquinolinesulfonyl)homopiperazine hydrochloride (“fasudil hydrochloride”) is commercially available under the trademark of “Eril Inj.” (manufactured by Asahi Kasei Pharma Corp.) and clinically used as an injection preparation for improving cerebrovascular spasm after a subarachnoid bleeding operation and an accompanying brain ischemia.
[0061] Hydroxy fasudil is a specific Rho-kinase inhibitor which suppresses the increase of Ca(2+) induced by Glutamate. The neuroprotective effect of hydroxy fasudil is attributed to repressing Glu excitotoxicity and calcium overload by inhibiting Ca(2+) release from Ca(2+) stores in neurons.
[0062] The use of fasudil as an orally bioavailble, novel antidepressant based upon its calcium mediated neuronal stabilization effects has been previously undisclosed.
[0063] Candesartan has been shown to modify the Angiotensin II response in tissue. Angiotensin II (Ang II) is a powerful signaling molecule in neurons and exerts some of its biological effects by modulating Ca(2+) currents. The physiological actions of Ang II in the brain, whether mediated by AT1 or AT2 receptors, involve changes in neuronal activity that are initiated by changes in the activity of membrane ionic currents and channels, intracellular signalling pathways couple neuronal AT1 and AT2 receptors to changes in the activity of membrane K+ and Ca2+ currents and channels.
[0064] Intracellular Ca2+ is known to play an important role in Ang II signaling in neurons and Ang II caused a rapid time-dependent increase in [Ca2+]I voltage-sensitive Ca2+ channels, which are the primary source of Ang II-induced increases in [Ca2+].
[0065] This observation leads to a previously undisclosed use of Candesartan or other ARB agents to treat neuropsychiatric disorders associated with abnormal calcium signaling in the brain. Candesartan, an AT(1) blocker, can improve conditions associated with abnormal Ca(2+) release mechanisms due to the observation that AT(1) receptor blockade protects neurons of cellular alterations typically associated with calcium mediated hyperexcitability. Therefore, prevention of these alterations by candesartan may present a useful and novel pharmacological strategy for the treatment of neuropsychiatric disorders associated with altered calcium signaling in the brain, such as mood disorders, autism, bipolar disease and schizophrenia.
[0066] A variety of A-II antagonists are, or will be, known to one skilled in the art. Subcutaneous or oral administration of the ARB candesartan inhibits brain as well as peripheral AT(1) receptors, indicating transport across the blood-brain barrier, making it the preferred embodiment of this invention because this invention applies to a novel use of this agent to treat disorders of the CNS.
[0067] Flunarizine is known as a nonspecific calcium channel blocker that has been used for decades for the treatment of migraine, vertigo, and cognitive deficits related to cerebrovascular disorders. Flunarizine also has dopamine D2 receptor blocking properties and was effective in animal models of predictive validity for antipsychotics. However, its clinical antipsychotic efficacy compared to haloperidol demonstrated no significant differences in PANSS overall score. It has a unique pharmacokinetic profile as an oral drug with long half-life (2-7 weeks).
[0068] The use of flunarazine in patients with mood disorders associated with cacna1c polymorphisms has been previously undisclosed.
[0069] In summary, results of this assay which indicate polymorphisms in the L type voltage gated calcium channel suggests a treatment or class of treatments which reduce excessive neuronal depolarization. These include mood stabilizers, Lithium, anti convulsants and specifically centrally acting calcium channel blockers such as Fasudil, Flunazarine, Nimodipine and Candesartan.
Stress Response and the Hypothalamic—Pituitary Adrenal Axis Genes in Depression
[0070] FKBP5 and BDNF Genes
[0071] FKBP5 regulates the cortisol-binding affinity and nuclear translocation of the glucocorticoid receptor. FKBP5 is a glucocorticoid receptor-regulating co-chaperone of hsp-90 and plays a role in the regulation of the hypothalamic-pituitary-adrenocortical system and the pathophysiology of depression.
[0072] FK506 regulates glucocorticoid receptor (GR) sensitivity. When it is bound the FKBP5 receptor complex, cortisol binds with lower affinity and nuclear translocation of the receptor is less efficient. FKBP5 expression is induced by glucocorticoid receptor activation, which provides an ultra-short feedback loop for GR-sensitivity.
[0073] Changes in the hypothalamic-pituitary-adrenocortical (HPA) system are characteristic of depression. Because the effects of glucocorticoids are mediated by the glucocorticoid receptor (GR), and GR function is impaired in major depression, due to reduced GR-mediated negative feedback on the HPA axis. Antidepressants have direct effects on the GR, leading to enhanced GR function and increased GR expression.
[0074] Polymorphisms the gene encoding this co-chaperone have been shown to associate with differential up-regulation of FKBP5 following GR activation and differences in GR sensitivity and stress hormone system regulation. Alleles associated with enhanced expression of FKBP5 following GR activation, lead to an increased GR resistance and decreased efficiency of the negative feedback of the stress hormone axis. This results in a prolongation of stress hormone system activation following exposure to stress. This dysregulated stress response might be a risk factor for stress-related psychiatric disorders.
[0075] Various studies have identified single nucleotide polymorphisms (SNPs) in the FKBP5 gene associated with response to antidepressants, and one study found an association with diagnosis of depression. Polymorphisms at the FKBP5 locus have also been associated with increased recurrence risk of depressive episodes. A recent study showed that FKBP5 genotypes also moderated the risk of post-traumatic stress disorder (PTSD). Four single-nucleotide polymorphisms (SNPs) FKBP5, rs3800373, rs9296158, rs1360780, and rs9470080, were genotyped on the complete sample.
[0076] In fact, the same alleles are over-represented in individuals with major depression, bipolar disorder and post-traumatic stress disorder.
[0077] Individuals homozygous for the TT-genotype at one of the markers (rs1360780) reported more depressive episodes and responded better to antidepressant treatment.
[0078] The stress hormone-regulating hypothalamic-pituitary-adrenal (HPA) axis has been implicated in the causality as well as the treatment of depression. FKBP5, a glucocorticoid receptor-regulating cochaperone of hsp-90, has been implicated in maintaining the HPA, and in depression. For example, recurrence of depressive episodes was observed with single-nucleotide polymorphisms FKBP5. These single-nucleotide polymorphisms were also associated with increased intracellular FKBP5 protein expression, which triggers adaptive changes in glucocorticoid receptor.
[0079] Major depression is associated with reduced hippocampal volume linked to stress and high glucocorticoid secretion.
[0080] In animal models, pretreatment with candesartan profoundly modifies the response to stress. The ARB prevents the central sympathetic activation characteristic of isolation stress and abolishes the activation of the hypothalamic-pituitary-adrenal axis during isolation.
[0081] Angiotensin II, through AT(1) receptor stimulation, is a major stress hormone, and that ARBs, in addition to their antihypertensive effects, may be considered for the treatment of neuropsychiatric disorders associated with FKBP5 polymorphisms.
[0082] Long-term pretreatment with an angiotensin II AT1 antagonist blocks angiotensin II effects in brain and abolishes the hypothalamic-pituitary-adrenal responses to isolation stress. AT1 receptor blockade prevented the isolation-induced increase in brain AT1 receptors and decrease in AT2 binding in the locus coeruleus. In addition, pretreatment with candesartan increased the time spent in and the number of entries to open arms of the elevated plus-maze, measure of decreased anxiety.
[0083] Calcium/calmodulin (Ca2+/CaM)-dependent protein kinase II (CaMKII) couples increases in cellular Ca2+ to fundamental responses in excitable cells. CaMKII is activated by angiotensin II, providing evidence that calcium signaling in the brain is activated by angiotensin II. The Ang II-induced apoptotic cascade converges in a common pathway mediated by CaMKII activation which results in p38MAPK activation and apoptosis.
[0084] Conversely, it follows that Angiotensin II blockade results in attenuated brain calcium signaling. It follows that modulation of abnormal calcium signaling via an AT(1) inhibitor may provide a novel means to treat altered calcium signaling associated with polymorphisms FKBP5.
[0085] A-II antagonist candesartan: 1-(cyclohexyloxycarbonyloxy)ethyl-2-ethoxy-1-[[2′-(1H)-tetrazol-5-yl)biphen yl-4-yl]methyl]benzimidazole-7-carboxylate and the pharmaceutically acceptable salts thereof which are disclosed in U.S. Pat. No. 5,196,444, the disclosure of which is incorporated herein by reference are claimed as specific agents for individuals with FKBP5 polymorphisms.
[0086] The dose administered must be carefully adjusted according to age, weight and condition of the patient, as well as the route of administration, dosage form and regimen and the desired result.
[0087] A preferred oral dosage form, such as tablets or capsules, will contain candesartan the ARB inhibitor in an amount of from about 1 to about 500 mg, preferably from about 1 to about 100 mg, and more preferably from about 5 to about 50 mg.
[0088] Tianeptine is also claimed as a potential psychopharmacological intervention based upon FKBP5 polymorphisms. Like the serotonin transporter polymorphism, individuals with FKBP5 polymorphisms may be susceptible to heightened cortisol as an effect of stress. This elevated cortisol leads to inhibition of glutamate reuptake, excess glutamate mediated neurotoxicity and structural changes in the brain in areas critical to cognition and emotion. Tianeptine is recognized as a dual serotonin transporter and glutamate transporter agonist, thus simultaneously reducing excess serotonin and glutamate, thereby preventing stress mediated neurotoxicity.
Serotonin Transporter Related Genes
[0089] Serotonin neurotransmitter transporters are the targets of various therapeutic agents used in the treatment of depression and anxiety. Specifically, the selective serotonin reuptake inhibitors, are the most widely prescribed agents for depression. The SSRI mechanism of action in depression is mediated by these agents acting as selective antagonists of the serotonin neurotransmitter transporter. Antagonists block uptake and prolong and/or enhance the action of serotonin. SSRI agents, drugs most widely used in depression, selectively block the reuptake of serotonin and result in increased serotonin in the synapse.
[0000] SLC6A4 5-HTTLPR (5-hydroxytryptamine Transporter Linked Polymorphic Region)
[0090] The serotonin transporter (5-HTT) is a high affinity carrier protein, localized to the plasma membrane of the presynaptic neuron. The role of 5-HTT is to remove serotonin (5-HT) from the synaptic cleft, resulting in serotonin reuptake into the presynaptic terminus. Elevated synaptic serotonin levels are associated with improved mood; thus the effectiveness of many antidepressant drugs (namely selective serotonin reuptake inhibitors, SSRIs) is thought to be due to their inhibition of the serotonin transporter, thereby reducing serotonin reuptake into the presynaptic terminus, and increasing serotonin availability in the synaptic cleft. In addition to mood improvement, elevated synaptic serotonin levels are also indirectly associated with a number of negative side effects including sleep disturbances, arousal, decreased gut motility, and sexual dysfunction.
5-HTTLPR Polymorphism
[0091] The short (S) allele results in 50% less expression of the active transporter protein as compared to the long (L) form. As these genetic differences in the 5-HTT affect both baseline serotonin levels and the availability of the transporter as a target for antidepressant therapy, they can affect the efficacy, of antidepressant therapy, the likelihood of side effects, and the nature and extent of depressive symptoms experienced. Studies have shown that compared to L/L patients, those homozygous for the short allele (S/S) are more likely to:
[0092] a) respond to antidepressant therapy more slowly,
[0093] b) experience adverse drug reactions (ADRs) during antidepressant therapy, and
[0094] c) develop major depression following adversity due to a poorer stress response.
[0095] In general, L/L individuals report a better and faster response to SSRI therapy than S/S patients. While these L/L individuals may demonstrate appropriate response to SSRI therapy in 2 to 4 weeks, individuals with the short allele (L/S or S/S) may respond to SSRI therapy much more slowly or may benefit from non-selective antidepressants.
[0096] In a meta analysis regarding the relationship of the serotonin transporter and depression, The SS genotype was significantly associated with an increased risk of MDD among Caucasian populations.
[0097] In addition to serotonin transporters being targets for anti depressant therapy, it is also recognized that assessment of serotonin transporter activity may be a useful biomarker in psychiatry. Various studies have demonstrated that patients with serotonin transporter short alleles are less likely to respond to SSRI therapy and are also more likely to experience treatment emergent side effects. The specific gene which is tested for, referred to as either the 5HTTLPR or SLC6A4, regulates the rate of serotonin metabolism. This gene controls a receptor located in the synaptic cleft. The receptor binds to serotonin and shuttles it back to the presynaptic neuron, terminating its activity at the post synaptic junction. The binding affinity of this receptor (referred to as SERT) is regulated by hereditary factors related to the length of an allele. Short alleles have reduced binding affinity effects on the serotonin transporter. Conversely, long alleles have better affinity, resulting in a more efficient reuptake process. Thus, the inherited short allele of the serotonin transporter results in more synaptic serotonin and the inherited tong allele leads to reduced serotonin in the synapse. The neurochemical consequences of possessing short alleles of the serotonin transporter results in increased synaptic serotonin, an effect that should be associated with better outcomes in antidepressant treatment based upon the conventional notion that increased synaptic serotonin is equated with better anti depressant response. However, in many studies the patients who are less likely to respond to serotonin agonist anti depressant therapy are precisely those who have a genetic predisposition to have relatively higher levels of serotonin in the synapse. Thus, results of large scale genomic studies which have correlated a percentage of patients who have depression associated with a short allele (and subsequently higher levels of synaptic serotonin), supports the notion that in a unique and previously unrecognized group of patients, there appears to be unique phenotype of depression characterized by higher, rather than lower, synaptic serotonin. It follows that in this unique subset of patients who are characterized by higher synaptic serotonin, the metabolic target should be to enhance serotonin reuptake as opposed to inhibiting serotonin reuptake.
[0098] Tianeptine has been described in French Patent Specification FR 2 104 728 as a new medicament for use in the treatment of psychoneurotic disorders. Furthermore, French Patent Specification FR 2 635 461 describes the use of tianeptine and compounds thereof in the treatment of stress. Tianeptine has a unique mechanism of action which is completely opposite drugs which are currently used for depression. Tianeptine no only activates serotonin reuptake into the synaptic ending but also activates its release from the ending into the synaptic cleft thus accelerating serotonin turnover rate in the synapse, a mechanism which is unique and opposite the majority of anti depressants in clinical use (such as the SSRI agents), which increase, rather than decrease synaptic levels of serotonin.
[0099] Tianeptine is a clinically used antidepressant that has drawn much attention, because this compound challenges traditional monoaminergic hypotheses of depression. It is now acknowledged that the antidepressant actions of tianeptine can be attributed to its particular neurobiological properties which are opposite those of traditional antidepressants, such as the SSRI class.
[0100] Acute treatment with tianeptine significantly enhances the levels of metabolites of 5-HT and 5-hydroxyindole acetic acid in the brain. In contrast to that found with inhibitors of the uptake of 5-HT such as the SSRIs, treatment with tianeptine markedly enhances the depletion of 5-HT. In vitro measurement of the uptake of 5-HT also confirms that tianeptine exerts opposite effects to those of classical SSRI antidepressants, since the in vivo administration of tianeptine induced a significant increase in the uptake of 5-HT in synapses. The fact that both inhibitors of the uptake of 5-HT (SSRIs) and tianeptine which, in contrast, enhances the in vivo uptake of 5-HT, are both potent and efficacious antidepressants, challenges the current hypothesis that SE reuptake is the exclusive mechanism of antidepressant response and that in subsets of patients, the opposite neurochemical effects—i.e., enhanced serotonin reuptake, may be the preferred mechanism to achieve an antidepressant response.
[0101] Described herein are novel methods and means for determining the genotype of the serotonin transport gene in order to selectively prescribe a treatment that is ideally coupled to patients with this specific genomic variation. In particular, described herein are methods for the use of tianeptine, of isomers thereof and of salts thereof, intended for the treatment of a specific subtype of depression associated with the short allele of the serotonin transporter.
[0102] general, described herein are methods of treating depression by determining the genotype of an individual patient's serotonin transporter (SERT), and prescribing a modulator of serotonin re-uptake and/or release based on the particular allele of that individual. The use of a genetic test in which a specific polymorphism of the serotonin transport gene is detected which informs the clinician that a patient likely has higher (rather than conventionally predicted tower) serotonin subsequently alter the decision to choose a SSRE instead of an SSRI.
[0103] For example, described herein are methods of treating an individual for depression by determining the individuals genotype for the serotonin transporter, and determining the appropriate prescription for a selective serotonin reuptake enhancer (SSRE) drug based on the genotype. Although the primary a selective serotonin reuptake enhancer (SSRE) drug described at the present time is tianeptine (Stablon, Coaxil, Tatinol), the methods described herein may be used with any appropriate a serotonin reuptake enhancer. Tianeptine is currently used as an antidepressant for the treatment or prophylaxis of depression in specific subtypes of depression. The methods described herein include the treatment of subjects exhibiting a particular genotype of the serotonin transporter with a selectively prescribed SSRE (e,g., tianeptine). Thus, the administration of an SSRE (such as tianeptine) is based upon the genotype. For example, the decision to prescribe and/or the dosage of a SSRE may be based upon the length of the patient's serotonin transporter allele. In some variations, patients with the short allele version of the transporter are selectively prescribed tianeptine. An alternative or supplemental treatment may be indicated in patents with longer alleles. For example, patient' with longer alleles may be prescribed serotonin reuptake inhibitors (e.g., SSRIs or other tricyclic compounds).
[0104] Thus, in the above example, a drug such as Tianeptine, which acts specifically as a serotonin reuptake enhancer, would be more appropriate because the metabolic and inherited state of the patient identifies a hyperserotonin state associated with depression.
[0105] The methods described herein are based on the recognition that by assessing genotypes (long vs. short alleles) of a polymorphism of the promoter region of the gene that encodes the serotonin transporter (5HTTLPR), one can identify persons who are more likely to respond to alternative anti-depressant therapies based upon unique and seemingly paradoxical effects on serotonin transporter. In these so-identified patients, a novel and previously undisclosed method of use for tianeptine is established based upon the expression and determination of the serotonin transport subtype. Thus, the methods described herein generally include the step of screening subjects for serotonin allele length, which may comprise determining the serotonin transporter gene promoter genotype (with respect to long and short alleles thereof) of a subject. The serotonin transporter gene promoter genotype may be used to indicate whether or not the subject will respond selectively to either a serotonin reuptake inhibitor, or more particularly, a serotonin reuptake agonist.
[0106] The methods described herein are particularly adapted to screening for tianeptine responsiveness based upon the expression of single nucleotide polymorphisms in the serotonin transporter. This invention discloses a novel indication for the use of tianeptine based upon the short allele of the serotonin transporter, and a mechanism intended to reduce, rather than enhance, synaptic serotonin.
[0107] In one particular embodiment, the method comprises determining the presence of two serotonin transporter gene promoter short alleles in a subject. If a subject is determined to have a depressed subtype characterized by higher synaptic serotonin (secondary to possession of the short allele of the serotonin transporter), tianeptine and/or enantiomers thereof is selectively prescribed, optionally in the form of pharmaceutically acceptable salts, shall be presented in pharmaceutical forms.
[0108] In addition to the dosage calibration by genotype, the dosage of the SSRE may vary according to the age and weight of the patient, the administration route, and the nature of the therapeutic indication and associated treatments. For example, in patients for whom tianeptine is indicated based on the genotype, the dose may range from 12.5 mg to 300 mg per dose or per administration. The number of administrations may also be modulated (e.g., 1×, 2×, 3×, 4× per day).
[0109] Any appropriate form of the SSRE may be used. For example, regarding tianeptine, bases that convert tianeptine or enantiomers thereof into salts may be used. The preferred salt of tianeptine is the sodium salt.
[0110] In some variations, an immediate-release form of the SSRE may be used. Immediate release may lead, in some subjects, to high blood peaks being obtained. A prolonged-release form may also be used. The prolonged-release form may make it possible to avoid these blood peaks and to obtain a uniform blood concentration in man. This may make it possible to reduce undesirable effects which may potentially occur by the “peak effect.” In one variation, a prolonged-release form of the sodium salt of tianeptine may be used to achieve a better therapeutic index in the treatment of anxiety and depression.
[0111] The dosage-release for tianeptine may be controlled in any appropriate manner. For example, a matrix tablet (as described in U.S. Pat. No. 5,888,542) that combines a polymer derived from cellulose and a calcium salt, may be used to compound the drug for controlled release of the active ingredient (e.g., tianeptine). This combination may be well-suited to the physicochemical characteristics of the sodium salt of tianeptine.
[0112] Controlled release (and particularly near-linear release) may make it possible to obtain a prolonged release of tianeptine leading to blood levels in the range between 50 and 300 ng/ml, up to 24 hours after administration of the tablet. As mentioned, in addition to the genotype, the unit dosage may be varied according to the age and the weight of the patient, and the nature and the seriousness of the condition. In general, dosage may range between 12.5 and 50 mg for a daily treatment in patients for whom the genotype screening suggests tianeptine is indicated.
[0113] Suitable routes for administration may include oral, parenteral, per- or trans-cutaneous, nasal, rectal, perlingual, sublingual tablets, glossettes, soft gelatin capsules, hard gelatin capsules, lozenges, suppositories, creams, ointments, dermal gels etc., and may include forms allowing the immediate release or the delayed and controlled release of the active ingredient.
[0114] A method for screening a subject for determining whether said subject is at an increased risk for depressed mood, said method comprising determining the subject's HTTLPR insertion/deletion polymorphism genotype within the serotonin transport (HTT) gene, wherein an LS heterozygote for the HTTLPR insertion/deletion polymorphism in the promoter region of the HTT gene has an increased risk for depressed mood. Subjects having the LS heterozygote for the insertion/deletion polymorphism in the promoter region of the serotonin transporter (HTT) gene have an increased risk of depression.
[0115] The short allele of the serotonin transporter has been suggested to be in epistasis with BDNF. For instance, the interaction between 5-HTTLPR and Val66Met polymorphisms significantly predicts dysfunctional thinking from before to after a standardized sad mood provocation. Cognitive reactivity increased among S/L(G) 5-HTTLPR homozygotes if they were also homozygous for the Val Val66Met allele, demonstrating biological epistasis between SLC6A4 and BDNF for predicting connectivity among neural structures involved in emotion regulation.
[0116] Some polymorphisms in the promoter region of the serotonin transporter gene (SLC6A4) are also involved in the pathogenesis/treatment of MDD; for instance, a single nucleotide substitution, rs25531 (A/G) in the serotonin transporter is also relevant. A variable number of tandem repeats (short (S) vs. long (L)) in the promoter region of the serotonin transporter gene (5-HTTLPR) and a functional variant of a single-nucleotide polymorphism (rs25531) in 5-HTTLPR have been associated with increased risk for major depressive disorder (MDD), this particular variant polymorphism rs 25531, referred to herein as L(g) carriers. In particular, relative to L/L homozygotes, S carriers and L(g)-allele carriers have a higher probability of developing depression after stressful life events. This is because individuals with the rs25531 polymorphism, despite having the long allele of the serotonin transporter, actually behave as if they possess the short allele. Based upon the functional consequences of this SLC6A4 polymorphisms, individuals with the rs25531 are predicted to respond in a similar fashion as those who actually possess the short allele of the transporter with reduced responsive effects to SSRI, more treatment emergent side effects and potentially better response to agents which enhance CaMKII mediated neurogenesis.
[0117] In summary, Tianeptine is claimed as a preferred agent in depressed individuals who express short variants of the serotonin transporter.
[0000] BDNF (rs6265) A>G Val66Met
[0118] Brain-derived neurotrophic factor is a member of the nerve growth factor family. It is induced by cortical neurons and is necessary neurogenesis and neuronal plasticity. BDNF has been shown to mediate the effects of repeated stress exposure and long term antidepressant treatment on neurogenesis and neuronal survival within the hippocampus. The BDNF Val66Met variant is associated with hippocampal dysfunction, anxiety, and depressive traits. Previous genetic work has identified a potential association between a Val66Met polymorphism in the BDNF gene and bipolar disorder. Meta-analysis based on all original published association studies between the Val66Met polymorphism and bipolar disorder up to May 2007 shows modest but statistically significant evidence for the association between the Val66Met polymorphism and bipolar disorder from 14 studies consisting of 4248 cases, 7080 control subjects and 858 nuclear families.
[0119] The BDNF gene may play a role in the regulation of stress response and in the biology of depression and the expression of brain-derived neurotrophic factor (BDNF) may be a downstream target of various antidepressants.
[0120] Exposure to stress causes dysfunctions in circuits connecting hippocampus and prefrontal cortex. BDNF is down-regulated after stress. Acute treatment with the antidepressants tianeptine reverses stress-induced down-regulation of BDNF. Tianeptine increases the phosphorylation of Ser831-GluA1. Psychological stress down-regulates a putative BDNF signaling cascade in the frontal cortex in a manner that is reversible by the antidepressant tianeptine. Thus agents which promote BDNF are novel mechanisms treat stress induced alterations in the limbic system.
[0121] Activation of AMPA receptors by agonists is thought to lead to a conformational change in the receptor causing rapid opening of the ion channel, which stimulates the phosphorylation of CAMK11/PKC sites and subsequently enhance BDNF expression.
[0122] Nefiracetam or Aniracetam are also agents that may be used to treat patients expressing the BDNF (rs6265) A>Ci Val66Met SNP.
[0123] A structural class of AMPA receptor positive modulators derived from artiracetam are called Ampakines. Aniracetam and Nefiracetam are neurological agents called ‘racetams’ that are analogs of piracetam. They are regarded as AMPA receptor potentiators and CaMKII agonists.
[0124] Small molecules that potentiate AMPA receptor show promise in the treatment of depression, a mechanism which also appears to be mediated by promoting BDNF via CaMKII pathways. Depression is associated with abnormal neuronal plasticity. AMPA receptors mediate transmission and plasticity at excitatory synapses in a manner which is positively regulated by phosphorylation at Ser831-GluR1, CaMKII/PKC site.
[0125] Aniracetam [1-(4-methoxybenzoyl)-2-pyrrolidinone] is AMPA receptor potentiator that preferentially slows AMPA receptor deactivation. AMPA receptor potentiators (ARPs), including aniracetam, antidepressant-like activity in preclinical tests. Unlike most currently used antidepressants. Interactions of aniracetam with proteins implicated in AMPA receptor trafficking and with scaffolding proteins appear to account for the enhanced membrane expression of AMPA receptors in the hippocampus after antidepressant treatment. The signal transduction and mote tar mechanisms underlying alpha-amino-3-hydroxy-5-methyl-4-isoxazole propiona (AMPA)-mediated neuroprotection evokes an accumulation of brain-derived neurotropic factor (BDNF) and enhance TrkB-tyrosine phosphorylation following the release of BDNF. AMPA also activate the downstream target of the phosphatidylinositol 3-kinase (PI3-K) pathway, Akt. The increase in BDNF gene expression appeared to be the downstream target of the PI3-K-dependent by AMPA agonists and Tianeptine (described above). Thus, AMPA receptors protect neurons through a mechanism involving BDNF release, TrkB receptor activation, and up-regulation of CaMKII which increase BDNF expression.
[0126] Olfactory bulbectomized (OBX) mice exhibit depressive-like behaviors. Chronic administration (1 mg/kg/day) of nefiracetam, a prototype cognitive enhancer, significantly improves depressive-like behaviors. Decreased calcium/calmocutin-dependent protein kinase II mediates the impairment of hippocampal long-term potentiation in the olfactory bulbectomized mice. Nefiracetam treatment (1 mg/kg/day) significantly elevated CaMKII in the amygdala, prefrontal cortex and hippocampal CA1 regions. Thus, CaMKII, activation mediated by nefiracetam treatment elicits an anti-depressive and cognition-enhancing.
[0127] Recommended aniracetam dosage is usually 1500 mg per day, taken in two 750 mg doses, one in the morning and one in the afternoon. Dose ranges can vary between 100 mg-5 grams. Recommended doses of Nefiracetam are 50-200 mg/day.
[0128] Tianeptine is claimed as an agent to treat depression associated with BDNF. The therapeutic potential of positive AMPA receptor modulators in the treatment of neurological and psychiatric diseases has been previously described, but its use in combination with Tianeptine, an atypical antidepressant with a similar mechanism of action, has been previously undisclosed.
[0129] Tianeptine increases BDNF expression in the amygdala, increases in neurotrophic factor expression that may participate in the enhancement of amygdala synaptic plasticity mediated by tianeptine. Preferred embodiments may include Tianeptine with Nefiracetam or Aniracetam in individuals with BDNF polymorphisms, associated with or without SERT ss allele subtype.
Methylation Related Genes
[0130] Certain examples pertain to use of the MTHFR gene or related gene products for determining an individual's tendency to experience depression based upon the said individual's inability to methylate certain pathways involved in catecholamine synthesis and or degradation. In one example, diagnosis involves testing a sample obtained from a subject for the presence of a polymorphism in the MTHFR gene.
[0131] Certain examples pertain to use of the COMT gene or related gene products for determining an individual's risk of developing or maintaining an addiction based upon the individual's ability to metabolize or maintain normal levels of dopamine in the brain. In one example, diagnosis involves testing a sample obtained from a subject for the presence of a polymorphism in the COMT gene.
[0132] The 5,10-methylenetetrahydrofolate reductase (MTHFR) is a key enzyme for intracellular folate homeostasis and metabolism. Methylfolic acid, synthesized from folate by the enzyme MTHFR, is required for multiple biochemical effects in the brain. A primary role involves the synthesis of dopamine in the brain. Folic acid deficiency results in fatigue, reduced energy and depression. Low folate blood levels are correlated with depression and polymorphisms of the MTHFR gene are closely associated with risk of depression.
[0133] MTHFR irreversibly reduces 5-Methyltetrahydrofolate which is used to convert homocysteine to methionine by the enzyme methione synthetase. The c677T SNP of MTHFR has been associated with increased vulnerability to several conditions and symptoms including depression.
[0134] Nucleotide 677 in the MTHFR gene has two possibilities: C. or T. 677C (leading to alanine at amino acid 222); 677T (leading to a valine substitution at amino acid 222) encodes a thermolabite enzymes with reduced activity. The degree of enzyme thermolability (assessed as residual activity after heat inactivation) is much greater in 677TT individuals (18-22%) compared with 677CT (56%) and 677CC (66-67%).
[0135] Suitable MTHF gene polymorphisms include polymorphisms in the 5,10-methylenetetrahydrofolate. reductase (MTHFR) gene, including MTHFR C677T and its association with common psychiatric symptoms including fatigue and depressed mood. These symptoms are proposed to be due to hypomethylation of enzymes which breakdown dopamine through the COMT pathway. In this model, COMT is disinhibited due to low methylation status, resulting in increased dopamine breakdown.
[0136] For unipolar depression, the MTHFR C677T polymorphism has been we described and validated.
[0137] COMT is an enzyme involved in the degradation of dopamine, predominantly in the frontal cortex. Several polymorphisms in the COMT gene have been associated with poor cognition, diminished working memory, and increased anxiety as a consequence of altered dopamine catabolism. Suitable COMT gene polymorphisms include, e.g., a polymorphism in a Catechol O-methyltransferase (COMT) gene, the major enzyme determining prefrontal dopamine levels, which has a common functional polymorphism (val(158)met) that affects prefrontal function and working memory capacity and has also been associated with anxiety and emotional dysregulation. A single nucleotide polymorphism in the COMT (Val158/108Met) gene affects the concentration of dopamine in the prefrontal cortex.
[0138] The COMT 158val/val genotype confers a significant risk of worse response after 4-6 weeks of antidepressant treatment in patients with major depression. There is a negative influence of the higher activity COMT 158val/val genotype on antidepressant treatment response during the first 6 weeks of pharmacological treatment in major depression, possibly conferred by decreased dopamine availability. This finding suggests a potentially beneficial effect of an antidepressive add-on therapy with substances increasing dopamine availability tailored according to COMT val158met genotype by inhibiting excess COMT activity
[0139] Dopamine agonists which can be selectively employed to individuals with this COMT polymorphism include COMT inhibitors, MAO inhibitors, Methylfolate and S adenosyl methionine.
Dopamine Based Single Nucleotide Polymorphisms
[0140] Dopamine receptor D2, also known as D2R, is a protein that, in humans, is encoded by the DRD2 gene. Of interest herein are DRD2 polymorphisms −141 c/d. Several lines of evidence suggest that antipsychotic drug efficacy is mediated by dopamine type 2 (D(2)) receptor blockade. Six studies reported results for the −141C Ins/Del polymorphism (total sample size: N=687) which indicated that the Del allele carrier is significantly associated with poorer antipsychotic drug response relative to the Ins/Ins genotype. These findings suggest that variation in the D(2) receptor gene can, in part, explain variation in the timing of clinical response to antipsychotics and higher risk of weight gain in deletion allele subtypes of the DRD2 gene.
[0141] Many antipsychotic medications carry a substantial liability for weight gain, and one mechanism common to all antipsychotics is binding to the dopamine D2 receptor. Carriers of the deletion allele showed significantly more weight gain after 6 weeks of treatment regardless of assigned medication. Thus, it is recommended that in patients who display the DRD2 del allele, either an alternative to a neuroleptic or a neuroleptic which had preferential antagonist effects at the 5HT2A>DRD2 be suggested.
SNP Detection
[0142] As an example, a patient visits with a psychiatrist or other mental health worker. After taking a history, the health care worker obtains a small sample of tissue from the mouth and sends it to a specialized lab which is able to analyze the DNA through methods used to those skilled in the art. The lab determines over a brief period of time the results of the DNA test. As one example, the test indicates whether a patient has one of three subtypes related to the gene, referred to as either LL, LS, or SS (long/long long,/short, and short/short) Certain individuals will possess two short alleles. This indicates that the serotonin transporter is less efficient with the short allele than the version in the long allele. The value of this result is as an assessment of serotonin synaptic levels, a more specific serotonin modulation drug can be chosen.
[0143] Various real-time PCR methods can be used to detect SNPs, including, e.g., Taqman or molecular beacon-based assays (U.S. Pat. Nos. 5,210,015; 5,487,972; and PCT WO 95/13399) are useful in monitor for the presence of absence of a SNP. Many other SNP detection methods are known in the art, including, without limitation, DNA sequencing, sequencing by hybridization, dot blotting, oligonucleotide array (DNA Chip) hybridization analysis.
[0144] Applied Biosystems, Inc (Foster City, Calif.) has developed several aspects of SNP genotyping technology. In one well used protocol PCP amplification of a desired SNP region is conducted using targeting primers, including two allele-specific fluorogenic probes, each consisting of a different fluorescent reporter dye and a fluorescent quencher. Prior to PCR, proximity of the quencher to the fluorphore causes fluorescence resonance energy transfer (FRET), reducing the fluorescence from the reporter dye. During PCR, the 5′ nuclease activity of Taq digests the allele-specific probe bound to the region of the SNP, releasing the fluorescent dye from the quencher and allowing generation of a fluorescence signal.
[0145] Any tissue sample may be used for genotyping the polymorphisms described in this art, or for determining levels gene products, including but not limited to, blood, saliva, spinal fluid, brain biopsy, cultured cells, stool, urine, or frozen sections taken for histologic purposes. In certain examples, blood is obtained from a subject for assaying with respect to the mentioned polymorphisms. In an example, venous blood is obtained from a subject using standard venipuncture techniques. In another example, a buccal swab can be obtained for analysis.
[0146] In any of the variations described above, a report summarizing the findings/screenings, and providing therapeutic guidance or suggestions may be provided to the patient, the patient's physician, or both. In some variations the report is a written report (provided electronically or in paper) stating the results of screening for the polymorphism, and well as the proposed or alternative therapeutic information such as which drugs to propose for treatment of the individual given their specific genetic profile.
[0147] FIG. 2 is a table showing pathways tested (e.g., serotonin, dopamine, Glutamate, and drug metabolism), listing the genes, the polymorphism examined, and providing interpretive comments describing proposed therapeutic application of each of the examined and examples of therapies. In some variations, this report (customized to include an indication of an individual's results) is provided each time the test is run. One or all of the genes described herein may be included on the report; in some variations only a subset (e.g., one from each category) are included.
[0148] For example, a summary of the overall treatment recommendations based (in part) on one or more alleles of the genes described above. The table shown in FIG. 3 illustrates some of the therapeutic recommendations that may be provided based on the presence of each polymorphism. For example, tianeptine may be recommended in cases in which the s-allele of SERT is identified, and particularly SERT ss. BDNF polymorphisms may indicate the use of Tianeptine or agents of the chemical class racetams, such as Aniracetam or Nefiracetam. A polymorphism in CACNAIC may indicate the use of calcium channel blockers, Fasudil, Flunazarine, Nimodipine, Candesartan, etc. A polymorphism in FKBP5 may also suggest the use of tianeptine, or other phosphodiesterae inhibitors. The DRD2 del allele suggests Clozaril, and/or atypical antipsychotics with preferable 5HT2A antagonist, instead of DRD2 antagonism. Finally MTHF/COMT val/val polymorphism suggests the use of methylating agents MTHF, S adenosylmethionine, or dopamine agonists such as MAO inhibitors, and/or stimulants.
[0149] In general, the screens, assays, tests and reports described herein highlight key genetic loci forming a previously unrecognized epistatic group that are relevant to the treatment of depression (TRD). By determining a patient's genotype for the key genetic loci, as well as providing information specific the possible outcomes, the methods and reports described herein may enhance patient care. | Described herein are assays, kits and methods for treating mood disorders by testing for one or more polymorphisms in a specific group of genes and for analyzing the results of polymorphism testing; the genes included may converge in one or more signaling pathways, and may be epigenetic. The genes are included based on the relationships of the proteins encoded by the genes in the context of particular signaling pathways and provide a diagnostically relevant nexus. Also described herein are methods of presenting the data collected by the screen, including methods of delivering interpretive comments and/or treatment guidance based on the results of the genetic screening either individually or based on the genetic composition of particular clusters of genes which may be related to each other. Importantly, drugs which modulate these genetic disturbances are described for targeted therapeutic use based upon companion diagnostic method. | 2 |
BACKGROUND OF THE INVENTION
The invention relates to an antenna diversity system having at least two antennae for the mobile reception of very-high and ultra-high frequencies [hereinafter: VHF and UHF].
An antenna diversity system with at least two antennae is known having an antenna switch and a tuner to which a selected RF signal is supplied by the antenna switch, the tuner having an output which guides the intermediate-frequency signal or the demodulated signal and is connected with a diversity processor in which a signal evaluation is carried out, the results of which determine whether or not the antenna switch is made to switch through a more favorable input signal to its output via a control line leading from the diversity processor to the antenna switch.
Multipath propagation in mobile radio and television reception causes considerable reception interference. In the case of radio reception this interference greatly impairs listening pleasure due to noise and pronounced distortions of the low-frequency signal and in the case of television reception causes visual disturbance in ghost images, fluttering of the picture, color fading, and loss of synchronization and picture. Such reception interference considerably impairs the reception quality and must therefore be prevented.
An antenna diversity system for eliminating reception interference in frequency-modulated ultrashort-wave radio is known from the German Patent Application P 35 17 247. In this case, at least two antenna signals are supplied to a diversity processor containing a frequency deviation threshold and an amplitude threshold with which the frequency disturbance deviation pulse currently caused by interference and the interference-induced amplitude break-ins in the intermediate frequency signal supplied to the diversity processor from the receiver are compared. If the disturbances exceed the thresholds, a switching process is initiated such that another antenna signal or another linear combination derived from the antenna signals is supplied to the tuner with intermediate-frequency component.
An antenna diversity system for preventing picture interference in the mobile reception of television signals in the VHF and UHF band is described in the German Patent Application P 39 26 336.3. This antenna diversity system has a diversity processor with N antenna signal inputs and a television receiver. The video signal and the horizontal and vertical synchronizing signals are supplied to the diversity processor. The diversity processor contains a time gate which is opened by the horizontal synchronizing pulses during the horizontal blanking time so that the video signal is switched through for evaluating the signal quality. An address signal is generated via a control circuit during incipient picture interference in such a way that a new antenna signal or another linear combination derived from the antenna signals is supplied to the television receiver via an antenna combiner.
Each of the diversity systems described in the patent application mentioned above solves the problem of reducing reception interference in a radio or television channel caused by multipath propagation. But to improve the television sound in a vehicle in addition to the television picture, separate antennae and accordingly also separate antenna diversity systems are required for television reception as well as sound reception in the prior art. The use of the solution indicated in P 39 26 336.3 prevents the picture interference in mobile reception, but not the sound interference of the respective television sound. On the one hand, this is because the television picture is amplitude-modulated in a special manner, while the television sound is frequency-modulated and the criteria for determining the picture quality are completely different in principle than the criteria for determining sound interference. On the other hand, the frequency separation of 5.5 MHz between the picture and sound carriers causes the reception ratios at the location of a reception antenna for picture and sound carriers to be completely different with such a large frequency separation. As a result, e.g., the picture interference can be at a maximum and the sound carrier interference at a minimum simultaneously.
This means that at least four antennae must be arranged on the vehicle when using the aforementioned solutions according to the prior art. But to obtain a distinct improvement in reception a quantity of four antennae per diversity arrangement is recommended in the literature on the subject. This already results in eight antennae which must be mounted on the vehicle according to the prior art to efficiently eliminate picture and sound interference while traveling. Consequently, at least 12 antenna would have to be arranged on the vehicle in order for the stereo television sound transmitted in two bands separated by a gap in frequency to be improved by antenna diversity. Further, considering the enormous frequency band width of approximately 40 to 860 MHz which must be covered, the difficulty of covering this large frequency band with a single antenna presents an additional problem so that the required number of antennae is further increased by the use of band antennae. But it is not possible to accommodate such a large number of antennae on modern motor vehicles.
SUMMARY OF THE INVENTION
The present invention therefore has the object of providing an antenna diversity system for the mobile reception of VHF and UHF waves which makes it possible to use one and the same set of antennae for supplying two or more tuners having different reception requirements without an excessive number of antennae and to ensure the adjustment of diversity reception ratios favorable for each tuner.
According to the invention, the antenna diversity system for mobile reception of VHF and UHF waves comprises a plurality of antennae; an antenna distributor connected to each of the antennae to receive antenna signals from the antennae and having a plurality of sets of outputs; a plurality of antenna switches, each of the antenna switches being connected to one of the sets of outputs of the antenna distributor; a plurality of tuners, each of the tuners being connected to one of the antenna switches and producing one of an intermediate-frequency signal and a demodulated signal; a plurality of diversity processors, each of the diversity processors being connected to a tuner to receive the intermediate-frequency or demodulated signal therefrom and also to the antenna switch of the tuner connected thereto via a control line and being structured to carry out a signal evaluation of the signal received in the diversity processor to control the antenna switch so that the antenna switch switches through a more favorable input signal to the tuner connected thereto.
Such antenna diversity systems are preferably used to improve the television and sound reception in the VHF and UHF band in motor vehicles.
The advantages which can be achieved by the invention consist in the considerable reduction in the number of antennae for antenna diversity systems whose tuners are used for completely different reception requirements. Thus, in a construction according to the invention, a set of e.g., four antennae is sufficient for suppressing the reception interference of stereo television sound and television pictures as well as the reception interference in the ultrashort-wave radio. Accordingly, the possibility of operating a plurality of diversity devices simultaneously in a motor vehicle is provided for the first time. Clearly, with the current compact construction of motor vehicles it would no longer be possible to accommodate a large number of antennae on or at the vehicle, even apart from the difficulty of arranging cables and the enormous cost. In the case of television picture and sound reception, the antenna diversity system according to the invention has the additional advantage that e.g., the oscillator of the picture tuner can also be used for the sound tuner because of the compact construction, so that additional costs can be saved.
BRIEF DESCRIPTION OF THE DRAWING
The objects, features and advantages of the present invention will now be illustrated in more detail by the following detailed description, reference being made to the accompanying drawing in which:
FIG. 1 shows an antenna diversity system according to the invention having an antenna distributor, two antenna switches, two tuners and two diversity processors;
FIG. 2 shows an antenna distributor in an antenna diversity system according to FIG. 1 having passive networks;
FIG. 3 shows an antenna distributor in an antenna diversity system according to FIG. 1 having active circuits;
FIG. 4 shows an antenna distributor in an antenna diversity system according to FIG. 1 having active circuits and passive networks;
FIG. 5 shows an antenna distributor in an antenna diversity system according to FIG. 1 having active and passive networks for splitting the signals and networks for forming linear combinations;
FIG. 6 shows an antenna diversity system for preventing reception interference in the reception of stereo television sound and the television picture;
FIG. 7 shows an antenna diversity system for preventing reception interference in the reception of the stereo television sound and the television picture as well as of a ultrashort-wave radio channel;
FIG. 8 shows the joint use of the oscillator signal of the picture tuner for the reception of the respective television sound of a television channel.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows an antenna diversity system according to the invention. It has a set of N antennae A 1 to A N which are connected to the inputs of the antenna distributor 1. The outputs of the antenna distributor supply the antenna signals and are connected to the two antenna switches 2a and 2b. An output signal of the antenna distributor 1 is selected in the antenna switches by a control line 3a and 3b and switched through to the tuner 4a and 4b. The tuner 4a can be, e.g., a television picture tuner, as shown in FIG. 1. The RF signal 7a is converted to an intermediate frequency and demodulated in the tuner 4a so that its video signal and possibly other signals can be supplied to a 9a demodulated signal 8a. The current picture quality is compared with a threshold in the diversity processor in the horizontal blanking time in a known manner, e.g. via a time gate (see P 39 26 336), and if necessary the control line 3 a is set in such a way that the antenna switch 2a is made to switch to another output signal of the antenna distributor 1. In this way it is ensured that the available HF signal having the best picture quality is always switched through to the tuner 4a.
The tuner 4b in FIG. 1 is tuned to the television sound of the same television channel. The frequency-modulated, intermediate-frequency signal which is not yet limited is fed to the diversity processor 9b. The interference-induced frequency interference deviation peaks and the amplitude break-ins are compared with thresholds in the diversity processor in a known manner (see P 35 17 247). During sound interference the antenna switch 2b is caused to switch through a better television sound signal to the tuner 4b via the control line 3b. Such an antenna diversity system ensures that the television picture as well as the respective television sound have the least interference at any point in time independently of one another in that the respective tuner can access all other available antenna signals independently of the other tuners.
Due to the introduction of stereo sound or two-channel sound in television whose sound carriers have a separation of 242 kHz, another tuner 4c is required (see FIG. 6) because in this frequency separation, which is greater than the channel separation in ultrashort-wave radio, the reception signals already have a clearly different configuration over time at the location of the antennae, as is shown by measurements. The sound interference is also eliminated for the second sound channel according to the described method.
Another advantage in the antenna diversity systems according to the invention consists in that, in addition to the possibility of television reception with stereo sound, it enables ultrashort-wave radio reception with the same set of antenna signals, e.g. in luxury limousines. A standard car radio can be used as a tuner 4d in this case (see FIG. 7). Here as well, the frequency-modulated intermediate-frequency signal 8d is examined in the diversity processor 9d for reception interference in a known manner and reception interference is prevented by rapidly switching to an undisturbed signal.
In a particularly advantageous embodiment of the invention, a plurality of FM tuners for frequency-modulated ultrashort-wave radio are connected to the respective antenna switches. In this way it is possible, e.g. in radio reception in busses, for the passenger to be offered a number of radio programs via headphones with individual selection of the program. Each program, by itself, is reproduced in such a way as to be as free from interference as possible in mobile reception by antenna diversity. The improvement in reception is effected in that a separate diversity processor, to which the intermediate frequency which is not yet limited is supplied, is available for every radio program and in that the reception interference is prevented in a manner known per se by switching to other signals at the antenna switch.
In a particularly simple embodiment of the invention, the same number of antenna signals A 1 to A n which are supplied as input signals to the antenna distributor 1 are supplied to the antenna switches 2a and 2b in the antenna distributor 1 by passive networks 6a to 6n (see FIG. 2). The networks 6a to 6n have the task of dividing the antenna signals in output to two outputs as equally as possible and decoupling the respective two outputs from one another as well as possible so that the switching state of the antenna switch has a sufficiently low reaction on the other respective output. These requirements are met to a high degree e.g., by Wilkinson couplers which can be constructed according to the prior art so as to have a sufficiently broad band and have decoupling attenuations of more than 20 dB.
However, the construction of such a passive network for splitting signals with the absence of reaction is very complicated, takes up a great amount of space and is expensive to produce. Therefore, networks for splitting the signal are also available which enable a decoupling of the outputs by resistors, although greater signal output losses must be taken into account. The advantage in this consists in that, in addition to the simple and accordingly inexpensive implementation, the required band width can easily be covered at the same time. Such asymmetrical output dividers usually have decoupling values of 12 dB with simultaneous signal attenuation of 6 dB. But the resultant loss in sensitivity can frequently not be tolerated.
In this respect, substantially more favorable ratios can be achieved when the signal splitting is effected in the antenna distributor 1 by active circuits 10a to 10n (see FIG. 3). Such highly linear and low-noise band width circuits have decoupling of more than 25 dB to 1 GHz according to the prior art. At the same time, these active networks allow an amplification of the signal to compensate for any signal attenuations, e.g. in the antenna switch. In addition, the active circuits can compensate for the signal loss, which necessarily occurs in passive output dividers, by internal amplification.
However, a combination of active and passive networks (see FIG. 4) is also possible for the antenna distributor 1 when, e.g., active and passive antennae are mounted at the vehicle. Thus, the passive antenna signals can then be supplied to the antenna switches via active signal distributors 10 to counteract further impairment of the signal which would result when splitting the signal by resistance networks. Meanwhile the signals of the active antennae which undergo an improvement in the signal-to-noise ratio and an amplification as a result of the noise-adapted amplifiers arranged in the base of the antenna can be distributed to the antenna switch in a cost-saving manner by passive networks 6.
Extensive investigations have shown that the sound and picture interference caused by multipath propagation in mobile reception in the VHF and UHF band can be further reduced when additional signals formed by linear combination of existing antenna signals are supplied to the antenna switches in addition to the antenna signals themselves. As shown in FIG. 5, the output signal y of a circuit 11 for forming a linear combination is determined by the following equation: ##EQU1## where x i is the i-th input signal and a i is its complex linear coefficient by which this input signal is evaluated in the circuit 11. In order for the output signals of the linear combination circuits to be supplied to the antenna switches in addition to the antenna signals themselves, it is recommended that active signal distributors be used in the antenna distributor 1 for the antenna signals because of the greater flexibility associated with them, since these signals must also be supplied to the linear combination circuits. Passive signal distributors need only be resorted to in exceptional cases, especially when a greater signal attenuation is permissible. In principle, all available antenna signals can be used in the formation of the linear combinations. The linear coefficients, which are complex in the most general case, are predetermined according to magnitude and phase. The magnitude and the phase of the individual linear coefficients can be determined by test drives in which the efficiency is highest with respect to minimizing the reception interference.
Addition and subtraction from the input signals is a particularly simple form of linear combination. In this case, not all input signals need be used, rather, e.g., only particularly strong antenna signals can be made use of. This procedure corresponds to a case where the corresponding linear coefficients of the antenna signals which are not used are zero.
The number of signals offered to the antenna switches can vary in the interests of minimizing cost. This refers not only to the number of circuits for forming linear combinations but also to the number of antenna signals themselves.
The use of the invention provides the additional advantage that the placement of cables in the vehicle is considerably simplified, since only the coaxial cable of the wide-band antennae installed in the vehicle need be guided to an antenna distributor to be arranged at a suitable location. The various tuners for different reception tasks are also advisably installed at the same installation location. The cost for the additional tuners is accordingly reduced because, as shown in FIG. 8, e.g. the picture oscillator of the picture tuner can also be used simultaneously as an oscillator for the television tuner when the signal evaluation is effected on the sound intermediate frequency of 33.4 MHz in the assigned diversity processor.
If this signal is converted, e.g., to 10.7 MHz, by another fixed oscillator, then this frequency-modulated television sound signal, for example, could be switched to the radio intermediate frequency of 10.7 MHz of a radio available for ultrashort-wave diversity reception and the sound reproduction device of this radio could also be used for the sound reproduction of the television sound. Accordingly, the diversity processor originally used only for ultrashort-wave diversity reception could also be used for diversity reception of the television sound. The control line leading from the diversity processor is then connected with the antenna switch for receiving the television sound. In the case of radio reception, this control line would be connected with the antenna switch for the reception of the ultrashort-wave radio. Technical costs are considerably reduced due to this double use of the radio and assigned diversity processor.
In television receivers for home reception, the television sound signal is usually first demodulated to the frequency of 5.5 MHz after demodulating the picture signal. Of course, in an antenna diversity system according to the invention the signal evaluation of the television sound can also be effected on this frequency in the diversity processor.
While the invention has been illustrated and described as embodied in an antenna diversity system with at least two antennae for mobile reception of VHF and UHF waves, it is not intended to be limited to the details shown, since various modifications and structural changes may be made without departing in any way from the spirit of the present invention.
Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can, by applying current knowledge, readily adapt it for various applications without omitting features that, from the standpoint of prior art, fairly constitute essential characteristics of the generic or specific aspects of this invention. | The antenna diversity system for mobile reception of VHF and UHF waves has a plurality of antennae; an antenna distributor connected to each of the antennae to receive antenna signals from the antennae and having a plurality of inputs and sets of outputs; a plurality of antenna switches, each of the antenna switches being connected to one of the sets of outputs of the antenna distributor; a plurality of tuners, each of the tuners connected to one of the antenna switches and producing one of an intermediate-frequency signal and demodulated signal; a plurality of diversity processors, each of the diversity processors being connected to a tuner to receive an intermediate-frequency or demodulated signal therefrom and also to the antenna switch of the tuner connected thereto via a control line and being structured to carry out a signal evaluation of the signal received in the diversity processor to control the antenna switch to switch through a more favorable input signal to the tuner connected to it. | 7 |
BACKGROUND OF THE INVENTION
The present invention relates to single lever faucet assemblies and, more specifically, to single lever faucet assemblies including a valve cartridge adapted for easy installation and removal therefrom.
Present designs for single lever faucets are generally characterized by a pivoting arrangement which controls the degree of alignment between the valve spool, ball or disc and the valve inlets in order to control flow rate and mixing level from the hot and cold water supplies. U.S. Pat. No. 4,226,260 to Schmidt discloses a single lever faucet which is characteristic of this type. While single lever faucets have enjoyed a considerable degree of popularity, present designs suffer several disadvantages. The control arrangement permits both temperature and flow rate to be controlled by pivotal movement of the control lever in any direction within the free range of operation of the lever. Single lever faucets incorporating this design inherently lack adequate operating definition of the temperature and volume controls. Thus, operation of most present single lever faucets of this type is somewhat confusing and often requires a person to "play" with the faucet control lever in order to determine the proper adjustment of the faucet to attain the temperature and flow rate which is desired.
The ability of the faucet control mechanism to provide uniform movement of temperature regulation at any flow rate is referred to as a square operating pattern. A further disadvantage of many single lever faucet designs resides in their inability to provide uniform movement of temperature regulation at any flow rate. The gimbal-type control mechanism disclosed in U.S. Pat. No. 4,226,260 to Schmidt provides a delta operating pattern which results in variable temperature regulation movement. Thus, for example, whereas the stem of a valve may travel one inch from extreme hot to extreme cold in a full volume setting. only one-fourth inch may be provided for the same regulation when flow is at a trickle. This makes "fine tuning" very difficult, since the travel of one-sixteenth inch would far overshoot the desired selection, resulting in repeated attempts at correction. A square pattern, on the other hand, permits the same degree of travel at trickle settings as it does at full volume. Another advantage of a square pattern activation is the ability to preselect temperature before turning water on. The advantage of this feature can be readily appreciated by anyone who has experienced searching for the desired temperature setting on a shower faucet. Thus, a single lever faucet providing a square operating pattern offers a distinct improvement over other single lever faucet designs which inherently cannot provide a square operating pattern.
Another disadvantage which is present in certain types of single lever faucets involves the design of the flow pattern through the valve mechanism. Thus, it is perceived that many single lever faucet designs require valve arrangements which either segment the flow pattern therethrough, require the flow pattern to execute relatively sharp turns, or present other undesirable flow restrictions. Any obstruction or restriction in the flow pattern increases friction and results in a significant pressure decrease between the faucet inlet and outlet, thus reducing the maximum outlet flow rate attainable at any given inlet pressure.
Yet another disadvantage characteristic of all known single lever faucet designs resides in their lack of reversibility. For example, in plumbing back-to-back conventional faucet installations through a common wall, the supply connections to one of the faucets must be criss-crossed in order to orient the hot and cold water supply connections properly to both faucet installations. However, if the faucet temperature control is able to be reversed in orientation, simple parallel piping connections may be employed. Thus, it would be a distinct advantage to provide a single lever faucet assembly which avoids the disadvantages associated with having to criss-cross the hot and cold water supply lines in situations similar to that described above.
Finally, single lever faucets inherently have a more complicated valve arrangement than double lever faucets. This presents problems principly when replacement of a portion of the valve mechanism becomes necessary for any reason. In order to simplify installation and removal of the valve mechanism for replacement or repair purposes, many single lever faucets now use valve cartridges which are designed for quick and simple attachment and removal from the main faucet assembly. An example of such a cartridge is disclosed in U.S. Pat. No. 4,226,260 to Schmidt, previously mentioned above. One disadvantage of this assembly is that it requires the gimbal-type activating mechanism and control lever stem to be replaced in order to replace the valve mechanism. Since it is highly unlikely that both the valve mechanism and activating mechanism would become defective or worn out at the same time, this arrangement requires unnecessary replacement of working parts and is for this reason a disadvantage.
SUMMARY OF THE INVENTION
A single lever faucet assembly according to one embodiment of the present invention is characterized by a faucet base adapted to receive hot and cold water supply lines, a valve cartridge received within the faucet base, a faucet spout mounted on the faucet base, a faucet control lever, and a linkage means associated with the faucet control lever and the faucet base. The valve cartridge includes a valve body and a valve spool axially rotatable and slidable within the valve body. The valve body defines a cavity, a pair of inlets communicating the cavity with the hot and cold water supply lines and an outlet communicating the cavity with the faucet spout. The valve spool defines a mixing chamber and a first pair of inlets and an outlet, each of the valve spool inlets and outlet communicating the mixing chamber with the exterior of the valve spool. The valve cartridge serves to control the flow rate and temperature of water discharged through the valve body outlet and supplied from the hot and cold water supply lines by selective registry, partial registry or non-registry of the valve spool inlets with the valve body inlets. The linking means serves to provide independent control of axial and rotational movement of the valve spool within the valve body cavity by separate-patterned movements of the faucet control lever in order to effect the desired degree of registry between the valve body inlets and the valve spool inlets. The outlet flow temperature control is fully regulable between the temperatures of the discharge from the hot and cold water supply lines at any flow rate.
It is an object of the present invention to provide an improved single lever faucet assembly.
Related objects and advantages of the present invention is made apparent in the following figures and detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a fragmentary front elevation view of the single lever faucet assembly of the present invention in assembled relation and connected to a pair of hot and cold water supply lines, certain sections thereof having been removed in order to show various internal features.
FIG. 1A is a fragmentary section view showing portions of the valve spool and end cap of the present invention.
FIG. 2 is a cross section view taken along line 2--2 in FIG. 1.
FIG. 3 is a top plan view of the valve cartridge of the present invention.
FIG. 4 is a bottom plan view of the valve cartridge of the present invention. rotated 180° relative to FIG. 3.
FIGS. 5 and 6 are cross section views taken along lines 5--5 and 6--6, respectively, in FIG. 4 and rotated 90 degrees relative thereto.
DESCRIPTION OF THE PREFERRED EMBODIMENT
For the purposes of promoting an understanding of the principles of the invention, reference will now be made to the embodiment illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended, such alterations and further modifications in the illustrated device, and such further applications of the principles of the invention as illustrated therein being contemplated as would normally occur to one skilled in the art to which the invention relates.
Referring now to the drawings, the sing1e 1ever faucet assembly of the present invention is shown generally designated at 10 in FIG. 1 in assembled relation and mounted to hot and cold water supply lines 11 and 12, respectively. Faucet assembly 10 includes a base 13 which is normally mounted on a sink or lavatory with hot and cold water supply lines 11 and 12 received therein. Faucet assembly 10 further includes a faucet body 14 which houses the valving mechanism of the faucet assembly which comprises valve cartridge 15, to be described later herein. At this point it is sufficient to note that valve cartridge 15 controls the discharge flow rate and the discharge temperature from hot and cold water supply lines 11 and 12 and has a unitary design which is adapted for easy installation and removal from faucet assembly 10. Valve cartridge 15 is operably connected to control lever 16 by a linkage arrangement generally designated at 17 which is housed within and includes end cap 18. Faucet assembly 10 also includes a spout 19 which is in flow communication with hot and cold water supply lines 11 and 12 through valve cartridge 15. Only a portion of spout 19 is shown, and it is understood that spout 19 may have any of a number of desirable and well known shapes.
Referring now also to FIGS. 3-6, details of the construction of valve cartridge 15 will now be described in more detail. Valve cartridge 15 is generally comprised of a valve body 37 and a valve spool 22 which is axially slidably and rotatably received therein on axis 20. Valve spool 22 has a generally cylindrical shape and defines an axial bore 23 which is closed at one end by a plug 24 so as to define a mixing chamber for hot and cold water from supply lines 11 and 12. Valve spool 22 includes a first pair of inlets 25 and an outlet 27 which serve to communicate axial bore 23 with the exterior of valve spool 22. As may be seen with reference to FIG. 6, a second pair of inlets 26 is also provided which is angularly spaced from each of the spool inlets 25. While FIG. 6 shows only one of the two spool inlets 26, it is to be understood that a second inlet 26 is similarly positioned behind the other one of spool inlets 25. It is further to be understood that only one pair of inlet pairs 25 and 26 is operable at any one time, the purpose of the second pair of inlets being to provide for reversing of the orientation of control knob 16 with respect to spout 19 in a manner to be described later herein. At the end opposite retaining cap 24, valve spool 22 includes a slot 28 which is sized to journably receive a pin 31 attached to control lever 16. The exterior of valve spool 22 is provided with a pair of annular grooves 32 in which are received O-rings 33 disposed concentrically with axial bore 23. Valve spool 22 also includes a key 34 at the end opposite retaining cap 24 which is shaped to be slidably received within a longitudinal slot 35 in end cap 18 (FIG. 1A).
Valve body 37 is a generally cylindrically shaped member having an axial bore 38 within which is concentrically disposed valve spool 22. Valve body 37 includes an outlet 39 which communicates with outlet 27 of valve spool 22. A pair of inlets 40 is also provided, each of which contains an inlet seal 41, a spring 42 and a retainer 43. Each spring 42 is biased so as to urge the corresponding inlet seal 41 against valve spool 22. Four annular grooves 44 are provided along the exterior of valve body 37 in which are received O-rings 45 to seal the space between valve body 37 and faucet body 14. Valve body 37 also includes an axial slot 46 which is adapted to receive pin 49 which serves to accurately align the inlets and outlet of valve body 37 with the corresponding inlets and outlet of faucet body 14 and retain valve body 37 in the proper position.
Referring now to FIGS. 1 and 2, end cap 18 includes a stop pin 54 adapted to be journably received in an annular guide slot 55 at one end of valve body 37. Ring 56 secures end cap 18 to faucet body 14 in such manner that end cap 18 is able to be rotated on axis 20, it being understood that rotational movement of end cap 18 is restricted by the movement of stop pin 54 within guide slot 55. Control lever 16 includes a stem 58 having an annular groove 59 adapted to receive O-ring 60. Stem 58 is received within guide bushing 61 which is in turn received in a press fit within bore 63 of cap 18. Control lever 16 further includes a conventional style knob 62 which is received over one end of stem 58 and secured thereto by set screw 64. Pin 31 extends from the other end of stem 58 and is eccentrically positioned relative to the central axis 65 of stem 58 which is perpendicular to axis 20.
Spout 19 is seen to include a socket 68 which is fixedly attached at one end to faucet body 14 and at the opposite end receives therein hub 69 having an annular groove 70 receiving O-ring 71. Hub 69 is fixedly attached at one end to spout portion 72 and retained within socket 68 by pin 73 and retaining ring 74. Hub 69 includes an extra bore 75 for receiving pin 73 when it is desired to reverse the orientation of spout 19 for a purpose which will be made apparent later herein.
The operation of single lever faucet assembly 10 may be described as follows. When control lever 16 is rotated on central axis 65 clockwise in the direction of arrow 66, valve spool 22 slides along axis 20 in the direction of arrow 67 under the urging of eccentrically positioned pin 31 as pin 31 moves within slot 28. Thus, pin 31 cooperates with slot 28 to provide a means of indexing valve spool 22 along axis 20. Similarly, it is to be understood that counterclockwise rotation of knob 62 will cause valve spool 22 to move in a direction opposite to arrow 67. Of course, axial movement of valve spool 22 is restricted by faucet body 14 and end cap 18. Thus, rotation of control lever 16 serves to provide a mixing control by the relative alignment, partial alignment, or non-alignment of inlets 25 relative to inlets 40. On the other hand, pivoting control lever 16 about axis 20 causes valve spool 22 to rotate on axis 20 under the urging of end cap 18 along slot 35 against key 34. Pivoting movement of control lever 16 is of course restricted by the movement of spout pin 54 within guide slot 55. At this point it may be appropriate to mention that the rotating of valve spool 22 on axis 20 is in no way restricted by the position of pin 31 within slot 28. Similarly, axial movement of valve spool 22 under the urging of pin 31 against slot 28 is totally independent of the angular orientation of control lever 16. As a result, uniform temperature regulation movement is provided at any flow rate, or in other words, the control mechanism affords a square operating pattern.
It may be appreciated that the design of valve cartridge 15 of the present invention permits relatively easy installation and removal from faucet assembly 10. Thus, valve cartridge 15 is installed within faucet body 14 by simply inserting valve cartridge 15 therein and rotating it until axial slot 46 aligns with bore 50 in faucet body 14 whereupon pin 49 is advanced into axial slot 46 in order to fix the location of valve cartridge 15. End cap 18 is inserted over valve spool 22 such that key 34 is received within longitudinal slot 35 and end cap 18 is advanced until it is partially received within faucet body 14 and shoulder 51 of end cap 18 is urged against an opposing shoulder 52 on faucet body 14. It may be further noted that the design of faucet assembly 10 makes it possible to replace the entire valve mechanism without having to replace any activating parts such as end cap 18 or control lever 16.
It may also be noted that temperature control is accomplished by rotational movement of control lever 16 which is functionally quite different from the pivotal movement of control lever 16 to provide control of the discharge flow rate. The distinctiveness of the control functions is further enhanced by the fact that rotational movement takes place about an axis which is perpendicular to the axis about which control lever 16 pivots. Thus, directions for these controls are much easier to follow, and operability is thereby enhanced.
It may further be appreciated that the design of single lever faucet assembly 10 permits reversing of the orientation between control lever 16 and spout 19, thereby eliminating the need for criss-crossing the hot and cold supply lines 11 and 12 if a parallel connection of lines 11 and 12 to the built-in plumbing would result in an orientation which is reversed relative to the hot and cold directional indicators on knob 62. Thus, while FIG. 1 shows control lever 16 positioned to the right of spout 19, it is possible to position control lever 16 so that it is to the left of spout 19. This is quite simply accomplished by rotating base 13 and faucet body 14 180 degrees thus reversing the orientation of the hot and cold water supply lines 11 and 12 without having to criss-cross them. Retaining ring 56 is then removed from end cap 18 which is then disconnected from faucet body 14. Stop pin 54 is then removed from end cap 18 and relocated into an alternate bore (not shown) in end cap 18. End cap 18 is then reassembled to faucet body 14 in the manner previously described. The orientation of spout 19 is then also reversed by removing spout retaining ring 74 and spout retaining pin 73, rotating spout hub 69 180 degrees and then replacing retaining pin 73 in the extra hole 75 and resecuring retaining ring 74 to spout socket 68.
Another important feature afforded by the novel design of faucet assembly 10 which is readily apparent by reference to FIG. 1 involves the straight through flow path between hot and cold water supply lines 11 and 12 and spout 19. Thus, it is observed that the flow path is not segmented or characterized by significant bending which would present unnecessary restrictions to flow.
While the invention has been illustrated and described in detail in the drawings and foregoing description, the same is to be considered as illustrative and not restrictive in character, it being understood that only the preferred embodiment has been shown and described and that all changes and modifications that come within the spirit of the invention are desired to be protected. | A single lever faucet assembly having a faucet control lever which is reversibly mountable laterally on either side of the faucet spout without having to switch positioning of the hot and cold water supply lines thereto. The faucet assembly includes a valve cartridge which may be easily disconnected from the faucet control lever and removed from the faucet base for replacement. The valve cartridge is arranged and disposed to provide a straight through flow path from the hot and cold water supply lines to the faucet spout which is free of any obstructions, thereby maximizing outlet flow rates. The faucet assembly further includes a means for independently controlling discharge temperature and flow rate by separate-patterned movement of the faucet control lever so as to provide uniform temperature regulation at any flow rate. | 5 |
[0001] This application claims priority to U.S. Patent Appln. No. 61/936,652 filed Feb. 6, 2014.
BACKGROUND
[0002] The present disclosure relates to an additive manufacturing system and, more particularly, to an additive manufacturing system with a multi-energy beam gun and a method of operation.
[0003] Traditional additive manufacturing systems include, for example, Additive Layer Manufacturing (ALM) Systems, such as Direct Metal Laser Sintering (DMLS), Selective Laser Melting (SLM), Laser Beam Melting (LBM) and Electron Beam Melting (EBM) that provide for the fabrication of complex metal, alloy, polymer, ceramic and composite structures by the freeform construction of the workpiece, layer-by-layer. The principle behind additive manufacturing processes involves the selective melting of atomized precursor powder beds by a single directed energy source, producing the lithographic build-up of the workpiece. The energy source is focused and targeted onto localized regions of the powder bed producing small melt pools, followed by rapid solidification. This melting and solidification process is repeated many times to folio a single layer of the workpiece. Once a layer is completed, the powder bed is spread over the completed solidified layer and the process repeats as part of the layer-by-layer fabrication of the workpiece. These systems are typically directed by a three-dimensional model of the workpiece developed in a Computer Aided Design (CAD) software system.
[0004] The EBM System utilizes a single electron beam gun and the DMLS, SLM, and LBM Systems utilize a single laser as the energy source. Both system beam types are focused by a lens, then deflected by an electromagnetic scanner or rotating mirror so that the energy beam selectively impinges on the powder bed. The EBM System uses a beam of electrons accelerated by an electric potential difference and focused using electromagnetic lenses that selectively scan the powder bed.
[0005] Known ALM Systems have limited control over the heating and cooling cycles of the melt pools that can impact microstructure development of the workpiece and further lead to poor workpiece composition characteristics and properties.
SUMMARY
[0006] An energy gun of an additive manufacturing system for producing a workpiece from a substrate according to one, non-limiting embodiment of the present disclosure includes a plurality of energy beams constructed and arranged to follow one-another.
[0007] In a further embodiment of the foregoing embodiment the plurality of energy beams includes a first energy beam for producing a melt pool from the substrate and a second energy beam for post heating to control a solidification rate of the melt pool.
[0008] In the alternative or additionally thereto, in the foregoing embodiment, the plurality of energy beams includes a first energy beam for producing a melt pool from the substrate and a second energy beam for pre-heating the substrate associated with the melt pool.
[0009] In the alternative or additionally thereto, in the foregoing embodiment, the substrate is a powder.
[0010] In the alternative or additionally thereto, in the foregoing embodiment, the plurality of energy beams have different frequencies.
[0011] In the alternative or additionally thereto, in the foregoing embodiment, the gun further includes a plurality of energy source devices wherein each one of the plurality of energy source devices emits a respective one of the plurality of energy beams.
[0012] In the alternative or additionally thereto, in the foregoing embodiment, the plurality of energy sources have fiber optic outputs.
[0013] In the alternative or additionally thereto, in the foregoing embodiment, each one of the plurality of energy beams impart a hot spot upon the substrate at pre-arranged distances from one-another and the plurality of energy source devices are constructed and arranged to move the hot spots in unison across the substrate at a controlled velocity.
[0014] In the alternative or additionally thereto, in the foregoing embodiment, the gun includes a lens for focusing at least one of the plurality of energy beams.
[0015] In the alternative or additionally thereto, in the foregoing embodiment, the plurality of energy beams are focused by the lens and the distance between the hot spots is dictated by the lens.
[0016] In the alternative or additionally thereto, in the foregoing embodiment, the gun includes a housing constructed and arranged to move at the controlled velocity, and the lens is stationary with respect to the housing and the plurality of energy source devices are constructed and arranged to move with respect to the housing to control the distance between the hot spots.
[0017] In the alternative or additionally thereto, in the foregoing embodiment, fiber optic outputs of each one of the plurality of energy source devices are pivoted to produce the movement of the plurality of energy source devices.
[0018] In the alternative or additionally thereto, in the foregoing embodiment, the gun includes a housing constructed and arranged to move at the controlled velocity, a plurality of lenses wherein the lens is one of the plurality of lenses, and each one of the plurality of lenses are supported by and stationary with respect to the housing and focus a respective one of the plurality of energy beams, and wherein the plurality of energy source devices are constructed and arranged to move with respect to the housing to control the distance between the hot spots.
[0019] In the alternative or additionally thereto, in the foregoing embodiment, the gun includes a beam combinatory, and at least one of the plurality of energy beams of respective at least one energy source devices being reflected upon the beam combinator and at least one of the plurality of energy beams of respective at least one energy source devices are refracted upon the beam combinator.
[0020] In the alternative or additionally thereto, in the foregoing embodiment, the combinator is orientated between the plurality of energy source devices and the lens.
[0021] In the alternative or additionally thereto, in the foregoing embodiment, the gun includes a housing constructed and arranged to move at the controlled velocity, and wherein the lens and beam combinator are supported by and stationary with respect to the housing, and wherein at least one of the energy source devices is constructed and arranged to move with respect to the housing to control the distance between the hot spots.
[0022] In the alternative or additionally thereto, in the foregoing embodiment, the gun includes a housing constructed and arranged to move at the controlled velocity, a plurality of lenses wherein the lens is one of the plurality of lenses, and wherein each one of the plurality of lenses are supported by and stationary with respect to the housing, focus a respective one of the plurality of energy beams of each respective energy source device, and are located between the beam combinator and the respective energy source device, and wherein at least one of the plurality of energy source devices are constructed and arranged to move with respect to the housing to control the distance between the hot spots.
[0023] An additive manufacturing system according to another, non-limiting, embodiment includes a primary energy beam for selectively melting a powder layer into a melt pool, a secondary energy beam for heat conditioning the substrate proximate to the melt pool, and a build table for supporting the powder layer.
[0024] A method of additively manufacturing a workpiece according to another, non-limiting, embodiment includes the steps of melting a substrate into a melt pool with a first energy beam, and heat conditioning the substrate with a second energy beam.
[0025] In a further embodiment of the foregoing embodiment, the method includes the step of pre-heating a region of the substrate with the second energy beam before melting the region into the melt pool by the first energy beam.
[0026] The foregoing features and elements may be combined in various combinations without exclusivity, unless expressly indicated otherwise. These features and elements as well as the operation thereof will become more apparent in-light of the following description and the accompanying drawings. It should be understood; however, that the following description and figures are intended to be exemplary in nature and non-limiting.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] Various features will become apparent to those skilled in the art from the following detailed description of the disclosed non-limiting embodiments. The drawings that accompany the detailed description can be briefly described as follows:
[0028] FIG. 1 is a schematic view of an additive manufacturing system according to one non-limiting embodiment of the present disclosure;
[0029] FIG. 2 is a schematic view of an energy gun of the additive manufacturing system;
[0030] FIG. 3 is a schematic view of the energy gun having adjustably moveable energy source devices;
[0031] FIG. 4 is a schematic view of a second embodiment of an energy gun;
[0032] FIG. 5 is a schematic view of a third embodiment of an energy gun;
[0033] FIG. 6 is an enlarge schematic view of a beam combinator of the energy gun of FIG. 5 ; and
[0034] FIG. 7 is a schematic view of a fourth embodiment of an energy gun.
DETAILED DESCRIPTION
[0035] FIG. 1 schematically illustrates an additive manufacturing system 20 according to one non-limiting example of the present disclosure that may have a build table 22 for holding a powder bed 24 , a particle spreader or wiper 26 for spreading the powder bed 24 over the build table, an energy gun 28 for selectively melting regions of a layer of the powder bed, a powder supply hopper 30 for supplying powder to the spreader 26 , and a powder surplus hopper 32 . The additive manufacturing system 20 may be constructed to build a workpiece 36 in a layer-by-layer fashion.
[0036] A controller 38 may have an integral CAD system for modeling the workpiece 36 into a plurality of slices 40 additively built atop one-another generally in a vertical or z-coordinate direction (see arrow 42 ). Once manufactured, each solidified slice 40 corresponds to a layer 44 of the powder bed 24 prior to solidification. The layer 44 is placed on top of a build surface 46 of the previously solidified slice 40 . The controller 38 generally operates the entire system through a series of electrical and/or digital signals 48 sent to the system 20 components. For instance, the controller 38 may send a signal 48 to a mechanical piston 50 of the supply hopper 30 to sequentially push a supply powder 52 upward for receipt by the spreader 26 , or alternatively or in addition thereto, the supply hopper 30 may feed powder downward via gravity. The spreader 26 may be a wiper, roller or other device that pushes (see arrow 54 ) or otherwise places the supply powder 52 over the build surface 46 of the workpiece 38 by a pre-determined thickness established through downward movement (see arrow 42 ) of the build table 22 controlled by the controller 38 . Any excess powder 56 may be pushed into the surplus hopper 32 by the spreader 26 . It is further contemplated and understood that the layer 44 may not be composed of a powder but may take the form of any substrate that may be layed or applied across the build surface 46 in preparation for melting.
[0037] Once a substantially level powder layer 44 is established over the build surface 46 , the controller 38 may send a signal 48 to the energy gun 28 to activate and generally move along the top layer 44 at a controlled velocity and direction (see arrow 58 ) and thereby selectively melt the top layer 44 on a region-by-region basis into melt pools. Referring to FIGS. 1 and 2 , the energy gun 28 may have a housing 60 , a primary energy source device 62 for emitting a primary energy beam 64 , a secondary energy device 66 for emitting a secondary energy beam 68 for heat conditioning, and a lens 70 for focusing the energy beams 64 , 68 upon the layer 44 and identified as respective hot spots 72 , 74 on the layer. In FIG. 2 , the devices 62 , 66 and lens 70 are supported by, and held stationary with respect to, the housing 60 . Each energy source device 62 may further include fiber optic outputs 76 that emit and direct the energy beams 64 , 68 .
[0038] The energy beams 64 , 68 may be substantially parallel to one-another prior to being refracted through the lens 70 . Once refracted and focused, the beams are redirected to form the hot spots 72 , 74 at a pre-determined distance 76 away from one-another. That is, the lens 70 is chosen to establish the desired distance 76 between the hot spots. As illustrated, the primary hot spot 72 is the location of the desired melt pool region of the powder layer 44 , and the secondary hot spot 74 is the desired location for post heating, thereby controlling the cool down rate (or solidification rate) of the melt pool. Control of the solidification rate may be desired to reduce internal stresses of the workpiece and/or control microstructure development such as directional grain structure as, for example, that found in single crystal alloys. The pre-established distance 76 is dependent upon many factors that may include but is not limited to the powder composition, the power of the energy source devices 62 , 64 , the velocity of the energy gun 28 , and other parameters.
[0039] It is further contemplated and understood that the energy beams 64 , 68 may be laser beams, electron beams or any other energy beams capable of heating the powder to sufficient temperatures and at sufficient rates. Each beam may operate with different frequencies to meet manufacturing objectives. For instance, beams with shorter wavelengths may heat up the powder faster than beams with longer wavelengths. Different optical frequencies or wavelengths typically requires different types of lasers; for example, CO 2 lasers, diode lasers, and fiber lasers. However, to pre-select the best wavelength (thus laser type) for heating and/or melting, the wavelength selected may be based on the composition of the metal powder (for example). That is, particles of a powder may have different heat absorption rates impacting melting rates and solidification rates. Moreover, and besides wavelength, other properties of the beam may be a factor. For instance, pulsed laser beams or continuous laser beams may be desired to melt the powder. It is also understood that by interchanging the two energy source devices 62 , 64 , the secondary energy source device 64 may be used to pre-heat the desired region to be melted as oppose to post heating. Yet further the heat gun 28 may have two secondary energy source devices that both follow the primary source device for pre-heating and post-heating, respectively.
[0040] Referring to FIG. 3 , the energy gun 28 may be further capable of moving the energy source devices 62 , 64 in a tilting movement with respect to the housing 60 (see arrows 78 ) and generally along the same imaginary plane that contains the respective hot spots 72 , 74 . Controlled tilting of the devices 62 , 64 may then adjust the distance 76 between the hot spots 72 , 74 for any given parameters. With devices 62 , 64 have adjustable tilt capability, the distance 76 is not (or is less) dependent upon the choice of lenses 70 . It is further contemplated and understood that with a three dimensional lens 70 , the movement of the energy source devices 62 , 64 may also be three dimensional, thus enabling move complex operations of the system 20 . Yet further, it is contemplated that movement of the energy source devices 62 , 66 may be limited to the fiber optic outputs 76 , thereby relying on the routing capability and flexibility of the fiber optic technology.
[0041] Referring to FIG. 4 , a second, non-limiting, embodiment of the energy gun is illustrated wherein like components to the first embodiment have like identifying numerals except with the addition of a prime symbol. The energy gun 28 ′ of the second embodiment has a first lens 70 ′ for focusing a primary energy beam 64 ′ of a primary energy source device 62 ′. A second lens 80 focuses an energy beam 68 ′ of a secondary energy source device 66 ′. Both lenses 70 ′, 80 are supported by, and may be stationary with respect to, a housing 60 ′ and the devices 62 ′, 66 ′ are constructed and arranged to move or pivot to adjust a distance 76 ′ between hot spots 72 ′, 74 ′.
[0042] Referring to FIGS. 5 and 6 , a third, non-limiting, embodiment of the energy gun is illustrated wherein like components to the first embodiment have like identifying numerals except with the addition of a double prime symbol. The energy gun 28 ″ of the third embodiment has a beam combinator 82 positioned between a lens 70 ″ and primary and secondary energy source devices 62 ″, 66 ″. The combinator 82 is supported by a housing 60 ″ and is positioned at a prescribed angle 84 with respect to the lens 70 ″ and/or a powder layer 44 ″. The angle 84 may be about forty-five degrees with the primary energy source 62 ″ located above the combinator 82 such that an energy beam 64 ″ emitted from the device 62 ″ is directed downward and refracted, first through the combinator 82 and then through the lens 70 ″. The device 62 ″, the combinator 82 and the lens 70 ″ may be supported by and stationary with respect to the housing 60 ″. The secondary energy source device 66 ″ may be positioned such that a secondary energy beam 68 ″ is adjustably directed horizontally to reflect off of the combinator 82 and then refracted through the lens 70 ″.
[0043] Device 66 ″ may be supported by the housing 60 ″ and may also be constructed and arranged to pivot, tilt, or move with respect to the housing such that the beam 68 ″ is adjustably reflected off of the beam combinator 82 . As best shown in FIG. 6 , a distance 76 ″ between hot spots 72 ″, 74 ″ may be adjusted by changing the incident reflection angle upon the combinator 82 . More specifically, the beam 68 ″ may have a large reflection angle 86 producing a large distance between hot spots 72 ″, 74 ″. Moving or pivoting the energy source device 66 ″ to produce a smaller reflection angle 88 will reduce the distance 76 ″ between hot spots 72 ″, 74 ″. It is further contemplated and understood that the reflected beam 68 ″ may be held stationary and the energy source device 62 ″ emitting the energy beam 64 ″ may be adjustably pivoted or moved to adjust the refraction angle thereby adjusting the distance 76 ″.
[0044] Referring to FIG. 7 , a fourth, non-limiting embodiment of an energy gun is illustrated wherein like elements to the second and third embodiments have like identifying numerals except with the addition of a triple prime symbol. In the fourth embodiment, an energy gun 28 ′″ has a primary energy beam 64 ′″ that is first focused through a lens 70 ′″ and then refracted through a beam combinator 82 ′″. A secondary energy beam 68 ′″ is first focused through a second lens 80 ′″ and then reflected off of the combinator 82 ′″. A secondary energy source device 66 ′″, emitting the secondary energy beam 68 ′″, may be constructed and arranged to pivot or move with respect to a housing 60 ′″ to adjust a distance 76 ′″ between respective hot spots 72 ′″, 74 ′″.
[0045] Referring to FIG. 6 and in operation as step 100 , a CAD system as part of the controller 38 models the workpiece 36 in a slice-by-slice, stacked orientation. As step 102 , a powder bed layer 44 is spread directly over the build table 22 per signals 48 sent from the controller 38 . As step 104 , the energy gun 28 then melts on a melt pool by melt pool basis a pattern upon the layer 44 mimicking the contour of a bottom slice 76 of the plurality of slices 40 as dictated by the controller 38 . As step 106 , the melted portion of the powder layer solidifies over a pre-designated time interval thereby completing the formation of a bottom slice 76 . As step 108 , the controller 38 communicates with the controller 96 of the ultrasonic inspection system 34 and the controller 96 initiates performance of an inspection to detect defects 66 in the bottom slice 76 . As step 110 and if a defect is detected, the controllers communicate electronically with one-another and the bottom slice 76 is reformed by re-melting and re-solidification.
[0046] As step 112 , a powder bed layer 44 is spread over the defect-free bottom slice 76 . As step 114 , at least a portion of the layer is melted by the energy gun 28 along with a meltback region of the solidified bottom layer 76 in accordance with a CAD pattern of a top slice dictated by the controller 38 . As step 116 the melted layer solidifies forming the top slice 88 and a uniform and homogeneous interface 64 . As step 118 , the controller 38 communicates with the controller 96 and another ultrasonic inspection is initiated sending ultrasonic waves 82 through the bottom slice 76 and into the top slice 88 . As step 120 , the ultrasonic waves are in-part reflected off of any defects and in-part off of the build surface 46 of the top layer 88 , received by the array 70 and processed by computer software. As step 122 and if a defect is detected, such as a delamination defect at the interface 64 , the top slice 88 along with the meltback region is re-melted and re-solidified to remove the defects. The system 20 may then repeat itself forming yet additional slices in the same manner described and until the workpiece 36 is completed.
[0047] It is understood that relative positional terms such as “forward,” “aft,” “upper,” “lower,” “above,” “below,” and the like are with reference to the normal operational attitude and should not be considered otherwise limiting. It is also understood that like reference numerals identify corresponding or similar elements throughout the several drawings. It should be understood that although a particular component arrangement is disclosed in the illustrated embodiment, other arrangements will also benefit. Although particular step sequences may be shown, described, and claimed, it is understood that steps may be performed in any order, separated or combined unless otherwise indicated and will still benefit from the present disclosure.
[0048] The foregoing description is exemplary rather than defined by the limitations described. Various non-limiting embodiments are disclosed; however, one of ordinary skill in the art would recognize that various modifications and variations in light of the above teachings will fall within the scope of the appended claims It is therefore understood that within the scope of the appended claims, the disclosure may be practiced other than as specifically described. For this reason, the appended claims should be studied to determine true scope and content. | An additive manufacturing system includes an energy gun having a plurality of energy source devices each emitting an energy beam. A primary beam melts a selected region of a substrate into a melt pool and at least one secondary beam heat-conditions the substrate proximate the melt pool to reduce workpiece internal stress and/or enhance micro-structure composition of the workpiece. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of my prior U.S. nonprovisional patent application Ser. No. 13/609,189, filed Sep. 10, 2012, now pending, which is a continuation-in-part of my prior U.S. nonprovisional patent application Ser. No. 12/586,951, filed Sep. 30, 2009, now abandoned, which are hereby incorporated by reference in their entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to plumbing fixtures, and particularly to a toilet and support bars for the disabled that are specifically designed for handicapped persons, as well as anyone having difficulty using a conventional toilet fixture.
[0004] 2. Description of the Related Art
[0005] Conventional toilets are all arranged with the broader part of the seat (the part on which the user sits/places their buttocks) positioned at the rear, meaning nearest to the cistern/flushing tank, and the seat narrows towards the front. This is true for all toilets, whether close-coupled or not, and whether for the able-bodied or for the physically or mentally disabled. In toilets designed for the disabled, a handlebar may be provided to assist them in moving to and from the toilet, but this is normally positioned extending in a plane parallel to the front-rear axis of the toilet, either at the right- and/or left-hand side of the toilet.
[0006] For those with physical or mental disabilities, such as Muscular Dystrophy, Alzheimer's, spinal injuries or amputees, they generally have no choice but to use these conventional toilets, since there are no options available to them. They are, however, far from ideal for the disabled. A major problem with conventional toilet design is that when a wheelchair-bound disabled person wants to use the toilet, it is difficult for him/her to get off the wheelchair to make the transfer onto the toilet. The wheelchair user must turn 180° and maneuver onto the toilet seat.
[0007] Even for those who provide care for wheelchair users, it is hard for the caregiver to get the wheelchair user off of the wheelchair, carry them to the toilet, turn them around, and put them on the toilet seat. It is a cumbersome process, and a back-breaking job for the caregiver.
[0008] Thus, a toilet for the disabled solving the aforementioned problems is desired.
SUMMARY OF THE INVENTION
[0009] The toilet and support bars for the disabled includes a toilet bowl, a toilet seat, and a toilet bowl lid having a design configuration for reversed western toilet seating. In this manner, a user can access the toilet seat easily from a wheelchair by shifting forward from the wheelchair onto the toilet, and can easily move from the toilet to the wheelchair. A toilet tank or cistern coupled to the toilet bowl maintains a reservoir of water. Typically, a flush handle is disposed on either side of the tank or cistern, allowing the user to reach the flush handle with little effort. The tank or cistern sits atop a pedestal, which is anchored to the floor or other supporting structure. The toilet bowl communicates with the tank via the pedestal so that the flush water travels from the tank through the pedestal to the bowl, and finally through a drain to dispose of waste after use.
[0010] The toilet and support bars also have a support handlebar attached to the adjacent building structure (i.e., floor, walls). The support handlebar has a substantially inverted U-shaped member made from a rigid material. The legs of the inverted U-shaped member are attached to anchors, and extend vertically between the toilet tank and the toilet bowl. The top of the support handlebar provides a handle that extends horizontally between the legs across the width of the toilet. The handle may be covered with a resilient material for comfort. In use, the handle allows the user to maintain stability, balance, and coordination while using the toilet. The resilient material is formed of a substance resistant to microbes, bacteria, and other microorganisms, thus reducing the risk of spreading disease and infections to different users. In addition, the handle bar in accompanied with additional stabilizer bars, symmetrically disposed about the support handlebar for maintaining the handlebar in a fixed and rigid position.
[0011] These and other features of the present invention will become readily apparent upon further review of the following specification and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is a partially exploded perspective view of the toilet and support bar of a first embodiment.
[0013] FIG. 2 is a partially exploded perspective view of the toilet and support bar of a second embodiment.
[0014] FIG. 3 is an environmental perspective view of a third embodiment of a toilet and support bar for the disabled according to the present invention, showing a user in phantom demonstrating the manner of use.
[0015] FIG. 4 is a perspective view of a support bar and stabilizer of a toilet for the disabled according to the present invention.
[0016] FIG. 5A is a partially exploded perspective view of a first stabilizer of FIG. 4 .
[0017] FIG. 5B is a partially exploded perspective view of a second stabilizer of FIG. 4 .
[0018] FIG. 5C is another perspective view of the stabilizer of FIG. 4 .
[0019] Similar reference characters denote corresponding features consistently throughout the attached drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0020] Referring to FIGS. 1-3 , the toilet of the toilet and support bar includes a tank 12 having a lid. The tank 12 is a reservoir of water to be used for flushing or evacuating waste from the toilet. The tank 12 supports at least one flush handle 14 . The figures illustrate a preferred arrangement of two flush handles 14 (seen most clearly in FIG. 1 ) positioned on opposite sides of the tank 12 . The two flush handles 14 provide access for a user 2 having limited or restricted arm mobility. For example, in case the user 2 is lacking a left arm, a conventional toilet typically has a single handle positioned on the left side of the tank 12 , creating difficulty for the user 2 to flush with the usable right arm. Therefore, providing a flush handle 14 on each side of the tank 12 provides greater accessibility for the disabled person, providing the option of using either flush handle 14 . Alternatively, the flush handle may be a centrally mounted flush handle 14 ′ (shown in phantom), or the toilet 10 may have an automatic flushing system in lieu of the oppositely disposed flush handles 14 .
[0021] Referring to FIG. 1 , the toilet for the disabled, designated generally as 10 in the drawings, is illustrated. The tank 12 sits atop a pedestal 16 . Pedestal 16 provides a stable base and anchor for the toilet 10 . The pedestal 16 is secured to the supporting structure, such as a floor, in a conventional manner. The pedestal 16 includes the necessary conduits to allow water to flow from the tank 12 into the toilet bowl 20 , and to refill the tank 12 . As seen in FIG. 3 , the user 2 is able to slide forward from a wheelchair 4 onto the toilet seat 22 of the toilet bowl 20 . The body of the user 2 is not rotated, nor does the user 2 have to push the wheelchair 4 away in order to have room to the exercise the functions of the body. Also, the user 2 simply slides backward from the toilet seat 22 into the wheelchair once completed. Thus, the toilet for the disabled 10 gives freedom of mobility and easier access to accomplish toilet functions.
[0022] In FIG. 1 , a first embodiment of the toilet and support bar for the disabled is shown. A support bar 30 , which the user 2 grasps to assist in moving to and from the wheelchair, and the maintain stability while using the toilet 10 . The support bar 30 has a generally inverted U-shape configuration. As seen in FIG. 1 , positioned on the floor, one opposite sides of the pedestal 16 , a pair of anchors 36 having receiving orifices or sockets 38 . The anchors 36 are secured to the floor in any suitable and conventional manner in order to remain in a fixed and rigid position. The ends of the inverted U-shape of the support bar 30 have angled ends 32 that matingly engage with the receiving orifices or sockets 38 of the anchors 36 . The support bar 30 is preferably formed of a rigid material that provides a strong and stable handle for the user 2 to hold onto while sliding to and from the wheelchair 4 . The top crossbar of the inverted U-shape support bar 30 may be provided with a resilient material or padding 34 to provide a comfortable area for the user 2 to grasp. Although the use of the resilient material or padding 34 is preferable, the use of such material or padding 34 is optional.
[0023] As long as the surface is dimensioned and configured to be graspable, the support bar 30 , when the angled ends 32 are inserted into the receiving orifices or sockets 38 of the anchors 36 , becomes a safety structure to assist those that are disabled to independently use the toilet 10 . The legs of the support bar 30 raise the crossbar to a height that is above the tank 12 and provides sufficient clearance to raise and lower the toilet lid 24 , while being at a height convenient for a wheelchair-bound user to grasp for assistance in in pulling, pushing, or steadying maneuvers that may be required to move on or off the toilet seat 22 . In addition, the width of the support bar 30 is greater than that of the tank 12 , so that access to the flush handles 14 (or push-to-flush button 14 ′) is easily achieved.
[0024] The toilet bowl 20 has the toilet seat 22 , and a toilet lid 24 . Both the toilet seat 22 and the toilet lid 24 are each independently pivotally attached to the toilet bowl 20 by hinges. The toilet bowl 20 , the toilet seat 22 , and the toilet lid 24 are designed and configured in a reverse fashion from the standard western type toilets. This means that the wider portion of the toilet bowl 20 and the toilet seat 22 are forward and the narrower portions of the toilet bowl 20 and the toilet seat are closest to the pedestal 16 and tank 12 , which funnels waste matter towards a forward drain. The toilet bowl floor drain and S-trap or P-trap are also forward and reversed from their conventional configuration, rather than rearward, as in a conventional toilet bowl. In other words, the toilet bowl and its internal drain plumbing are reversed 180° from a conventional toilet bowl. This allows the user 2 to access the toilet for the disabled 10 without having to maneuver about a 180° turn from a wheelchair 4 .
[0025] It is noted that the resilient material or padding 34 is preferably formed from a bacterial and microbial resistant substance to reduce the possibility of contact with infectious or contagious disease carriers.
[0026] Referring to FIG. 2 , a second embodiment of a toilet and support bar for the disabled is illustrated. In this embodiment, the user 2 likewise will be able to slide from the wheelchair 4 onto the toilet seat 22 . The components of the toilet 10 are substantially identical in the two embodiments. The support bar 40 of the embodiment of FIG. 2 also has a generally inverted U-shape, although having straight legs, the top crossbar being covered with a resilient material or padding 44 . The resilient material or padding 44 provides a comfortable area for the user 2 to grasp onto the support bar 40 . Although the use of the resilient material or padding 44 is preferable, the material or padding 44 is optional. The surface is dimensioned and configured to be grasped by a user. It is noted that the resilient material or padding 44 is preferably formed from a bacterial and microbial resistant substance to reduce the possibility of contact with infectious or contagious disease carriers.
[0027] In order to attach the support bar 40 to the anchors 46 , the receiving orifices or sockets 48 , angled feet 42 are removably attached to the support bar 40 . However, if the support bar 44 is retrofitted to an existing toilet, then this second embodiment provides a solution. The support bar 44 is shown to terminate in straight ends. Each one of the straight ends of the support bar 44 engages an angled foot coupler 42 . The angled foot couplers 42 securely engage the orifices or sockets 48 , respectively, thereby anchoring the support bar 44 to the anchors 46 . The legs of the support bar 40 raise the crossbar 44 to a height that is above the tank 12 and provides sufficient clearance to raise and lower the toilet lid 24 , while being at a height convenient for a wheelchair-bound user to grasp for assistance in in pulling, pushing, or steadying maneuvers that may be required to move on or off the toilet seat 22 . In addition, the width of the support bar 40 is greater than that of the tank 12 , so that access to the flush handles 14 (or push-to-flush button 14 ′) is easily achieved.
[0028] Referring to FIG. 3 , the support bar 50 , as like support bar 30 of FIG. 1 , and support bar 40 of FIG. 2 , has a generally inverted U-shape configuration. As seen in FIG. 3 , the ends of the inverted U-shape of the support bar 50 have straight end legs 52 that matingly engage with the receiving orifices or sockets 58 of the anchors 56 . The top crossbar of the inverted U-shape support bar 50 may be provided with a resilient material or padding 54 to provide a comfortable area for the user 2 to grasp. Although the use of the resilient material or padding 54 is preferable, the use of such material or padding 54 is optional.
[0029] As long as the surface is dimensioned and configured to be graspable, the support bar 50 , when the ends of straight legs 52 are inserted into the receiving orifices or sockets 58 of the anchors 56 , becomes a safety structure to assist those that are disabled to independently use the toilet 10 . The legs of the support bar 50 raise the crossbar to a height that is above the tank 12 and provides sufficient clearance to raise and lower the toilet lid 24 , while being at a height convenient for a wheelchair-bound user to grasp for assistance in in pulling, pushing, or steadying maneuvers that may be required to move on or off the toilet seat 22 . In addition, the width of the support bar 50 is greater than that of the tank 12 , so that access to the flush handles 14 (or push-to-flush button 14 ′) is easily achieved.
[0030] FIG. 4 illustrates an optional accessory for the safety of the user 2 while using the toilet 10 . A plurality of stabilizers 60 are provided to maintain the rigidity of the support bar 50 (and likewise, 30 and 40 as well). Preferably, stabilizers 60 are used in pairs, and are symmetrically disposed about the support bar 50 . The stabilizers 60 have a substantially rigid bar 62 having two ends. The first end, like the ends of legs 52 of the support 50 , is received into orifices or sockets 68 of anchors 66 . The anchors 66 are substantially identical to anchors 56 ; however anchors 66 are mounted to a wall structure in any suitable or conventional manner in order to provide a fixed and rigid position. The second end of bar 62 has a clamp 64 thereon. Clamp 64 is designed and configured to receive a portion of the support bar 50 therein, and holds the support bar 50 in rigid fashion, so as to increase the stability of the support bar 50 about the toilet 10 .
[0031] FIGS. 5A and 5B illustrate two variations of the stabilizer 60 . In FIG. 5A , the stabilizer 60 is formed with a rigid bar 62 of a predetermined length. In FIG. 5B , the stabilizer 60 is formed with a telescoping feature, useable to capture any anomalies in a room structure. The telescoping feature has an inner rod 72 , and an outer sleeve 74 . The inner rod and outer sleeve function cooperatively to establish a predetermined length for maintaining the support bar 30 , 40 , 50 in a rigid and stable manner. The outer sleeve 74 is secured to the inner rod 72 when the predetermined length is established and thereby locked in place. Optionally, a biasing member 76 , shown as a spring, is located within the outer sleeve 74 . The biasing member 76 allows the stabilizer 60 to conform to a predetermined length, and yet give leeway or tolerance variations in stabilizing the support bar 30 , 40 , 50 .
[0032] The clamp 64 is also further illustrated in FIGS. 5A and 5B , clamp 64 is fixed to the end of rigid bar 62 or outer sleeve 74 via attachment 88 . Clamp 64 has a clamp end 80 coupled to attachment 88 . Clamp end 80 has a groove 84 , shown having a semi-circular form but it is understood that the groove 84 is semi-circumferential, so as to conform to the circumferential shape of support bar 30 , 40 , 50 whether round or parallelepiped. In addition, clamp end 84 has outwardly extending edges supporting a plurality of holes 86 . The clamp 64 also has an end cover 82 that is a mirror image of clamp end 80 . In that end cover 82 has a semi-circumferential groove 84 ′ and outwardly extending edges also supporting a plurality of holes 86 . When clamp end 80 and end cover 82 are coupled together around a portion of support bar 30 , 40 , 50 , a plurality of fasteners secured the clamp 64 via the aligned plurality of holes 86 .
[0033] FIG. 5C illustrates an alternate arrangement for the stabilizers 60 when used with the support bar 30 , 40 , 50 . The stabilizers 60 can also be attached so as to circumferentially capture a portion of the support bar 30 , 40 , 50 and the padding 34 , 44 , 54 , respectively. In this fashion, the support bar 30 , 40 , 50 and respective padding 34 , 44 , 54 are held so that the support bar 30 , 40 , 50 is stabilized to support the user 2 , as well as maintaining the padding 34 , 44 , 54 in a fixed position on the crossbar of support bar 30 , 40 , 50 . Thus preventing any slippage of the padding 34 , 44 , 54 about, along, or around the support bar 30 , 40 , 50 .
[0034] It is to be understood that the present invention is not limited to the embodiments described above, but encompasses any and all embodiments within the scope of the following claims. | The toilet and support bars for the disabled has a toilet bowl and toilet seat configured to face the toilet tank, thereby enabling disabled and physically debilitated persons to move forward to sit on the toilet seat. The toilet has a pedestal on which the tank is mounted, and an inverted U-shaped support bar having legs supported by the building structure, to provide stability for the disabled person to use the toilet. The support bar includes a crossbar handle above the level of the tank that a disabled person may grasp for assistance in moving forward onto the toilet seat and rearward off the toilet seat. The handle may have a resilient grip. The support bar may also include stabilizers for maintaining the support bar in a rigid and fixed position so that the user is assured to find the necessary support. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an electromagnetic clutch, and more specifically, to an electromagnetic clutch suitable for use in compressors.
2. Description of Related Art
An electromagnetic clutch is used as a power transmission for a compressor. For example, a known structure of a scroll-type compressor having an electromagnetic clutch is constructed as depicted in FIG. 17 . In FIG. 17, electromagnetic clutch 100 is assembled around cylindrical projected portion 121 a of front housing 121 of scroll-type compressor 120 . Electromagnetic clutch 100 includes rotor 101 , which is mounted upon projected portion 121 a via bearing 123 . Rotor 101 has inner cylindrical portion 101 a , outer cylindrical portion 101 b , and bottom portion 101 c connecting the ends of cylindrical portions 101 a and 101 b . Containing space 101 d is formed by portions 101 a , 101 b and 101 c . Electromagnet device 102 is enclosed within containing space 101 d of rotor 101 .
Armature 103 is provided facing one end of rotor 101 . Armature 103 is connected to stopper plate 105 via plate spring 104 . Stopper plate 105 is fixed to boss portion 106 via rivets 107 . Boss portion 106 is fixed to end portion 122 a of drive shaft 122 by threaded nut 108 .
In electromagnetic clutch 100 , a rotational torque is transmitted from an external power source (not shown) to rotor 101 via a V belt (not shown). When electromagnet device 102 is not energized, because armature 103 is urged by plate spring 104 away from rotor 101 , even if rotor 101 rotates, armature 103 does not rotate. Therefore, the rotational torque of rotor 101 is not transmitted to drive shaft 122 . When electromagnet device 102 is energized, armature 103 is attracted to the end of rotor 101 by the attracting force generated by electromagnet device 102 , in opposition to the urging force applied by plate spring 104 . Therefore, rotor 101 and armature 103 are integrated, and rotated together. The rotational torque of rotor 101 is transmitted to drive shaft 122 through stopper plate 105 and boss portion 106 , thereby driving compressor 120 .
FIG. 18 depicts an inclined plate-type compressor as another type of compressor. In FIG. 18, electromagnetic clutch 110 is assembled around of cylindrical projected portion 131 a of front housing 131 of inclined plate-type compressor 130 . Electromagnetic clutch 110 may have a structure similar to that depicted in FIG. 17 .
FIG. 19 depicts an example of the detailed structure of the electromagnet device depicted in FIG. 17 or 18 . In FIG. 19, electromagnet device 102 has ring member 113 forming therein a containing chamber 113 a . Ring-like plate 114 is provided on one end outer surface of ring member 113 for fixing ring member 113 on a front housing of a compressor. Coil bobbin 112 provided with coil element 111 is housed within containing chamber 113 a of ring member 113 . Coil bobbin 112 is enclosed within containing chamber 113 a by charging resin 115 , such as an epoxy resin into containing chamber 113 a . Thus, in a known technology, a method for molding a resin is employed for preventing water or foreign material from entering into an electromagnetic clutch, including for ensuring the properties of vibration resistance, heat radiation resistance, and water proofing.
FIG. 20 depicts another example of the detailed structure of the electromagnet device depicted in FIG. 17 or 18 . In FIG. 20, electromagnet device 102 ′ has bobbin 116 formed as two separate parts. After coil element 111 is enclosed within the two parts of bobbin 116 , bobbin 116 is housed within containing chamber 113 a of ring member 113 . Enclosed bobbin 116 then is fixed by caulked portions 117 formed at the partial inner edges of the opening portion of containing chamber 113 a.
In the known structure depicted in FIG. 19, however, because resin 115 for molding generally is a thermosetting resin, such as an epoxy resin, manufacturing electromagnet device 102 requires an expensive furnace for curing of the resin. Further, it takes a long period of time to cure the resin, thereby decreasing the productivity of manufacturing processes for such an electromagnetic clutch.
In the known structure depicted in FIG. 20, it is difficult to completely prevent water from entering into coil element 111 through a gap between the two parts of bobbin 116 . Therefore, there is a problem insulating coil element 111 .
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide an improved structure for an electromagnetic clutch that may increase the productivity of manufacturing processes by stopping use of a molding resin, and that may ensure the proper insulation of an electromagnet device.
To achieve the foregoing and other objects, an electromagnetic clutch according to the present invention is provided. The electromagnetic clutch includes an electromagnet device housed within a rotor. The electromagnet device comprises a ring member having a containing chamber, a coil member housed within the containing chamber of the ring member. The coil member comprises a bobbin and a coil element provided within the bobbin. The electromagnet device comprises a seal mechanism provided for enclosing the coil element within the containing chamber of the ring member in a sealed-off condition.
In the electromagnetic clutch, the seal mechanism comprises a seal plate to improve the seal formed between the bobbin and the ring member. The seal plate engages an engaging portion formed on an inner surface of the containing chamber of the ring member. The seal plate may comprise a side plate portion integral with the bobbin. Alternatively, the seal plate may comprise a resin plate provided separately from the bobbin.
The engaging portion may comprise a first groove formed on the inner surface of the containing chamber of the ring member. The first groove extends circumferentially about the ring member. Further, the engaging portion may comprise a stepped portion formed on the inner surface of the containing chamber of the ring member. The stepped portion extends circumferentially about the ring member.
The seal plate may have a projection extending circumferentially about the ring member. The projection engages the engaging portion formed on the inner surface of the containing chamber of the ring member. The projection may be brought into contact with the engaging portion. Further, the projection may be fitted into a second groove formed on the engaging portion. The second groove extends circumferentially about the ring member.
Further, the seal plate may have a V-shaped groove on its radial end surface, i.e., a radially outer end surface, or a radially inner end surface, or both. The seal plate may have a notch on its edge portion. The notch extends circumferentially about the seal plate.
The seal plate is fixed in the containing chamber of the ring member. For example, a part of the inner surface of the containing chamber of the ring member is crimped, and the seal plate is fixed in the containing chamber of the ring member by the crimping. Crimping may include the formation of a wave, bulge, crinkle, warp, or similar deformation in the ring member surface. A plurality of crimped portions may be disposed circumferentially about the ring member, or a crimped portion may extend continuously over the entire circumference of the ring member. The crimped portion, or portions, may be disposed on the inner surface of an outer cylindrical portion of the ring member, or an outer surface of an inner cylindrical portion of the ring member, or both.
An inner surface of of the containing chamber of the ring member positioned below the engaging portion, may be formed as a tapered surface causing a width of the containing chamber to gradually decrease.
The seal mechanism may comprise a protruded portion placed into contact with an inner surface of the containing chamber of the ring member. The protruded portion extends circumferentially about the ring member. The cross-sectional shape may be rectangular, semi-circular, triangular, or trapezoidal.
Such an electromagnetic clutch is used, for example, for a compressor. Any type of the compressor may be available.
In the electromagnetic clutch according to the present invention, the seal mechanism does not require a molding resin to achieve a desired quality of seal. The number of manufacturing steps may be decreased by stopping use of the molding resin, thereby reducing the cost for the manufacture of the electromagnetic clutch.
Further, because the seal mechanism may achieve a high quality of seal for the coil element without using a molding resin, the proper insulation of the coil element may be ensured readily and less expensively.
Further objects, features, and advantages of the present invention will be understood from the following detailed description of preferred embodiments of the present invention with reference to the accompanying figures.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the invention are now described with reference to the accompanying figures, which are given by way of example only, and are not intended to limit the present invention.
FIG. 1 is a perspective, cut-away view of an electromagnet device of an electromagnetic clutch according to a first embodiment of the present invention.
FIG. 2 is an enlarged, partial cross-sectional view of the electromagnet device depicted in FIG. 1 .
FIG. 3A is an exploded and enlarged, partial cross-sectional view and
FIG. 3B is an enlarged, partial cross-sectional view of a seal mechanism in the electromagnet device depicted in FIG. 2 according to a modification of the first embodiment.
FIG. 4A is an exploded and enlarged, partial cross-sectional view and
FIG. 4B is an enlarged, partial cross-sectional view of a seal mechanism in the electromagnet device depicted in FIG. 2 according to another modification of the first embodiment.
FIG. 5A is an exploded and enlarged, partial cross-sectional view and
FIG. 5B is an enlarged, partial cross-sectional view of a seal mechanism in the electromagnet device depicted in FIG. 2 according to a further modification of the first embodiment.
FIG. 6 is a partial, cross-sectional view of an electromagnet device of an electromagnetic clutch according to a second embodiment of the present invention.
FIG. 7A is an exploded and enlarged, partial cross-sectional view and
FIG. 7B is an enlarged, partial cross-sectional view of a seal mechanism in the electromagnet device depicted in FIG. 6 according to a modification of the second embodiment.
FIG. 8A is a partial, cross-sectional view of an electromagnet device of an electromagnetic clutch according to a third embodiment of the present invention.
FIGS. 8B-8D are enlarged, partial cross-sectional views of various modifications of the seal mechanism of the electromagnet device depicted in FIG. 8 A.
FIG. 9 is a partial, cross-sectional view of an electromagnet device of an electromagnetic clutch according to a fourth embodiment of the present invention.
FIG. 10 is an exploded cross-sectional view of the electromagnet device depicted in FIG. 9, showing the assembly of the electromagnet device.
FIG. 11 is a partial, cross-sectional view of an electromagnet device of an electromagnetic clutch according to a fifth embodiment of the present invention.
FIG. 12 is an exploded cross-sectional view of the electromagnet device depicted in FIG. 11, showing the assembly of the electromagnet device.
FIG. 13 is a partial, cross-sectional view of an electromagnet device of an electromagnetic clutch according to a sixth embodiment of the present invention.
FIG. 14 is an exploded cross-sectional view of the electromagnet device depicted in FIG. 13, showing the assembly of the electromagnet device.
FIG. 15 is a partial, cross-sectional view of an electromagnet device of an electromagnetic clutch according to a seventh embodiment of the present invention.
FIG. 16 is an exploded cross-sectional view of the electromagnet device depicted in FIG. 15, showing the assembly of the electromagnet device.
FIG. 17 is a cross-sectional view of a known scroll-type compressor including an electromagnetic clutch.
FIG. 18 is a cross-sectional view of a known inclined plate-type compressor including an electromagnetic clutch.
FIG. 19 is a partial, cross-sectional view of an example of an electromagnet device used in the electromagnetic clutch depicted in FIG. 17 or 18 .
FIG. 20 is a partial, cross-sectional view of another example of an electromagnet device used in the electromagnetic clutch depicted in FIG. 17 or 18 .
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
An electromagnetic clutch according to a first embodiment of the present invention is depicted in FIGS. 1 and 2. Referring to FIGS. 1 and 2, electromagnet device 10 provided in an electromagnetic clutch comprises ring member 5 , coil member 1 , and fastening member 6 . Ring member 5 has outer cylindrical portion 5 a , inner cylindrical portion 5 b , and bottom portion 5 c connecting the ends of outer and inner cylindrical portions 5 a and 5 b . Containing chamber 5 d is formed as a ring-like groove portion in ring member 5 by respective portions 5 a - 5 c . Coil member 1 is contained in containing chamber 5 d . Fastening member 6 is fixed to a front housing of a compressor, as depicted in FIG. 17 or 18 .
Coil member 1 comprises ring-like bobbin 2 , made from a resin, and coil element 3 provided in bobbin 2 . Bobbin 2 has a U-shaped cross section formed by side plate portion 2 a (a ceiling plate portion), the other side plate portion 2 c (a bottom plate portion), and connecting plate portion 2 b . Coil element 3 is contained within the U-shaped bobbin 2 .
Engaging portion 7 is formed on the upper end portion of each of the radial inner surface of outer cylindrical portion 5 a and the radial outer surface of inner cylindrical portion 5 b , at the opening portion of U-shaped ring member 5 . In this embodiment, engaging portion 7 is formed as a stepped portion extending circumferentially about ring member 5 . The radial outer and inner edges of side plate portion 2 a of bobbin 2 engage engaging portion 7 . A part of the upper end of each of the radial inner surface of outer cylindrical portion 5 a and the radial outer surface of inner cylindrical portion 5 b above engaging portion 7 is crimped on each of the radial outer and inner edges of side plate portion 2 a of bobbin 2 . A plurality of crimped portions 5 e are disposed circumferentially about ring member 5 on the respective surfaces of outer and inner cylindrical portions 5 a and 5 b.
By this crimping, coil member 1 may be securely fixed in ring member 5 at a condition in that bottom plate portion 2 c of bobbin 2 is brought into contact with the upper surface of bottom portion 5 c of ring member 5 . Referring to FIG. 2, the width of side plate portion 2 a of bobbin 2 is slightly larger than the distance between the radial inner surface of outer cylindrical portion 5 a and the radial outer surface of inner cylindrical portion 5 b , measured above engaging portion 7 . Therefore, side plate portion 2 a of bobbin 2 is press fitted into the portion between outer and inner cylindrical portions 5 a and 5 b , and both radial end surfaces of side plate portion 2 a are press contacted to the radial inner surface of outer cylindrical portion 5 a and the radial outer surface of inner cylindrical portion 5 b . From this configuration, coil member 1 is fixed in ring member 5 by the crimping. Thus, seal mechanism 11 is formed by side plate portion 2 a of bobbin 2 engages portions 7 and includes crimped portions 5 e . Because seal mechanism 11 seals coil member 1 with press fitted side plate portion 2 a of bobbin 2 , coil element 3 may be enclosed in containing chamber 5 d of ring member 5 and substantially completely sealed-off from the outside.
In the embodiment of FIG. 2, it is not necessary to use a molding resin for sealing coil element 3 , which has required an extended period of time for curing and several steps. Therefore, the time and the number of steps for manufacturing the electromagnetic clutch may be decreased, and the cost for the manufacture may be reduced. Further, the desired insulation for coil element 3 may be achieved readily and less expensively without using a molding resin.
FIGS. 3A and 3B depict seal mechanism 11 a according to a modification of the above-described first embodiment of the present invention. As depicted in FIG. 3A, in seal mechanism 11 a , a groove 7 a extending over the entire circumference of ring member 5 is formed on the upper surface of engaging portion 7 formed on radial outer cylindrical portion 5 a , or radial inner cylindrical portion 5 b , or both (hereinafter, these portions are referred to as a “cylindrical portion 24 ”). Side plate portion 2 a of bobbin 2 (hereinafter, referred to as a “seal plate 25 ”) has projection 25 a extending over the entire circumference of seal plate 25 , at a position corresponding to the position of groove 7 a . Seal plate 25 has a width larger than the distance between the surfaces of cylindrical portions 24 , measured above engaging portion 7 . Seal plate 25 is inserted and press fitted into the opening portion of ring member 5 , as shown by the arrow in FIG. 3 A.
As depicted in FIG. 3B, after seal plate 25 is press fitted and projection 25 a is inserted into groove 7 a formed on engaging portion 7 , an inner upper edge portion of cylindrical portion 24 is crimped to form crimped portion 5 e . Thus, seal plate 25 is fixed in ring member 5 , and coil element 3 is enclosed in containing chamber 5 d of ring member 5 in a completely sealed-off condition.
FIGS. 4A and 4B depict seal mechanism 11 b according to another modification of the first embodiment of the present invention described above. As depicted in FIG. 4A, in seal mechanism 11 b , engaging portion 7 formed as a stepped portion extends over the entire circumference of ring member 5 on radial outer cylindrical portion 5 a , or radial inner cylindrical portion 5 b , or both (hereinafter, these portions are referred to as a “cylindrical portion 26 ”). Side plate portion 2 a of bobbin 2 (hereinafter, referred to as a “seal plate 27 ”) has notch 27 a extending over the entire circumference of seal plate 27 , at a position corresponding to the shoulder position of engaging portion 7 . The portion positioned below engaging portion 7 on the inner surface of cylindrical portion 26 is formed as a tapered surface 26 a causing the width of containing portion 5 d to gradually decrease. The edge portion of seal plate 27 having notch 27 a engages engaging portion 7 including the upper portion of tapered inner surface 26 a of cylindrical portion 26 by inserting and press fitting seal plate 27 into the opening portion of ring member 5 , as shown by the arrow in FIG. 4 A.
As depicted in FIG. 4B, after seal plate 27 is press fitted and notch 27 a engages engaging portion 7 including the upper portion of tapered inner surface 26 a , an inner upper edge portion of cylindrical portion 26 is crimped to form crimped portion 5 e . Thus, seal plate 27 is fixed in ring member 5 , and coil element 3 is enclosed in containing chamber 5 d of ring member 5 in a completely sealed-off condition.
FIGS. 5A and 5B depict seal mechanism 11 c according to a further modification of the first embodiment of the present invention described above. As depicted in FIG. 5A, in seal mechanism lic, engaging portion 7 formed as a stepped portion extends over the entire circumference of ring member 5 on radial outer cylindrical portion 5 a , or radial inner cylindrical portion 5 b , or both (hereinafter, these portions are referred to as a “cylindrical portion 28 ”). Side plate portion 2 a of bobbin 2 (hereinafter, referred to as a “seal plate 31 ”) has projection 31 a extending over the entire circumference of seal plate 31 on its lower surface, at a position corresponding to the upper surface of engaging portion 7 . The edge portion of seal plate 31 engages engaging portion 7 as well as projection 31 a and is placed into contact with the upper surface of engaging portion 7 , by inserting and press fitting seal plate 31 into the opening portion of ring member 5 , as shown by the arrow in FIG. 5 A.
As depicted in FIG. 5B, after seal plate 31 is press fitted and projection 31 a is placed into contact with the upper surface of engaging portion 7 , an inner upper edge portion of cylindrical portion 28 is crimped to form crimped portion 5 e . Thus, seal plate 31 is fixed in ring member 5 , and coil element 3 is enclosed in containing chamber 5 d of ring member 5 in a completely sealed-off condition.
FIG. 6 depicts an electromagnet device of an electromagnetic clutch according to a second embodiment of the present invention. In FIG. 6, electromagnet device 20 provided in an electromagnetic clutch comprises coil member 1 , ring member 5 , and fastening member 6 . Coil member 1 comprises ring-like bobbin 2 , and coil element 3 provided in bobbin 2 . Bobbin 2 has a U-shaped cross-section formed by side plate portion 2 a (a ceiling plate portion), the other side plate portion 2 c (a bottom plate portion), and connecting plate portion 2 b . Coil element 3 is contained within the U-shaped bobbin 2 . Side plate portion 2 a has a width larger than the width of coil element 3 .
Ring member 5 has outer cylindrical portion 5 a , inner cylindrical portion 5 b , and bottom portion 5 c connecting the ends of outer and inner cylindrical portions 5 a and 5 b . Containing chamber 5 d is formed as a ring-like groove portion in ring member 5 by respective portions 5 a - 5 c . Grooves 8 provided as engaging portions are formed on the radial inner surface of outer cylindrical portion 5 a and the radial outer surface of inner cylindrical portion 5 b , at positions close to opening portion 5 f of U-shaped containing chamber 5 d of ring member 5 . The radial outer and inner edges of side plate portion 2 a of bobbin 2 are completely fitted into grooves 8 to form seal mechanism 33 .
When the edges of side plate portion 2 a of bobbin 2 are inserted into grooves 8 , the width of opening portion 5 f may be expanded by elastically deforming cylindrical portions 5 a and 5 b by pressing side plate portion 2 a into containing portion 5 d through opening portion 5 f . Alternatively, the width of side plate portion 2 a may be decreased by elastically deforming side plate portion 2 a by applying a pressing force from both ends of side plate portion 2 a , so that the deformation of side plate portion 2 a may be recovered by its elasticity after the edges of side plate portion 2 a are inserted into grooves 8 . Further, the width of opening portion 5 f may be expanded by using an appropriate jig (not shown).
Thus, seal mechanism 33 seals coil member 1 by engaging side plate portion 2 a with grooves 8 . Coil element 3 may be enclosed in containing chamber 5 d of ring member 5 and substantially completely sealed-off from the outside. In this embodiment, it is not necessary to use a molding resin for sealing coil element 3 , which has required an extended period of time for curing and several steps. Therefore, the time and the number of steps for manufacturing the electromagnetic clutch may be decreased, and the cost for the manufacture of the clutch may be reduced. Further, the desired insulation for coil element 3 may be achieved readily and less expensively without using a molding resin.
FIGS. 7A and 7B depict seal mechanism 33 a according to a modification of the above-described second embodiment of the present invention. As depicted in FIG. 7A, in seal mechanism 33 a , a groove 8 extends over the entire circumference of ring member 5 and is formed as an engaging portion on the surfaces of radial outer cylindrical portion 5 a , or radial inner cylindrical portion 5 b , or both (hereinafter, these portions are referred to as a “cylindrical portion 22 ”). Side plate portion 2 a of bobbin 2 (hereinafter, referred to as a “seal plate 23 ”) has V-shaped groove 23 a on its radial end surface. V-shaped groove 23 a extends over the entire circumference of seal plate 23 . Seal plate 23 has a width larger than the distance between the opposing bottom surfaces of grooves 8 . Seal plate 23 is inserted and press fitted into the opening portion of ring member 5 , as shown by the arrow in FIG. 7 A.
As depicted in FIG. 7B, when seal plate 23 is press fitted into groove 8 , pressure is applied to the edge of seal plate 23 having V-shaped groove 23 a . Consequently, the arms of V-shaped groove 23 a are spread outwardly in groove 8 to form portions 23 b deformed against the sides of groove 8 . Deformed portions 23 b are brought into complete contact with both side surfaces of groove 8 . Thus, in seal mechanism 33 a , seal plate 23 is fixed in ring member 5 in complete contact with groove 8 , and coil element 3 is enclosed in containing chamber 5 d of ring member 5 in a completely sealed-off condition.
FIG. 8A depicts an electromagnet device of an electromagnetic clutch according to a third embodiment of the present invention. In FIG. 8A, electromagnet device 30 provided in an electromagnetic clutch includes a ring member 5 , coil member 13 , and fastening member 6 . Coil member 13 comprises bobbin 12 formed from a resin having an elasticity, and coil element 3 provided in bobbin 12 . Bobbin 2 has a U-shaped cross-section formed by side plate portion 12 a (a ceiling plate portion), the other side plate portion 12 c (a bottom plate portion), and connecting plate portion 12 b . Coil element 3 is contained within the U-shaped bobbin 12 . Side plate portion 12 a extends in the radial direction beyond the radial end of coil element 3 . Connecting plate portion 12 b has protruded portion 12 d extending over the entire circumference of bobbin 12 at an upper position on the outer surface of connecting plate portion 12 b (a radially inner surface of bobbin 12 ). When bobbin 12 of coil member 13 is inserted into containing chamber 5 d of ring member 5 , the radial outer edge of side plate portion 12 a is fitted into groove 8 formed on the radial inner surface of outer cylindrical portion 5 a of ring member 5 to form seal mechanism 33 . The corner portion of bobbin 12 between side plate portion 12 a and connecting plate portion 12 b is fixed by crimped portion 14 formed by a part of the surface portion of the upper edge of inner cylindrical portion 5 b of ring member 5 to form seal mechanism 34 . Protruded portion 12 d is press fitted onto the surface of inner cylindrical portion 5 b at a position below seal mechanism 34 to further enhance the ability of this portion to seal containing chamber 5 d . At the same time, side plate portion 12 a is pressed in a radially outer direction by the reactive force due to the press fitting between protruded portion 12 d and the surface of inner cylindrical portion 5 b . Therefore, the radial outer edge of side plate portion 12 a is fitted into groove 8 more securely. Further, even when there occurs a vibration in the electromagnetic clutch, for example, by a vibration of an engine of a vehicle, coil member 13 may be maintained within ring member 5 at a proper position more securely by providing protruded portion 12 d.
FIGS. 8B-8D depict various modifications with respect to the cross-sectional shape of protruded portion 12 d . As depicted in FIG. 8B, the cross-sectional shape of protruded portion 12 d , may be semi-circular. As depicted in FIG. 8C, the cross-sectional shape of protruded portion 12 d 2 may be rectangular or trapezoidal. As depicted in FIG. 8D, the cross-sectional shape of protruded portion 12 d 3 may be triangular.
FIG. 9 depicts an electromagnet device of an electromagnetic clutch according to a fourth embodiment of the present invention. In FIG. 9, electromagnet device 40 provided in an electromagnetic clutch includes a ring member 5 ; coil member 15 ; ring-like resin plate 17 , which is provided as a seal plate separately from bobbin 16 ; and fastening member 6 . Coil member 15 comprises bobbin 16 and coil element 3 provided in bobbin 16 . Bobbin 16 has a U-shaped cross-section formed by side plate portion 16 a (a ceiling plate portion), the other side plate portion 16 c (a bottom plate portion), and connecting plate portion 16 b . Coil element 3 is contained within the U-shaped bobbin 16 . Resin plate 17 is provided on side plate portion 16 a of bobbin 16 . Resin plate 17 has a width greater than the width of containing chamber 5 d of ring member 5 . The radial edge portions of resin plate 17 are engaged to engaging portions 7 , and fixed by crimped portions 5 e . Side plate portion 16 a has a width less than the width of containing chamber 5 d.
As depicted in FIG. 10, after coil member 15 is inserted into containing chamber 5 d of ring member 5 through its opening portion 5 f , elastic resin plate 17 is press fitted into containing chamber 5 d through opening portion 5 f . Resin plate 17 is pressed onto engaging portions 7 . Then, a part of the radial inner edge portion of outer cylindrical portion 5 a and a part of the radial outer edge portion of inner cylindrical portion 5 b are crimped to form crimped portions 5 e . Thus, seal mechanism 11 is completed. Coil element 3 may be enclosed by seal mechanism 11 using resin plate 17 in a completely sealed-off condition.
In this embodiment, seal mechanisms similar to seal mechanisms 11 a - 11 c shown in FIGS. 3-5 may be employed by substituting the seal plates depicted in FIGS. 3-5 with resin plate 17 .
FIG. 11 depicts an electromagnet device of an electromagnetic clutch according to a fifth embodiment of the present invention. In FIG. 11, electromagnet device 50 provided in an electromagnetic clutch includes a ring member 5 , coil member 15 , ring-like resin plate 17 provided as a seal plate separately from bobbin 16 , and fastening member 6 . Coil member 15 comprises bobbin 16 , and coil element 3 provided in bobbin 16 . Coil element 3 is contained within the U-shaped bobbin 16 . In this embodiment, grooves 8 are defined on the radial inner surface of outer cylindrical portion 5 a of ring member 5 and on the radial outer surface of inner cylindrical portion 5 b of ring member 5 . Resin plate 17 has a width slightly greater than the distance between the bottom portions of grooves 8 facing each other. The radial edge portions of resin plate 17 are press fitted into grooves 8 . Thus, seal mechanism 33 is formed.
As depicted in FIG. 12, after coil member 15 is inserted into containing chamber 5 d of ring member 5 through its opening portion 5 f , resin plate 17 is press fitted into grooves 8 through opening portion 5 f . When resin plate 17 is inserted into containing chamber 5 d , cylindrical portions 5 a and 5 b may be elastically deformed, so that the width of opening portion 5 f is temporarily enlarged, or resin plate 17 may be elastically deformed, so that the width of resin plate 17 is temporarily decreased. After the edges of resin plate 17 are press fitted into corresponding grooves 8 , elastically deformed opening portion 5 f , or elastically deformed resin plate 17 , may recover its original shape. Thus, seal mechanism 33 is completed. Coil element 3 may be enclosed by seal mechanism 33 using resin plate 17 in a completely sealed-off condition.
In this embodiment, a seal mechanism similar to seal mechanisms 33 a shown in FIG. 7 may be employed by substituting the seal plate depicted in FIGS. 7 for resin plate 17 . Further, a jig (not shown) may be used for enlarging the width of opening portion 5 f prior to inserting resin plate 17 .
FIG. 13 depicts an electromagnet device 60 of an electromagnetic clutch according to a sixth embodiment of the present invention. In FIG. 13, electromagnet device 60 provided in an electromagnetic clutch includes a ring member 5 ; coil member 21 ; ring-like resin plate 17 , which is provided as a seal plate separately from bobbin 18 ; and fastening member 6 . Coil member 21 comprises bobbin 18 , and coil element 3 provided in bobbin 18 . Coil element 3 is contained within the U-shaped bobbin 18 . In this embodiment, groove 8 is defined on the radial inner surface of outer cylindrical portion 5 a of ring member 5 . The radially outer edge of resin plate 17 is fitted into groove 8 . Thus, seal mechanism 33 is formed. Side plate portion 18 a (a ceiling portion) of bobbin 18 radially extends shorter than coil element 3 in the radially outward direction. Protruded portion 18 d is provided on the outer surface of connecting portion 18 b of bobbin 18 , similarly in the embodiment depicted in FIG. 8 A. Protruded portion 18 d is pressed onto the radially outer surface of inner cylindrical portion 5 b of ring member 5 . The inner edge of resin plate 17 is fixed by crimped portion 14 . Thus, seal mechanism 34 is formed.
As depicted in FIG. 14, after coil member 21 is inserted into containing chamber 5 d of ring member 5 through its opening portion 5 f , resin plate 17 is inserted into containing chamber 5 d . The outer edge of resin plate 17 is fitted into groove 8 , and the inner edge of resin plate 17 is fixed by forming crimped portions 14 . Seal mechanisms 33 and 34 enclose coil member 21 in containing chamber 5 d of ring member 5 . In particular, in seal mechanism 34 , even if water enters through a gap between caulked portions 14 , the entry of water may be interrupted by the engagement mechanism of protruded portion 18 d pressed onto connecting portion 5 b of ring member 5 . Therefore, coil element 3 may be enclosed in a completely sealed-off condition.
Protruded portion 18 d may have another cross-sectional shape, such as a shape depicted in FIG. 8B, 8 C, or 8 D.
FIG. 15 depicts an electromagnet device 70 of an electromagnetic clutch according to a seventh embodiment of the present invention. In FIG. 15, electromagnet device 70 provided in an electromagnetic clutch includes a ring member 5 ; coil member 15 ; elastic ring-like resin cover 35 (a resin plate), which is provided as a seal plate separately from bobbin 16 ; and fastening member 6 . Coil member 15 comprises bobbin 16 , and coil element 3 provided in bobbin 16 . Coil element 3 is contained within the U-shaped bobbin 16 . In this embodiment, groove 8 is not formed on the surfaces of cylindrical portions 5 a and 5 b of ring member 5 . The surfaces of cylindrical portions 5 a and 5 b are tapered surfaces, so that the width of containing chamber 5 d increases gradually towards its opening portion 5 f . Side plate portion 16 a (a ceiling portion) of bobbin 16 extends in the radially outward direction less than coil element 3 . Resin cover 35 comprises upper plate portion 35 a , radial outer side portion 35 b , and radial inner side portion 35 c . Protruded portion 36 a extending over the entire circumference of ring cover is formed on the outer surface of radial outer side portion 35 b . Protruded portion 36 b extending over the entire circumference of ring cover is formed on the outer surface of radial inner side portion 35 c . Resin cover 35 is press fitted into containing chamber 5 d . The inner edge of resin cover 35 is fixed by crimped portion 14 . Thus, seal mechanism 37 and seal mechanism 38 are formed.
As depicted in FIG. 16, after coil member 15 is inserted into containing chamber 5 d of ring member 5 through its opening portion 5 f , elastic resin cover 35 is press fitted into containing chamber 5 d . Resin cover 35 then is fixed by a plurality of crimped portions 14 . Coil member 15 is sealed by the press fitting seal mechanisms between the radial inner surface of outer cylindrical portion 5 a and protruded portion 36 a and between the radial outer surface of inner cylindrical portion 5 b and protruded portion 36 b . In particular, even if water enters through a gap between crimped portions 14 , the entry of water may be interrupted by pressed protruded portions 36 a and 36 b . Therefore, coil element 3 may be enclosed in a completely sealed-off condition.
In this embodiment, crimped portion 14 may be provided at the outer edge side of resin cover 35 to fix resin cover 35 , or may be provided at both inner and outer edge side positions.
In the above-described embodiments, the number of crimped portions disposed circumferentially may be varied as appropriate to obtain the desired seal. Further, a crimped portion continuously extending over the entire circumference may be provided.
Although embodiments of the present invention have been described in detail herein, the scope of the invention is not limited thereto. It will be appreciated by those skilled in the art that various modifications may be made without departing from the scope of the invention. Accordingly, the embodiments disclosed herein are only exemplary. It is to be understood that the scope of the invention is not to be limited thereby, but is to be determined by the claims which follow. | An electromagnetic clutch includes an electromagnet device housed in a rotor. The electromagnet device has a ring member having a containing chamber, a coil member having a bobbin and a coil element and housed in the containing chamber of the ring member, and a seal mechanism provided for enclosing the coil element in the containing chamber at a sealed-off condition. A desired seal mechanism is formed without using a molding resin. The productivity of manufacturing processes for the electromagnetic clutch may be increased by stopping use of a molding resin. Moreover, the proper insulation of the electromagnet device may be ensured by the desired seal mechanism. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to ceramic sintered bodies of which main component is a sialon with high fracture toughness value and relates to the method of producing the same.
2. Description of the Related Art
Sialon type sintered bodies of which main component is Si-Al-O-N have excellent characteristics of such as small coefficient of thermal expansion, high heat resistance, high acid resistance, and high erosion resistance. The sialon type sintered bodies have been used as structural materials like Si 3 N 4 group sintered bodies, SiC group sintered bodies, and so forth.
The sialon type sintered bodies have excellent characteristics of such as small degradation of strength in high temperature range and high acid resistance in comparison with the Si 3 N 4 group sintered bodies. On the other hand, the sialon type sintered bodies have a disadvantage of lower reliability as a structural material than the Si 3 N 4 group sintered bodies. To improve the reliability of the sialon type sintered bodies, particles which are not solid solved in a sialon type sintered body, for example, particles of SiC, have been dispersed therein. An object of this attempt was to improve the fracture toughness value by a complex effect along with dispersed particles.
The sialon type sintered bodies in which different particles of such as SiC are dispersed and contained can be produced by adding different particles of such as SiC to powder satisfying a sialon composition (hereinafter named sialon powder). However, when the different particles of such as SiC are added to sialon powder, the sintering characteristic of the sialon powder is remarkably degraded. Thus, so far, when a pressure-free sintering method such as normal pressure sintering method was used, at most around 5 parts by weight of SiC or the like as dispersed particles could be added to 100 parts by weight of sialon powder. If more parts of SiC or the like were added, sintered bodies could not be constructed with high density by the pressure-free sintering method. Thus, so far, the effect of improving the fracture toughness value due to dispersed particles could not be satisfactorily accomplished by the conventional method.
On the other hand, by using a hot press method, it is possible to add around 50 parts by weight of SiC particles or the like to 100 parts by weight of sialon powder. However, the hot press method has the following disadvantages. In other words, when the hot press method is used, the shapes of products are limited to simple ones. In addition, the hot press method is not suitable for mass production due to a high production cost. Moreover, even if the hot press method is used, the fracture toughness value which can be obtained is not satisfactory. Furthermore, even if HIP method or the like is used, a remarkable effect cannot be achieved.
In comparison with the hot press method, the pressure-free sintering method has advantages of high degree of freedom with respect to shapes of sintered bodies, a low production cost, and suitability of mass production. Thus, it was strongly desired to provide sialon type sintered bodies with high fracture toughness value by using the pressure-free sintering method.
SUMMARY OF THE INVENTION
Therefore, an object of the present invention is to provide sialon type sintered bodies having high density and high fracture toughness value, the sintered bodies being able to be produced by pressure-free sintering process suitable for mass production,. In addition, a further object of the present invention is to provide a method of producing sialon type sintered bodies with high density and high fracture toughness value by pressure-free sintering method suitable for mass production.
A sialon sintered body according to the present invention comprises a primary phase substantially satisfying β and/or α prime sialon composition, and a dispersion phase dispersedly contained in the primary phase, the dispersion phase having 1 to 60 parts by weight of hafnium oxide and 5 to 30 parts by weight of silicon carbide for 100 parts by weight of the primary phase.
In addition, a sialon type sintered body according to the present invention is characterized in that a mixture of 1 to 60 parts by weight of hafnium oxide, 5 to 30 parts by weight of silicon carbide, and 100 parts by weight of silicon nitride containing 2.5% to 20% by weight of aluminum oxide is molded and sintered.
Moreover, a method of producing sialon type sintered bodies according to the present invention comprises the steps of mixing 1 to 60 parts by weight of hafnium oxide powder and 5 to 30 parts by weight of silicon carbide powder with 100 parts by weight of silicon nitride powder containing 2.5 to 20 by weight of aluminum oxide powder, molding the mixture powder into a desired shape, and sintering the resultant molded body in a pressure-free atmosphere.
The primary phase of the sintered bodies according to the present invention substantially satisfies the sialon composition. In other words, when 90% or more by volume of the primary phase are the sialon, the effects of the present invention can be obtained. The primary phase may contain a secondary phase of around several % by weight of glass phase or the like besides the sialon phase. Thus, the starting material for obtaining the primary phase may not always and strictly satisfy the sialon composition. However, with respect to the characteristics of the sialon, the starting material may not preferably contain the glass phase or the like.
The sialons can be categorized as β prime sialon composition and α prime sialon composition. The primary phase of the ceramic sintered bodies according to the present invention is the β prime sialon which can be substantially represented with Si 6-z Al z O z N 8-z (where 0<z≦4.2). However, the primary phase of the ceramic sintered bodies according to the present invention may be the α prime sialon.
The sialon type sintered bodies according to the present invention are particle dispersed type where the above mentioned primary phase contains hafnium oxide and silicon carbide which are dispersed therein. Hafnium oxide and silicon carbide are not solid soluble in crystalline particles of the sialon. Thus, hafnium oxide and silicon carbide are present independently in the structure of sintered bodies and construct a dispersion phase.
Hafnium oxide functions as a sintering assistant agent for the sialon type sintered bodies containing silicon carbide. In other words, in the sintering process, hafnium oxide becomes a liquid phase and promotes sintering in the liquid phase and thereby contributing to high density of the sintered bodies. After the sintering process, hafnium oxide is present independently in the structure of the sintered body as a dispersion phase. When a standard sintering assistant agent such as yttrium oxide is used, it is present in the sintered body as a glass phase or the like. The glass phase degrades the strength at high temperature of the sialon type sintered bodies. High strength at high temperature is one of characteristics of the sialon type sintered bodies. On the other hand, hafnium oxide does not degrade the high temperature characteristic. In addition, hafnium oxide contributes to improving the mechanical strength of sintered bodies and so forth as dispersed particles. The particles of hafnium oxide are present at the triple point of the sialon crystalline particles and at the interface between the sialon crystalline particles and the silicon carbide particles.
Even for the composition where silicon carbide is added, hafnium oxide readily contributes to high density sintering thereof. Thus, a large amount of silicon carbide can be added to the sialon type sintered bodies. In addition, the sintering assistant agent does not degrade the high temperature characteristic. An adding amount of hafnium oxide has to be in the range from 1 to 60 parts by weight to 100 parts by weight of the above mentioned primary phase. When the adding amount of hafnium oxide is less than 1 part by weight, the sialon sintered bodies cannot have satisfactory high density. In contrast, when the adding amount of hafnium oxide exceeds 60 parts by weight, it degrades the sintering characteristic and increases specific gravity. The adding amount of hafnium oxide is preferably in the range from 5 to 50 parts by weight. The adding amount of hafnium oxide is more preferably in the range from 10 to 30 parts by weight. The adding amount of hafnium oxide is preferably determined in accordance with the adding amount of silicon carbide because of the reasons described later.
Silicon carbide is present independently in a particle state in the structure of the sialon type sintered bodies. Thus, silicon carbide constructs a dispersion phase in the sialon type sintered bodies. The dispersion phase causes the fracture toughness value and mechanical strength to be improved. In other words, in the cooling process after the sintering process, a residual stress field is formed at the periphery of the silicon carbide particles. This residual stress field prevents further cracking. Thus, the fracture toughness value of the sialon type sintered bodies is improved. The mechanical strength is also improved. Silicon carbide which is present in the primary phase may be either in normal particle state or in whisker state. When silicon carbide is in the particle state, the average particle diameter is preferably 50 μm or less. On the other hand, when silicon carbide is in the whisker state, the shorter diameter and the aspect ratio thereof are preferably in the range from 0.2 μm to 30 μm and in the range from 1:30 to 1:20, respectively.
Thus, when hafnium oxide is added, it is possible to add a large amount of silicon carbide to the primary phase, namely, add 5 to 30 parts by weight of silicon carbide to 100 parts by weight of the primary phase. The fracture toughness of the sialon type sintered bodies can be remarkably improved when an addition amount of nitrogen oxide exceeds around 5 parts by weight to 100 parts by weight of the primary phase. However, when the adding amount of silicon carbide exceeds 30 parts by weight, even if hafnium oxide is also added, it becomes difficult to obtain the sintered bodies with satisfactory high density.
When a large amount of hafnium oxide is added in accordance with adding a large amount of silicon carbide, the particles of hafnium oxide grow and thereby occasionally forming a large particle aggregate with a diameter of around 150 μm. Since giant particles of hafnium oxide tend to be deformed at a high temperature, they may degrade the high temperature characteristic of the sintered bodies. The degradation of the high temperature characteristic by giant particles of hafnium oxide can be suppressed by using at least one of structures (a) and (b) as follows;
(a) by dispersing a part of silicon carbide particles in hafnium oxide particles and
(b) by coating the periphery of silicon carbide with hafnium oxide.
In the structure (a), a part of silicon carbide particles is dispersed in giant hafnium oxide particles which are formed by addition in large quantities. The silicon carbide particles prevent the giant hafnium oxide particles from being dislocated at a high temperature. In other words, the residual stress field formed at the periphery of the silicon carbide particles reinforces the hafnium oxide particles themselves. Thus, the high temperature characteristic of the sialon type sintered bodies can be prevented from being degraded. The disadvantage resulting from the giant hafnium oxide particles can be solved in the above mentioned manner. However, when the hafnium oxide particles become too large, the uniformity of the structure of the sintered bodies is degraded. Thus, the size of the hafnium oxide particles is preferably at most about 500 μm.
In the structure (b), the hafnium oxide particles are concentrated at the periphery of the silicon carbide particles in the sintering process so as to suppress the formation of an aggregate of the giant hafnium oxide particles. Thus, the high temperature characteristic of the sialon type sintered bodies can be prevented from being degraded. In addition, when the periphery of the silicon carbide particles is coated with hafnium oxide, the degradation of the sintering characteristic caused by silicon carbide can be further suppressed. Thus, it is possible to further add silicon carbide in large quantities. For example, it becomes possible to add around 40 parts by weight of silicon carbide to 100 parts by weight of the primary phase. The hafnium oxide present at the periphery of the silicon carbide particles may be in a film state or of an aggregate of particles. The thickness of the hafnium oxide is preferably 10 μm or less. When the thickness of the hafnium oxide exceeds 10 μm, the residual stress field formed at the periphery of the silicon carbide particles is absorbed by the hafnium oxide layer and thereby the adding effect of silicon carbide cannot be satisfactorily obtained.
The sialon type sintered bodies according to the present invention can be produced for example in the following manner.
First, around 2.5% to 20% by weight of Al 2 O 3 powder are added to Si 3 N 4 powder to prepare a starting material for the primary phase which almost satisfies the β prime sialon composition. Al 2 O 3 is solid solved in Si 3 N 4 and thereby a sialon is formed. When the adding amount of Al 2 O 3 exceeds 20% by weight, the strength of the sintered body degrades and thereby the amount of a secondary phase such as a grain boundary phase increases. In contrast, when the adding amount of Al 2 O 3 is less than 2.5% by weight, it becomes difficult to obtain the sintered body with high density. The most suitable adding amount of Al 2 O 3 is around 10% by weight.
The starting material for the primary phase which can be used is not limited to the above mentioned powder. Further, it is possible to use for example Si 3 N 4 - Al 2 O 3 - AlN type, Si 3 N 4 - AlN - SiO 2 type, and commercially available synthesized β prime sialon powder. However, when the Si 3 N 4 - Al 2 O 3 type is used, the effect of fineness of the crystalline particles and the like can be obtained. Thus, the mixed powder of the above mentioned two groups has a higher improvement effect of the characteristic than synthesized β prime sialon powder and mixed powder satisfying the normal β prime sialon composition. In addition, since the β prime sialon phase is formed only with Al 2 O 3 , water can be used as a dispersing medium.
Thereafter, predetermined amounts of HfO 2 and SiC are added to the starting material for the primary phase and then adequately mixed to prepare material powder of a sintered body.
The starting material of HfO 2 is preferably fine powder with an average particle diameter of 2 μm or less. The starting material of HfO 2 is more preferably fine powder with an average particle diameter of 1 μm or less. By using such fine powder, the uniformly dispersing characteristic of HfO 2 is improved. To further improve the dispersing characteristic of HfO 2 , as a starting material of HfO 2 , an organic compound which contains hafnium and which is liquid at normal temperature can be effectively used. In the liquid organic compound containing hafnium, hafnium is uniformly present in the material powder. Thus, the effect of hafnium oxide can be effectively and uniformly accomplished. In addition, deviation among production lots can be remarkably decreased. Moreover, since hafnium oxide can be uniformly dispersed, the adding amount thereof can be decreased. Thus, the formation of an aggregate of giant particles of hafnium oxide can be suppressed.
Examples of the organic compounds which contain hafnium and are liquid at normal temperature are alkoxide hafnium such as tetramethoxide hafnium, tetraethoxide hafnium, and tetrabutoxyde hafnium. In the sintering process, such organic compounds become hafnium oxide. When an organic compound which contains hafnium and which is liquid at normal temperature is used, the adding amount of the organic compound should be determined by converting into that of hafnium oxide.
When an organic compound which contains hafnium and which is liquid at normal temperature is used as a starting material of hafnium oxide, an advantage can be obtained not only in the production process of sialon type sintered bodies, but also in that of silicon nitride type sintered bodies. For example, when silicon nitride group sintered bodies are produced, hafnium oxide is used as a sintering assistant agent. In this case, an organic compound which contains hafnium and which is liquid at normal temperature can be used as a starting material of hafnium oxide. An example of a material mixture of silicon nitride group sintering bodies is described in the following. Oxides of rare earth elements such as yttrium oxide, and aluminum nitride as sintering assistant agents are added and mixed with silicon nitride powder. 1 to 15 parts by weight of the sintering assistant agents are preferably added to 100 parts by weight of silicon nitride. Thereafter, the organic compound which contains hafnium and which is liquid at normal temperature is added to the resultant mixture to prepare a material mixture.
The starting material of SiC may be in either a particle state or a fiber state such as whisker. When the particle state SiC is used, if the size of the particles is large, a defect takes place and thereby occasionally degrading the mechanical strength of the sintered body. Thus, it is preferable to use SiC with an average particle diameter of 50 μm or less and with a maximum particle diameter of 100 μm or less.
Thereafter, the above mentioned material powder is molded into a desirable shape by a known molding method such as press molding method. Thereafter, the molded body is sintered in an inertia gas atmosphere of pressure-free at temperatures ranging from 1700° C. to 1900° C. Thereby, a sialon type sintered body according to the present invention can be obtained.
In addition, the above mentioned structure (a) can be obtained by satisfying the following conditions. First, the ratio between hafnium oxide and silicon carbide is properly determined. Then, the temperature rising speed is adjusted. After the sintering process, the materials are heated at a temperatures lower than the sintering temperature. Thereby, the silicon carbide particles can be dispersed in the hafnium oxide particles. By adjusting the temperature rising speed, the particle growing speed of hafnium oxide can be controlled. In the heating process after the sintering process, while the silicon carbide particles are dispersed, the hafnium oxide particles can be grown. The ratio of adding amounts between hafnium oxide and silicon carbide (ratio by weight) is preferably for example in the range from 2:1 to 1:2.
The above mentioned structure (b) can be obtained by using for example silicon carbide having a particular amount of oxide layer on the surface thereof. With this silicon carbide, a hafnium oxide layer can be readily formed at the periphery of silicon carbide. In this case, the amount of oxygen on the surface is preferably detemined so that the amount of free SiO 2 is in the range from around 0.2% to around 2.0%. In addition, by properly setting the sintering temperature and the adding amount of hafnium oxide, the hafnium oxide layer can be readily formed at the periphery of the silicon carbide particles. The ratio of the adding amounts of hafnium oxide and silicon carbide (ratio by weight) is preferably for example in the range from 1:2 to 2:1.
The sialon type sintered bodies according to the present invention can be constructed with high density and have high fracture toughness value by pressure-free sintering method. However, it should be understood that the effects of the sialon type sintered bodies according to the present invention can be accomplished by using other sintering methods such as atmospheric pressure sintering method, hot press method, and hot static water pressure sintering method (HIP).
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a photo taken by a transmission type electron microscope, the photo showing a structure of a sialon type sintered body produced in accordance with an embodiment of the present invention.
DESCRIPTION OF PREFERRED EMBODIMENTS
With reference to embodiments, the present invention will be described in more detail.
Embodiment 1
First, 2.5% by weight of Al 2 O 3 powder with an average particle diameter of 0.9 μm were added and mixed with Si 3 N 4 powder with an average particle diameter of 0.7 μm so as to prepare a starting material for a primary phase. Thereafter, 5 parts by weight of HfO 2 powder with an average particle diameter of 0.9 μm and 5 parts by weight of SiC powder with an average particle diameter of 0.5 μm were added to 100 parts by weight of the above material for the primary phase. These compounds were mixed by a ball mill with a dispersing medium of ethanol for 48 hours. Thereafter, the mixture was dried so as to prepare sintering material powder.
Thereafter, around 5 parts by weight of a binder were added to the 100 parts by weight of the above starting powder for a sintered body and then a plate shape molded body with dimensions of 50 mm long×50 mm wide×5 mm thick was produced at a molding pressure of 1000 kg/cm 2 . After the plate shape molded body was degreased in a nitrogen gas atmosphere, the resultant molded body was sintered in a nitrogen gas atmosphere of the normal pressure at a temperature of 1850° C. for 2 hours. Thereby, a sintered body with the primary phase of a sialon was obtained.
In addition, in comparison with the sintered body according to the present invention, a sialon type sintered body (comparison 1) was produced in the same conditions as the embodiment 1 except that the adding amount of HfO 2 was 0.5 parts by weight (out of the scope of the present invention).
The sintered body density (relative density) and the fracture toughness value K IC for each sintered body thus produced were measured by micro indentation method. As the results, the sintered density of the sintered body according to the comparison 1 was as low as 88.0% and the fracture toughness value K IC thereof was also as low as 4.0 MPa m 1/2 . In contrast, the sintered density of the sintered body according to the embodiment 1 was as high as 97.2% and the fracture toughness value K IC thereof was as high as 4.7 MPa m 1/2 .
Thereafter, the sectional structure of the sintered body according to the embodiment 1 was observed by using a transmission type electron microscope. A photo taken by the transmission type electron microscope is shown in FIG. 1. In the figure, "H" represents HfO 2 . Other than SiC are sialon crystalline particles. As shown in FIG. 1, HfO 2 (H) is present at the triple point by the sialon crystalline particles and at the interface between the sialon crystalline particles and the SiC particles.
Embodiments 2 to 12
Si 3 N 4 power with an average particle diameter of 0.7 μm and Al 2 O 3 powder with an average particle diameter of 0.9 μm were used with composition ratios shown in Table 1 so as to prepare starting materials for the primary phase. Thereafter, HfO 2 powder with an average particle diameter of 0.9 μm and SiC powder with an average particle diameter of 0.5 μm or SiC whisker with an aspect ratio of 1:20 were used to prepare material powder with composition ratios (parts by weight) shown in Table 1. Each material powder was used to produce a sialon type sintered body in the same condition as the embodiment 1.
In the comparison 2, material powder was produced without HfO 2 and then it was sintered by the hot press sintering method in a nitrogen gas atmosphere at a temperature of 1850° C. for 1 hour.
The sintered body density and the fracture toughness value K IC of each sialon type sintered body were measured in the same manner as the embodiment 1. The results are also shown in Table 1.
TABLE 1__________________________________________________________________________ Power for primary phase Added compound (parts by weight to (mother phase) (% by weight) 100 parts by weight of mother phase) Sintered Si.sub.3 N.sub.4 Al.sub.2 O.sub.3 HfO.sub.2 SiC (particles) SiC (Whisker) density (%) K.sub.IC__________________________________________________________________________Embodiments1 97.5 2.5 5 5 0 97.2 4.72 95 5 10 10 0 98.9 4.93 90 10 5 5 0 99.0 4.84 90 10 20 15 0 98.7 5.95 90 10 60 30 0 96.7 6.86 85 15 20 25 0 97.4 6.27 80 20 40 30 0 98.0 6.78 85 15 10 10 0 98.2 5.99 97.5 2.5 5 0 5 97.2 4.910 90 10 40 0 25 96.2 7.111 90 10 15 0 10 98.1 5.312 80 20 60 0 30 98.0 6.9Comparison 1 95 5 0.5 5 0 88.0 4.0Comparison 2 95 5 0 10 0 95.0 4.3__________________________________________________________________________ *Only in the comparison 2, the hot press method was used.
As shown in Table 1, when both HfO 2 and SiC were used, the sintered body according to each embodiment had high density. In addition, when a large amount of SiC was added, the sintered body had high density. Accordingly, the fracture toughness value K IC was clearly improved.
Further, as a comparison 3, the sialon type sintered body was produced in the same manner as the embodiments except that Y 2 O 3 powder was used instead of HfO 2 powder. This sialon type sintered body has the almost same sintered body density and the fracture toughness value K IC as those of the embodiments. However, the high temperature strength (at 1300° C.) was remarkably reduced to be 400 MPa. The high temperature strength of the sialon type sintered body of the each embodiment was about 700 MPa.
Embodiment 13
First, 10% by weight of Al 2 O 3 powder were added and mixed with Si 3 N 4 powder with an average particle diameter of 0.7 μm. Thereafter, 100 parts by weight of a solution of Hf (OC 3 H 7 )4 which were equivalent to those of HfO 2 (the amount of a solution of Hf (OC 3 H 7 )4 means 10 parts by weight of HfO 2 when Hf (OC 3 H 7 )4 is converted to HfO 2 ) and 15 parts by weight of SiC powder with an average particle diameter of 0.5 μm were added to 100 parts by weight of the above mentioned mixture. They were mixed with a dispersing medium of ethanol for 24 hours. Thereafter, the resultant mixture was dried thereby to produce material powder.
After around 5 parts by weight of a binder were added to the 100 parts by weight of the above mentioned material powder, a plate shape molded body with dimensions of 50 mm long×50 mm wide×5 mm thick was produced at a molding pressure of 1 ton/cm 2 . Thereafter, the molded body was degreased in a nitrogen gas atmosphere and then sintered in a nitrogen gas atmosphere of normal pressure at a temperature of 1850° C. for 2 hours. Thereby, a sintered body with the primary phase of a sialon was obtained. Thereafter, in the same conditions, 100 pieces of the sintered bodies were produced.
In addition, as a reference example, 100 pieces of sialon type sintered bodies were produced in the same conditions as the embodiment 13 except that hafnium oxide powder was used instead of alkoxide hafnium.
The relative density, the high temperature strength by a three-point bending test, and the fracture toughness value K IC were measured for each sintered body produced in the above manner. The results are shown Table 2.
TABLE 2______________________________________ Embodiment 13 Reference 1______________________________________Average sintered body density 98.5 98.3(%)Maximum and minimum values of 3.29 to 3.34 3.25 to 3.33sintered body densityAverage strength of high temper- 680 660ature three-point bending test at1300° C. (MPa)Maximum and minimum values of 660 to 720 600 to 700high temperature strengthAverage fracture toughness 5.7 5.6value K.sub.IC (MPa m.sup.1/2)Maximum and minimum values 5.3 to 5.9 5.0 to 5.9of fracture toughness______________________________________
As shown in Table 2, when hafnium alkoxide as a starting material of hafnium oxide is used, each characteristic can be further improved with small deviation thereof.
Embodiment 14
First, Si 3 N 4 powder with an average particle diameter of 0.7 μm, Al 2 O 3 powder with an average particle diameter of 0.9 μm, and AlN powder with an average particle diameter of 0.6 μm were prepared. These compounds were mixed so as to satisfy the composition of Si 5 Al 1 O 1 N 7 (z=1) and powder for the primary phase was prepared. Thereafter, 10 parts by weight of HfO 2 powder with an average particle diameter of 1.6 μm and 10 parts by weight of SiC whisker with an average shorter diameter of 2 μm and with an aspect ratio of 1:20 (with a surface oxide concentration of 0.8%) were added to 100 parts by weight of the above mentioned powder for the primary phase. These compounds were mixed by a ball mill with a dispersing medium of ethanol for 48 hours. Thereafter, the mixture was dried so as to prepare material powder for sintered body.
Thereafter, around 5 parts by weight of a binder were added to 100 parts by weight of the above mentioned material powder for sintered body. Thereafter, a plate shape molded body with dimensions of 50 mm long×50 mm wide×5 mm thick was produced at a molding pressure of 1000 kg/cm 2 . Thereafter, the molded body was degreased in a nitrogen gas atmosphere and then sintered in a nitrogen gas atmosphere of 5 kg/cm 2 at a temperature of 1850° C. for 4 hours. Thereby, a sintered body with the primary phase of a sialon was produced.
The structure of the sialon type sintered body obtained in the above manner was observed by the transmission type electron microscope. As the result, it was found that a HfO 2 layer with a thickness of around 0.01 μm was formed at the periphery of SiC whisker which was present in the primary phase (sialon phase). In addition, although the HfO 2 particles were dispersed to other than the periphery of SiC whisker, the diameter thereof was as small as around 3 μm.
In addition, the sintered body density, the three-point bending strength at 1300° C., and the fracture toughness value K IC by the micro indentation method were measured for the above mentioned sintered body. As the results, good values where the relative density was 98.3%, the three-point bending strength at 1300° C. was 82 kgf/mm 2 , and the fracture toughness value K IC was 6.9 MPa m 1/2 were obtained.
Reference 2
A sintered body with the primary phase of a sialon was produced in the same conditions as the embodiment 1 except that 70 parts by weight of HfO 2 powder and 40 parts by weight of SiC whisker were added to the powder for the primary phase produced in the embodiment 14, the HfO 2 powder and the SiC whisker being the same as those used in the embodiment 14.
Thereafter, the structure of the sialon type sintered body being produced in the above manner was observed by using a scanning type electron microscope. As the results, although a HfO 2 layer was formed at the periphery of SiC whisker, the thickness thereof was as much as 12.3 μm. In addition, the relative density of the above mentioned sintered body, the three-point bending strength at 1300° C. thereof, and the fracture toughness value K IC thereof were 85.1%, 41 kgf mm 2 , and 4.2 MPa m 1/2 , respectively.
Embodiment 15
10 parts by weight of HfO 2 powder with an average particle diameter of 1.6 μm and 15 parts by weight of SiC powder with an average particle diameter of 0.5 μm were added to 100 parts by weight of the powder for the primary phase produced in the embodiment 14. Thereafter, these compounds were mixed with a dispersing medium of ethanol by a ball mill for 48 hours. Thereafter, the mixture was dried to prepare material powder for sintered body.
Thereafter, around 5 parts by weight of a binder were added to 100 parts by weight of the above mentioned material powder for sintered body and then a plate shape molded body with dimensions of 50 mm long×50 mm wide×5 mm thick was produced at a molding pressure of around 1000 kg/cm 2 . Thereafter, the molded body was degreased in a nitrogen gas atmosphere. Thereafter, the resultant molded body was heated in a nitrogen gas atmosphere of 5 kg/cm 2 at a temperature rising speed of 15° C./min until the temperature became 1850° C., held at this temperature for 2 hours, and then heated at a temperature of 1825° C. for 20 hours. Thereby, a sintered body with the primary phase of a sialon was produced.
The structure of the sialon type sintered body produced in the above mentioned manner was observed by using the transmission type electron microscope. As the results, it was found that HfO 2 particles were precipitated in such a manner that they were mixed into crystalline particles of the sialon. Although the diameter of the HfO 2 particles was as large as around 50 μm, SiC particles were distributed therein. In addition, at the grain boundary of the sialon crystalline particles, the SiC particles were distributed. The average diameter of the SiC particles was around 1.5 μm.
In addition, the relative density of the above mentioned sintered body, the three-point bending strength at 1300° C. thereof, and the fracture toughness value K IC thereof were 98.3%, 79 kgf/mm 2 , and 6.7 MPa m 1/2 , respectively.
Embodiment 16
First, 10% by weight of Al 2 O 3 powder were added and mixed with Si 3 N 4 powder with an average particle diameter of 0.7 μm. Thereafter, 4 parts by weight of a solution of Hf (OC 3 H 7 )4 were added to 100 parts by weight of the above mentioned mixture and then mixed with a dispersing medium of ethanol for 48 hours. Thereafter, the resultant mixture was dried and then material mixture powder was obtained.
Thereafter, around 5 parts by weight of a binder were added to 100 parts by weight of the above mentioned material mixture powder so that the resultant mixture was granulated. Thereafter, a plate shape molded body with dimensions of 50 mm long×50 mm wide×5 mm thick was produced at a molding pressure of 1 ton/cm 2 . Thereafter, the resultant molded body was degreased in a nitrogen gas atmosphere and then sintered in a nitrogen gas atmosphere of 5 kg/cm 2 at a temperature of 1850° C. for 2 hours. Thereby, a sintered body with the primary phase of a sialon was produced. 100 pieces of the sintered bodies were produced in the same conditions.
In addition, as the comparison 4, 100 pieces of sialon type sintered bodies were produced in the same conditions as the embodiment 16 except that hafnium oxide powder was used instead of alkoxide hafnium.
The relative density of each sialon type sintered body produced in the above mentioned manner, the high temperature strength by the three-point bending strength test thereof, and the fracture toughness value K IC thereof were measured. The results are shown in Table 3.
TABLE 3______________________________________ Embodiment 16 Comparison 4______________________________________Average sintered body density 99.8 99.3(%)Maximum and minimum values of 3.23 to 3.239 3.205 to 3.235sintered body densityAverage strength of high temper- 880 810ature three-point bending test at1300° C. (MPa)Maximum and minimum values of 850 to 900 720 to 890high temperature strengthAverage rupture toughness 4.2 4.2value K.sub.IC (MPa m.sup.1/2)Maximum and minimum values 4.0 to 4.6 3.9 to 4.7of rupture toughness______________________________________
As shown in Table 3, when alkoxide hafnium was used as a starting material of hafnium oxide, each characteristic could be improved with very small deviation thereof.
Embodiment 17
First, 5 parts by weight of Y 2 O 3 powder, 5 parts by weight of AlN powder, and 2 parts by weight of Hf (OC 3 H 7 )4 were added and mixed with 100 parts by weight of Si 3 N 4 with an average particle diameter of 0.7 μm. These compounds were mixed with a dispersing medium of ethanol for 24 hours and then dried to prepare material mixture powder.
Thereafter, 5 parts by weight of a binder were added to 100 parts by weight of the above mentioned material mixture powder so that the resultant mixture was granulated. Thereafter, a plate shape molded body with dimensions of 50 mm long×50 mm wide×5 mm thick was produced at a molding pressure of 1 ton/cm 2 . Thereafter, the resultant molded body was degreased in a nitrogen gas atmosphere and then sintered in a nitrogen gas atmosphere of 5kg/cm 2 at a temperature of 1850° C. for 2 hours. Thereby, a ceramic sintered body with the primary phase of silicon nitride was produced. 100 pieces of the sintered bodies were produced in the same conditions.
In addition, as the comparison 5, 100 pieces of silicon nitride sintered bodies were produced in the same conditions as the embodiment 17 except that hafnium oxide powder was used instead of alkoxide hafnium.
The sintered body density of each silicon nitride group sintered body produced in the above manner, the high temperature strength by the three-point bending strength test thereof, and the fracture toughness value K IC thereof were measured. The results are shown in Table 4.
TABLE 4______________________________________ Embodiment 17 Comparison 5______________________________________Average sintered density (%) 99.9 99.7Maximum and minimum values of 3.278 to 3.282 3.260 to 3.281sintered densityAverage strength of high temper- 830 790ature three-point bending test at1300° C. (MPa)Maximum and minimum values of 810 to 850 690 to 820high temperature strengthAverage rupture toughness 7.3 7.3value K.sub.IC (MPa m.sup.1/2)Maximum and minimum values 7.0 to 7.6 6.9 to 7.7of rupture toughness______________________________________
As was described in above embodiments, in the sintered bodies with the primary phase of sialon according to the present invention, by adding hafnium oxide, even if an adding amount of silicon carbide is increased, the sintered bodies can be constructed with high density by pressure-free sintering. Moreover, in comparison with a sintered body constructed with high density by hot press process without adding hafnium oxide, the sintered bodies according to the present invention have high fracture toughness value. Thereby, sialon type sintered bodies with high fracture toughness value and high reliability can be produced by pressure-free sintering process suitable for mass production. | Sintered bodies with the primary phase of β and/or α prime sialon. In the sialon phase which is the primary phase, hafnium oxide and silicon carbide are dispersedly contained as dispersion phases. 1 to 60 parts by weight of hafnium oxide are contained in 100 parts by weight of the primary phase. 5 to 30 parts by weight of silicon carbide are contained in 100 parts by weight of the primary phase. Hafnium oxide suppresses decrease of sintering characteristic which is caused by silicon carbide. Thus, a large amount of silicon carbide can be added, thereby improving the fracture toughness value. | 2 |
This is a division of application Ser. No. 08/214,804 filed Mar. 15, 1994, now U.S. Pat. No. 5,451,414.
BACKGROUND AND SUMMARY OF THE INVENTION
The present invention relates to mineral micronutrient supplements for food products, and to systems and processes for their production. More particularly, the present invention relates to food products incorporating basic copper chloride as a mineral supplement, and to systems and processes for producing such supplements.
Mineral sources, when used at levels consistent with good feeding practices, are important dietary supplements. The need for copper, for example, in poultry and livestock is critical. W. Mertz (Ed.) Trace Elements in Human and Animal Nutrition. Vol I. pp. 301-364 Academic Press, New York (1987). Copper deficiency is a major problem in cattle. Copper tends to form insoluble complexes with molybdenum and sulfide in a cow's rumen, where pH is about 6.0. These complexes remain insoluble through subsequent digestion, even though the pH drops to about 2.5. Thus, there is a need to provide copper supplements in animal feeds where the copper is present in a form in which insoluble complexes cannot form.
A number of copper sources have been approved for use in animal feeds, including, for example, copper sulfate and copper oxide. But current copper sources suffer from a variety of problems. Copper oxide has been shown to have low bioavailability. Copper sulfate, which has adequate bioavailability, often causes instability of desirable organic constituents in a feed mix. Labile nutrients such as vitamins and antibiotics are typically highly susceptible to oxidation. In fact, the dominant destabilizing effect on vitamins in feed mixes is redox reactions by trace minerals. Because copper sulfate has a particularly high water solubility, and because some moisture is inevitably present in feed mixes, copper sulfate tends to create a higher redox potential in the feed mix and release copper ions to catalyze oxidation of vitamins, antibiotics, or other nutrients.
Furthermore, in manufacturing copper-based micronutrient additives for feed products, controlling the particle size of the additive may present problems. Small particle size is generally desirable because small particles can be more easily blended with feed to create a finished feed mix having a relatively uniform distribution of micronutrient additive. However, if particles are too small, a dusting problem is created at the point of blending the additive with the feed, adding manufacturing costs.
With the presence of small particles it is also exceedingly difficult (in some cases nearly impossible) to rinse away the undesirable background constituents from the mother liquor during manufacture of the additive. For example, in manufacturing copper sulfate, the crystallization process is generally operated to produce relatively large crystals to allow free sulfuric acid and other impurities from the mother liquor to be rinsed off more completely. To produce smaller particles for blending into a feed mix, either the copper sulfate crystallization has to be run at suboptimal conditions, or the product has to be ground after formation. This, too, adds manufacturing costs.
The presence of background salts can be exceedingly problematic. For example, ammonium-based background salts may contribute to poor physical characteristics of the micronutrient additive, complicating handling and blending operations. Such salts are typically strongly hygroscopic, and tend to agglomerate when exposed to humid conditions, resulting in the formation of a hydrated, pasty product which is difficult to dewater and to break into a useful powdery material. Moreover, such salts can be highly astringent, which may lead to a reduction in feed intake.
The presence of contaminants in the copper source itself can also be exceedingly problematic. For example, low-cost copper sources often contain contaminants such as arsenic, which complicate separation operations. Furthermore, such a difficult separation operation may significantly increase production costs.
Thus, there is a need to provide a copper-based micronutrient additive which is compatible with vitamins and other nutrients or antibiotics likely to be present in the feed mix, which exhibits excellent bioavailability, and which also has an appropriate particle size.
According to the present invention, a food product is provided. The food product comprising a nutrient blend and, as a source of bioavailable copper, a compound of the formula Cu(OH) x Cl.sub.(2-x). Compounds of this general formula have been referred to as "basic copper chloride." Advantageously, basic copper chloride has low redox potential due to low water solubility, and has high bioavailability.
In accordance with a further aspect of the present invention, a process is provided for producing basic copper chloride from a copper source and a source of chloride ions. The process comprises the steps of retaining a predetermined amount of pre-formed basic copper chloride in a reactor and reacting the copper source and the source of chloride ions in the reactor in the presence of the pre-formed basic copper chloride. In one preferred embodiment, a soluble chloride salt of copper provides both the copper source and the source of chloride ions.
Advantageously, basic copper chloride produced by this process possesses good blending and handling characteristics. The basic copper chloride is produced as a free-flowing powder which can readily be blended into feed mixes for good micronutrient distribution, and which can also be readily blended into fertilizer mixtures. However, the particle size of the basic copper chloride produced by the present process is actually larger than that obtained by the use of previous processes. Background salts can be more easily removed from these larger particles.
In accordance with yet a further aspect of the present invention, a process is provided in which spent etchant streams (e.g., from an operation for manufacturing printed circuit boards) are regenerated to yield basic copper chloride and water-white, reusable ammonium chloride liquor which can be converted into etchant by additional processing. The process comprises the steps of reacting a spent alkaline etchant stream with an acidifying agent at a pH of about 1.8 to about 8.0 to form a product mixture including a copper-containing slurry and an ammonium chloride liquor containing dissolved copper, separating the copper-containing slurry from the ammonium chloride liquor, and contacting the ammonium chloride liquor with a metal scavenger to remove dissolved copper from the ammonium chloride liquor. In one preferred aspect of the process, the acidifying agent is a spent cupric etchant stream.
Advantageously, this process in its preferred embodiments makes use of waste material--preferably a spent cupric etchant stream and a spent alkaline etchant stream--to form a copper-containing slurry from which, for example, basic copper chloride can be recovered. Further advantageously, this process, through the controlled growth of particles, overcomes previous difficulties in removing ammonium chloride, a background salt, from the copper-containing slurry, enabling basic copper chloride to be recovered from the slurry for use as a micronutrient supplement or as a copper source in other products, including fertilizers.
In accordance with yet a further aspect of the present invention, a fertilizer product is provided which comprises a fertilizer blend and a compound of the formula Cu(OH) x Cl.sub.(2-x), wherein x is greater than 0 and less than or equal to 2.0.
Additional objects, features, and advantages of the invention will become apparent to those skilled in the art upon consideration of the following detailed description of preferred embodiments exemplifying the best mode of carrying out the invention as presently perceived by the inventor.
BRIEF DESCRIPTION OF THE DRAWINGS
The detailed description particularly refers to the accompanying FIG. 1 showing a flowsheet of a process and system for producing basic copper chloride from spent etchant solution.
DETAILED DESCRIPTION OF THE INVENTION
The present invention relates to food products and other products, including fertilizers, which make use of basic copper chloride as a copper source. The invention also relates to systems and processes useful for producing basic copper chloride regardless of whether the basic copper chloride is ultimately used as a micronutrient supplement, as an additive to fertilizer, or as an additive for other products. The systems and processes preferably make use of spent etchant streams as feedstocks, thus disposing of such streams in an environmentally sound manner while at the same time producing a useful product.
As used herein, "food product" encompasses both agricultural products (conventionally referred to as "feed") as well as food products for human consumption. "Nutrient blend" as used herein encompasses customary sources of nutrition in food products, including but not limited to carbohydrates, proteins, fats, and the like. "Fertilizer blend" as used herein encompasses the customary components of fertilizers for use on agricultural crops, such components typically including nitrogen, phosphorus, potassium and trace elements such as zinc, manganese, and copper.
"Basic copper chloride," as used herein, refers to a homologous series of compounds of the general formula Cu(OH) x Cl.sub.(2-x) where x is greater than 0 but less than 2.0. More preferably, x is greater than or equal to about 0.5 but less than or equal to about 1.5. Thus, basic copper chlorides are partially neutralized copper salts of hydrochloric acid. Basic copper chlorides generally have pH's ranging from about 1.9 to about 8.0, although the correlation between pH and speciation may vary somewhat depending upon the ionic matrix from which the compounds are formed. Individual members in the homologous series differ only in ratios of hydroxide and chloride and in the possible inclusion of water of crystallization. It is believed that the basic copper chloride produced with the processes and systems of the present invention is predominantly di-copper chloride tri-hydroxide (i.e., x=1.5).
Basic copper chloride occurs naturally as the mineral atacamite. The stability of atacamite is evidenced by its ability to endure dynamic regimes in its natural geologic environment. Atacamite is found as a secondary mineral in oxidation zones of ore deposits in various parts of the world. It is also found as an alteration product of ancient copper and bronze artifacts.
Basic copper chloride can be produced by a carefully controlled neutralization of either an acidic or an alkaline stream of soluble copper. For production via the acidic pathway, cupric chloride is typically used as the acidic copper source and may be neutralized with a wide variety of available bases, such as lime, caustic soda, ammonia, or other bases.
For production of basic copper chloride by the alkaline pathway, basic copper chloride may be precipitated from cuprammine chloride neutralized by HCl or other available acidic solutions. This reaction is as follows:
2Cu(NH.sub.3).sub.4 Cl.sub.2 +HCl+3H.sub.2 O→Cu.sub.2 (OH)3Cl+4NH.sub.4 Cl
More preferably, both the acidic copper source and the alkaline copper source are combined under mildly acidic conditions, one neutralizing the other, to produce more product per unit volume of resultant solution. Such a self-neutralization reaction using a cupric chloride solution as the acidic copper source and a cuprammine solution as the alkaline copper source is as follows:
Cu(NH.sub.3).sub.4 Cl.sub.2 +CuCl.sub.2 +HCl+3H.sub.2 O→Cu.sub.2 (OH).sub.3 Cl+4NH.sub.4 Cl
Soluble copper feedstocks for use in these reactions may be derived from a wide variety of sources. Substantially pure elemental copper or scrap copper (such as copper foil from which printed circuit boards are manufactured) may be used. Such copper could be dissolved in an ammonia-based alkaline solution as follows:
Cu.sup.0 +2NH.sub.4 OH+2NH.sub.4 Cl+1/2O.sub.2 (air)→Cu(NH.sub.3)4Cl.sub.2 +3H.sub.2 O
However, more preferably, waste copper streams from various manufacturing processes may be used. Copper "mud" from wire manufacturing (comprised primarily of elemental copper, copper oxide dust, and lubricant) may be used. More preferably, significant volumes of copper solutions, acidic and alkaline etchant solutions, are discharged from printed circuit board etching operations and can be used as feedstocks in the present process.
Etchant solutions are well known and are commercially available in the printed circuit board manufacturing industry. At one time, acidic etchants were widely used. For example, chlorine gas has been fed directly into a copper-containing etching bath, yielding a cupric chloride etchant solution. Smaller installations have used hydrochloric acid and an oxidizing agent such as sodium chlorate or hydrogen peroxide to form very low pH cupric chloride etching solutions.
Alkaline etchant solutions are more common today. Proprietary solutions made up predominantly of ammonium chloride and ammonium hydroxide are typically used. For example, ETCHANT ET1401 (formerly Alympic Max Etch 20 Starter) and ETCHANT ET1402 (formerly Alympic Max Etch 20 Replenisher) sold by Dexter Electronic Materials Division may be used as a fresh etchant precursor for the present processes and systems.
Fresh etchant solutions such as these eventually become saturated with copper after multiple etching operations. Spent etchant solutions are either discarded or are shipped back to the supplier for regeneration. Such spent solutions contain high levels of copper and may contain a variety of contaminants introduced during the etching operation. Arsenic, lead, and tin, for example, may be present in spent etchant solutions.
Etchant solutions are conventionally regenerated by either a boil-off process or by liquid ion exchange. In the boil-off process, caustic soda is added to the spent etchant and the mixture is heated to the boiling point to drive ammonia out as a gas. The ammonia is re-adsorbed in hydrochloric acid, resulting in the formation of "fresh" ammonium chloride and ammonium hydroxide for reuse as etchant. Copper is recovered from the process as cupric oxide, which can be sold. A waste brine of sodium chloride must be treated to remove copper and thereafter discharged. High energy and chemical consumption drive up operating costs in this process.
In the liquid ion exchange process, an ion exchange polymer dissolved in an organic liquid such as kerosene is contacted with the spent etchant solution. Copper is extracted into the organic phase, which subsequently is contacted with sulfuric acid to form copper sulfate and to regenerate the ion exchange polymer. The aqueous phase can be recycled as fresh etchant. However, this process involves high capital costs, and does not adequately deal with contaminants in the spent etchant solution. Moreover, some carryover of the organic phase into the aqueous phase is likely to occur.
A system 10 for producing basic copper chloride in accordance with the claimed invention is illustrated in FIG. 1. A first feed stream 12 is a spent copper-containing alkaline etchant solution (such as a cuprammine solution), and a second feed stream 14 is a spent copper-containing acidic etchant solution (such as a cupric chloride solution). Sets of plural storage tanks 16, 17, and 18, 19 may be provided for the etchant feedstocks. Advantageously, the system can be operated to produce basic copper chloride by either the alkaline pathway in which a spent alkaline feedstock is neutralized by HCl or by self-neutralization of spent acidic and alkaline etchant solutions. With minor modifications, system 10 could be used to produce basic copper chloride by either neutralizing the alkaline etchant with HCl or by neutralizing the acidic etchant with a convenient alkaline agent such as lime.
Typically, quality assurance procedures will be performed before the etchant feedstock is pumped from the storage tanks. When one of tanks 16, 17 (or 18, 19) is filled with a new batch of etchant feedstock, that tank is closed off and inputs to the process come from the other tank. The new etchant solution in the closed tank is then checked for appearance, acidity/alkalinity, organic content, copper and trace metallic impurities, and specific gravity. The contents of the tank are then homogenized before the tank is brought on-line.
Alkaline feed stream 12 is fed at a controlled rate into the process. For example, stream 12 may be pumped from tanks 16, 17 by a metering pump (not shown) or the like. Where stream 12 contains high levels of soluble arsenic (e.g., 20 mg/l or more), it can be treated in a pretreatment reactor 32 before being fed to the primary reactor.
A variety of techniques may be used to convert substantial amounts of soluble arsenic to insoluble forms in pretreatment reactor 32. Most preferably, at least one calcium compound and at least one magnesium compound (e.g., magnesium chloride and calcium chloride from a source 35) are added to pretreatment reactor 32 to precipitate arsenic in the form of low solubility calcium magnesium arsenates. Precipitation should be complete in less than one hour. Stream 12 may then be filtered using standard filtration equipment 39 to remove the precipitate. Through use of this method, spent alkaline etchant containing 20 mg/l soluble arsenic can be treated to reduce soluble arsenic levels to less than 1.0 mg/l.
When system 10 is operated to produce basic copper chloride by the self-neutralization pathway, a spent copper-containing acidic etchant feedstock is mixed with alkaline feed stream 12. Acidic feed stream 14 is fed at a controlled rate into the process (for example, by being pumped from storage tanks 18, 19 by a metering pump or the like). Where stream 14 is a spent acidic etchant stream contaminated with arsenic, pretreatment in a pretreatment reactor 33 may again be necessary. Here, the preferred pretreatment method involves pH control. It is speculated that when the pH is raised, relatively insoluble complex arsenates are formed.
In the preferred method of pretreating stream 14 to reduce levels of soluble arsenic, the pH of stream 14 is raised to the point where precipitation begins to occur, and the precipitate is filtered out using standard filtration equipment 41. Alkaline stream 12, or another alkaline source (such as ammonia from a source 37), may preferably be used to raise the pH. By use of this pretreatment method, arsenic levels in stream 14 can be reduced from about 20 ppm to about 6.0 ppm.
For operation of system 10 via the alkaline pathway, copper-containing alkaline etchant stream 12 is pumped to primary reactor 26 after optionally being treated as described to remove arsenic. Hydrochloric acid (or any other suitable neutralizing agent) from a source 36 is pumped directly to reactor 26 in an amount effective to maintain the pH of the reaction mixture within a predetermined range as set forth below.
Reactor 26 includes a standard agitator 34. Because the reaction in reactor 26 is run at ambient conditions and is only mildly exothermic, no special provisions for heat input, heat removal, or high pressure need be made. The reaction mixture in reactor 26 is preferably maintained at a pH of about 1.8 to about 8.0. More preferably, the pH of the reaction mixture is about 4.0 to about 5.0. Most preferably, the pH is about 4.5. Redundant pH controllers (not shown) of any well-known variety are provided and are routinely calibrated to assure carefully-monitored pH conditions.
Residence times may vary. Although the reaction is nearly instantaneous, it may be preferable to use an oversized reactor to provide as much as an eight hour residence time to give a strong buffering effect. However, it is believed that residence times as low as about five minutes may be effective.
The reaction products (basic copper chloride and soluble background salts) are pumped from reactor 26 to a settler 40 by way of a line 42. Settler 40 separates the reaction products from reactor 26 into a supernatant brine and a copper-containing slurry. The brine is comprised primarily of ammonium chloride liquor and dissolved copper, while the slurry is comprised of basic copper chloride along with a variety of background salts.
A predetermined portion of the copper-containing slurry is withdrawn for use as a seed stream for "seeding" the crystallization of basic copper chloride in reactor 26. The "seed" material is pumped through a seed line 43 by a pump 45 from settler 40 to the bottom of primary reactor 26.
The use of a seed stream provides numerous advantages. The presence of "seed" product appears to facilitate the growth of basic copper chloride crystals. Seeding also allows control over final product particle size. That is, seeding may be used to produce relatively large particles which can be more readily separated from background salts, but not so large as to create problems in blending the basic copper chloride with food products. The desired particle size is in the range of 30-300 microns.
It is important to maintain an appropriate concentration of seed slurry in the reactor. This parameter will be controlled by withdrawing a sample and checking the "seed index" (settled volume of slurry in the reactor after five minutes) periodically. For example, the "seed index" for reactor 26 may range from about 15 to about 50% under typical processing conditions, although it may range higher or lower under certain processing conditions.
The supernatant brine from settler 40, an ammonium chloride liquor, passes directly to a finishing operation 49 by way of a line 47. The remaining portion of the slurry from settler 40 not used as seed material is pumped by a pump 46 though a line 44 to a drying operation 51.
Drying operation 51 includes a filter 48, a dryer 58, and a sieve 68. Filter 48 is preferably a standard vacuum filter familiar to those of skill in the art. A water wash from a water supply 52 is provided to assist in removing ammonium chloride from the solids, with the effluent wash water 54 being sent to disposal. Filter 48 operates to remove excess liquid from the slurry, yielding a substantially dry filter cake. The excess liquid flows through line 50 for further treatment in finishing operation 49 as will be subsequently described.
When the filter cake is substantially free of ammonium chloride, the filter cake is discharged to a final dryer 58. Dryer 58 is typically supplied with an external heat source. An automatic sieve 68 positioned downstream of dryer 58 is used to monitor the size of dewatered filter cake fractions emerging from dryer 58. Appropriately sized fractions pass through sieve 68 and are transported to a packaging operation where they are packaged for sale in bags 72 or the like for use as a micronutrient supplement or for use as a copper source in a fertilizer product. Oversized and undersized fractions are forced into a recycle line 70 to be returned to dryer 58.
Advantageously, the basic copper chloride product made in accordance with the present process is a fine powder which can readily be blended with food products using standard blending techniques and equipment (not shown). The product is substantially free of background salts and contaminants such as arsenic. The product combines the desirable characteristics of high bioavailability with very low water solubility. Thus, when blended into food products as a micronutrient supplement, basic copper chloride produced in accordance with the present process will be highly effective in achieving desired nutritional levels and will be less likely than current micronutrient supplements to destabilize vitamins and antibiotics in the food product.
Basic copper chloride produced in accordance with this process is also usable in other applications requiring copper sources where copper sulfate, copper oxide, or other copper salts are presently used. For example, the basic copper chloride may be blended into a fertilizer.
As noted, supernatant ammonium chloride liquor from settler 40 (in line 47) and ammonium chloride liquor recovered from product filter 48 (in line 50) are fed to polishing operation 49. Polishing operation includes a polishing reactor 74 and a filter press 86.
Polishing reactor 74 (preferably an agitated tank reactor including an agitator 76) receives and treats mixed ammonium chloride liquor from lines 47 and 50. A metal scavenger 78 such as dimethyl dithiocarbamate (sold under the tradename NAMET (Buckman Laboratories, Memphis, Tenn.)) is fed to polishing reactor 74 by way of line 80 in an amount sufficient to substantially reduce levels of dissolved copper and other metals. For example, ammonium chloride liquor containing 500-1000 mg/l dissolved copper can be treated to yield an effluent containing less than about 5.0 mg/l dissolved copper.
The effluent liquor from polishing reactor 74 is pumped by a pump 82 through a line 84 to reach filter press 86. Filter press 86 is preferably a standard filter press operated in the conventional fashion.
The liquor in line 84 is fed through press 86 to yield a "water-white" ammonium chloride liquor (which is discharged into a line 88) and a substantially dried by-product cake (which is dumped from by-product press 86 to a by-product container 90. The by-product cake is primarily dimethyldithiocarbamate and copper which can be processed by a copper smelter for recovery of copper values.
The clear ammonium chloride liquor in line 88 can be finished into fresh etchant or can be sold itself. Preferably, about 30% by volume of the ammonium chloride liquor is split off into a line 92 to be stored in a storage vessel 94. Ammonium chloride liquor from tank 94 may be sold for use in a variety of manufacturing processes, including the manufacture of galvanizing flux or dry-cell batteries.
The remaining 70% by volume of clear ammonium chloride liquor is fed to a finishing tank 96 by means of a line 93. Anhydrous ammonia 100 and carbon dioxide 102 are supplied to finishing tank 96 by way of lines 106, 108 in amounts sufficient to finish the ammonium chloride liquor into regenerated alkaline etchant solution.
Processes in accordance with the present invention are preferably operated semi-continuously. That is, holding tanks 16, 17 and 18, 19 of incoming spent etchant solution will be filled, analyzed, and run through the process as a batch. Primary reactor 26, however, will be run continuously to maintain uniform operating conditions. Filter 48 and dryer 58 will operate continuously, although batchwise operation of both is also possible.
The system and process in accordance with the present invention may be further understood with reference to the following examples.
EXAMPLE I
Basic copper chloride was produced in accordance with the process of the present invention in a 500 gallon pilot reactor. The sources of soluble copper were spent etching solution (acidic and alkaline) from a printed circuit board manufacturer. The basic copper chloride produced by this process was a fine, light-green powder which was extensively tested for stability and trace impurity levels. The basic copper chloride produced in accordance with this example has the following specifications:
______________________________________ Element (mg/kg)______________________________________ Copper 589400 Chloride 167700 Nitrogen <5000 Aluminum 9.2 Antimony 100 Arsenic 43.7 Cadmium 0.05 Lead 1.8 Mercury 0.02 Nickel 1.8 Zinc 77.3______________________________________
Thermal stability of the product was evaluated by use of thermogravimetric analysis (TGA). This analysis showed that the product was thermally stable in air to about 400° C.
EXAMPLE II
An experiment was conducted to compare the bioavailability of copper from basic copper chloride with that of reagent grade cupric sulfate (CuSO4.5H 2 O). A basal corn-soybean diet containing 26 ppm copper (dry matter basis) by analysis was formulated. The copper sources were added to the basal diet at 150, 300, and 450 ppm copper and confirmed by analysis. A total of 288 one-day-old Ross×Ross chicks was used in the 21-day experiment. There were six pens of six chicks (three male and three female) fed the basal diet and seven pens of six chicks fed each copper-supplemented diet. Birds were housed in Petersime brooder batteries with stainless steel fittings and maintained on a 24 hr constant light schedule. Tap water containing no detectable copper and feed were available ad libitum. At the end of the experiment, the birds were sacrificed and livers were collected. Copper concentrations in feed, water, livers, and copper sources were determined by flame temperature atomic absorption spectrophotometry on a Model 5000 with an AS-50 autosampler after dry ashing and solubilizing the ash in HCl.
Chicks fed 450 ppm copper as copper sulfate had lower (P<0.05) feed intakes than those fed basic copper chloride or the basal diet at all dietary concentrations. Moreover, estimates of relative bioavailability of basic copper chloride ranged from 90% to 106% compared with 100% for copper sulfate. Thus, the detrimental effect of copper sulfate on feed intake was not observed with basic copper chloride, yet the bioavailability of basic copper chloride was equal to that of copper sulfate.
Furthermore, a strong inter-species correlation is recognized in bioavailability of copper from poorly-available sources such as cupric carbonate and cupric oxide when compared with cupric sulfate and cupric acetate. This suggests high bioavailability for basic copper chloride in other species as well.
EXAMPLE III
A standard feed mix supplemented with basic copper chloride had the specifications shown in the table below. In the table, the "microingredients" were supplied per kilogram of diet. The microingredients included 6000 IU vitamin A, 2200 ICU vitamin D 3 , 2.2 mg menadione dimethylpyrimidinol bisulfite, 500 mg choline chloride, 4.4 mg riboflavin, 13.2 mg pantothenic acid, 39.6 mg niacin, 22 μg vitamin B 12 , 125 mg ethoxyquin, 60 mg manganese, 50 mg iron, 6 mg copper, 1.1 mg iodine, 35 mg zinc and 100 μg selenium. Vitamin E and pyridoxine are added separately at a concentration to provide 5 IU and 3 mg, respectively to each kg of diet.
Further, the "dicalcium phosphate" included 22% Ca and 18.5% P. In addition, the "variables" included a copper source and washed builder's sand in appropriate concentrations to furnish the desired final dietary copper concentration.
______________________________________ Percentage In DietINGREDIENTS Starter Grower______________________________________Yellow corn 57.28 63.50Soybean meal (48.5% CP) 33.87 28.43Microingredients .50 .50Corn oil 3.80 3.34Ground limestone 1.05 1.25Dicalcium phosphate 2.35 1.90DL-Methionine .18 .11Iodized salt .40 .40Coban .07 .07Variables .50 .50TOTAL 100.00 100.00Calculated AnalysisCrude protein (%) 21.50 19.50ME (kcal/kg) 3103.00 3138.00Lysine (%) 1.21 1.05Methionine + Cysteine (%) .87 .75Calcium (%) .92 .90Phosphorus (% available) .55 .55______________________________________
EXAMPLE IV
A fertilizer product containing basic copper chloride typically falls within the following specification:
______________________________________Total Nitrogen 30%3.0% Amm. Nitrogen27.0% Urea NitrogenAvailable Phosphoric acid 10%(P.sub.2 O.sub.5)Soluble Potash (K.sub.2 O) 10%Boron (B) 0.02%Copper (Cu) 0.07%Iron (Fe) 0.325%Manganese (Mn) 0.19%Molybdenum (Mo) 0.005%Zinc (Zn) 0.07%______________________________________
Although the invention has been described in detail with reference to certain preferred embodiments, variations and modifications exist within the scope and spirit of the invention as described and defined in the following claims. | Basic copper chloride having the empirical formula Cu(OH) x Cl 2-x is prepared from waste etchant streams. The compound exhibits properties that lends advantage to its use as a source of bioavailable copper in multinutrient fertilizer compositions. Novel fertilizer compositions for plant nutrition containing basic copper chloride as a bioavailable source of copper are described. | 2 |
TECHNICAL FIELD
[0001] The present invention relates to a body for surrounding the end, a branching or a connection point of a high-voltage cable according to preamble in claim 1 . The invention also relates to a cable element, in particular a cable end seal or a cable sleeve, fitted with such a surrounding body.
[0002] The surrounding body contains at least one field control element based on a polymer and filler embedded in the polymer and containing microvaristors. The field control element is characterised by a nonlinear current-voltage characteristic and has at least one axially elongated and flat-shaped hollow body section which has an axially symmetrical inner surface that can be applied or guided to an outer surface of the cable by deforming the surrounding body.
[0003] Basically, the surrounding body can be assigned to two classes of surrounding bodies. The surrounding bodies assigned to one class contain electrically conductive elastomers as field control element—as a rule filled with soot. With these elastomers the field-controlling effect is achieved by the geometric shaping, such as e.g. a funnel-shaped opening. This type of field-control is designated as geometric field-control. The surrounding bodies assigned to the other class contain as field control element polymers, in which fillers with field-controlling properties are embedded. These field-controlling material properties can e.g. be achieved by relatively high dielectric constants or by nonlinear, i.e. field strength-dependent, electrical resistances or by a combination of both. The advantage of this type of field control elements is that they can consist of thin-walled, cylindrical pipes or hoses and therefore thin, spce-saving and thus also cost-effective products can be produced.
PRIOR ART
[0004] A surrounding element of the type initially described, which is used in manufacturing an end seal of a shielded synthetic-insulated single-conductor cable with operating voltages of 10 kV or 20 kV, respectively, is described in EP 0 875 087 B1. To produce a cable head of a 20 kV cable on a cable end, at first wires of a cable shielding are removed from a cable insulation provided between a cable conductor and the shielding and are fixed to form a coil of wires, i.e. wires having a common ring-like edge. A conductive layer, e.g. a graphite coating, on the cable insulation is removed as far as an offset edge projecting over the coil of wire. Then the cable insulation provided on the end of the cable conductor is removed and a field-controlling, tubular surrounding element is placed onto the cable end. This surrounding element is formed by a field control element made of a polymer and a microvaristor based on filler containing doped zinc oxide and by an outer layer surrounding the field control element coaxially made of heat-shrinkable insulating material. With its one end the field control element contacts the end of the conductive layer guided as far as the offset edge. The other end of the field control element is guided out over the offset edge to the cable insulation and, depending on the control task, can be connected to the open end of the cable conductor, or can also end on the cable insulation without connection to the cable conductor.
[0005] The structure and properties of a field control element used in the above-mentioned surrounding element are described in detail in a publication by R. Strümpler et al. “Smart Varistor Composites”, Proceedings of the 8 th CIMTEC Ceramic Congress and Forum on Materials Symposium (1994). The field control element is designed as composite material and is filled with a ceramic material, consisting of small—substantially spherical—ZnO particles. The ZnO particles are doped with different metal oxides, such as e.g. Sb 2 O 3 , Bi 2 O 3 , Cr 2 O 3 and Co 3 O 4 and are sintered at temperatures of between 900° C. and 1300° C. Like a varistor the sintered particles have nonlinear electrical properties that depend on the electrical field strength. In the case of low field strengths the particles behave like an insulator, and with increasing field strength the particles become more conductive. Owing to these nonlinear electrical properties the polymer composite material has good field-control properties.
[0006] A further surrounding body for surrounding a connection point of two high voltage cables having different diameters is described in U.S. Pat. No. 6,171,669. This surrounding body has on its inner side a layer of field control material. This layer is guided on both cables in each case to a transition area which is arranged between the associated cable insulation and a layer made of semiconductive material.
DESCRIPTION OF THE INVENTION
[0007] The object of the invention, as specified in the claims, is to provide a surrounding body of the type initially described, which enables very precise field-control of a cable element, such as in particular of a cable head or a cable sleeve in a particularly simple manner.
[0008] With the inventive surrounding body the inner surface of the hollow body section is designed differently from the outer surface of the cable and in such a way that the field control is achieved by changing the number of microvaristors per surface unit as a result of expansion and/or shrinkage of the hollow body section after the deforming. The electrical properties of the field control element depend substantially on the mutual distance of the microvaristors in the polymeric matrix or on the proportion of microvaristors. Thus e.g. the dielectric constant grows with increasing concentration of microvaristors, in particular those based on a ceramic, such as ZnO, and vice versa the electrical resistance generally drops with a given field strength with increasing filler concentration. If the field control element is now expanded/shrunk during the production of a cable element, for example a cable head or a cable sleeve, then the mutual distances of the microvaristors increase/decrease in circumferential direction of the field control element with the expansion/shrinkage, or, respectively, the number of microvaristors per unit area of the flat designed hollow body section increases/decreases and the electrocial properties of the field control element change accordingly. This fact is capitalised on by the inventive surrounding element in a favourable manner to produce locally differing electrical properties, such as in particular dielectric constant and electrical resistance, through differnet local expansion and/or shrinkage of the hollow body section along the axis. Thus, apart from the parameters related to the material of the microvaristors, such as e.g. filler content, composition, sintering conditions as well as geometric dimensions, one obtains an additional design parameter to optimise the field-control properties in the cable element provided with the inventive surrounding body by establishing the expansion/shrinkage ratios along the hollow body section of the field control element. Therefore, the inventive surrounding element can also be used in cables in the voltage range of far over 100 kV.
[0009] At the same time the field control element and thus also the surrounding body have a thin wall thickness. A cable element fitted with the inventive surrounding body and provided for high-voltage applications is characterised by a slender design, in spite of having optimised electrical properties. This also gives rise to other advantages, such as:
a) Smaller footprint. This is particularly significant with connections in gas-insulated high-voltage facilities (GIS plant), because with thinner cable elements, such as end seals, smaller pipe diameters in the GIS plant become possible, as well. (b) Less material requirement. In the case of thinner field control elements thinner cable elements for external applications are also possible. Because these days a large quantity of insulating material is often needed due to the length in external applications, material can be saved using thinner cable elements and installation costs can be reduced. (c) Greater application range with different cable diameters. Because with thinner cable elements the effort required for pushing it onto a cable are generally less than for cable elements with geometric field-control, these cable elements can be dimensioned such that one size can be used for several cable diameters.
[0013] Before the surrounding body is placed on the cable the inner dimension of the hollow body section can change continuously along the axis. When the surrounding body is withdrawn to a section of the cable designed as a cylinder or flat band, the preferred expansion/shrinkage for the desired electrical properties of the field control element is achieved.
[0014] Basically, it is also possible, however, that before the surrounding body is placed on the cable the inner dimension is kept constant along the axis. The preferred expansion/shrinkage for the desired electrical properties of the field control element is then achieved by designing the mantle surface of the cable or the cable insulation, respectively, such that this expansion/shrinkage is caused.
[0015] It is recommended that an inner diameter determining the dimensions of the inner surface changes along the rotation axis continuously, preferable montonously, in particular linearly. Since the inner surface of the inventive surrounding body is then designed predominantly conically, a casting core used in a casting procedure for producing a surrounding body can be removed comparatively easily.
[0016] In order to solve simple field control tasks it is sufficient, if the inner diameter of the hollow body section changes linearly along the axis of rotation. Here, but also in solving complicated field control tasks, the ratio of the minimum inner diameter to the maximum inner diameter of the hollow body section should appropriately be 0.2 to 1.0 times.
[0017] An additional field-control improvement is achieved by changing the electrical resistance or the impedance in that, in addition to the inner dimension, also the wall thickness of the hollow body section changes along the axis. By way of example, also the cross-section surface decreases with diminishing wall thickness and therewith the resistance parallel to the axis increases. The wall thickness can also be correspondingly large in certain areas, preferably where a larger electrical conductivity is desired, for example directly on the offset edge.
[0018] In a simple manner in manufacturing-engineering terms the field control element can be formed in an inner surface of an elastically deformable support element made of insulating material.
[0019] Instead of only one first field control element formed in the support element at least one additional field control element can be formed in the support element. To achieve good field-control also at high voltages, for example at voltages over 100 kV, the other field control element should enclose the first field control element and be separated from the latter by an electrically insulating intermediate layer.
[0020] Polymers, in which primarily spherical particles formed as microvaristors by sintering metal-oxide-doped zinc oxide granulate are embedded, are particularly suitable as material for the first field control element and the optionally provided additional field control element. The microvaristors can also comprise microvaristors based on doped SnO 2 , TiO 2 , SrTiO 3 or SiC in each case singly or in a mixture. Through different filler concentrations, selection of filler and/or sintering conditions the electrical properties of the field control elements can be altered substantially. Thereby and through selection of at least two field control elements, which have different electrical properties and/or dimensions, the inventive surrounding body can solve a plurality of field control tasks with particularly keen precision.
[0021] It is recommended to also embed electrically conductive particles in the polymer apart from the microvaristors as filler, since on the one hand high energy absorption of a cable element, for example a cable head, fitted with the surrounding element is ensured, and since on the other hand the dielectric constant of the field control element is increased by the particles, that are formed preferably as metal flakes or graphite, in a particularly advantageous manner for solving specific field control tasks. To achieve a high energy uptake and an efficient raising of the dielectric constant the electrically conductive particles provided in the filler should make up approximately 0.05 to approximately 5 volume % of the filler. They can also be applied directly to the microvaristors for the purpose of simplifying the production of the surrounding body.
[0022] In a cable element configured preferably as a cable head or cable sleeve with a cable section, which comprises a cable conductor that can be used at high-voltage potential, an electrically conductive cable shielding and a cable insulation arranged between cable conductor and cable shielding, and with an inventive surrounding body being attached to the cable section, a good field control can be achieved, if the first field control element comprises a changed number of microvaristors per unit area in a first section, that encloses an offset edge of a layer of the cable shielding and an unshielded area of the cable insulation, compared to a second section connecting to the first section and comprising a shielded area of the cable insulation. To achieve good field control for voltages in the region of several 10 kV up to a several 100 kV and in particular for direct-current applications, the field control element should connect the cable shielding and the cable conductor to one another.
[0023] With higher voltages, a particularly good field control is achieved if the field control element and an additionally provided outer field control element, which surrounds the other field control element coaxially, are guided in an axial direction over the offset edge of the cable shielding and are connected only to the cable shielding. This advantageous effect is likewise achieved if the outer field control element is held on floating potential. For certain applications, in particular in high-voltage applications, it can be an advantage if a further outer field control element is connected directly to the conductor being on high-voltage potential.
[0024] The above-described effect can still be improved considerably if in addition an electrically conducting layer is arranged between both field control elements, and is connected electrically conductively to the outer field control element.
[0025] For reasons of reproducible production of a dielectrically high-grade cable element it is recommended to apply an annular layer made of electrically conductive material to the inner surface of the hollow body section of the inner field control element, which layer extends in the direction of the axis of rotation over the offset edge. These measures bring about a pressure release of the dielectrically critical area around the offset edge. This is an advantage to the extent that in contrast to the offset edge this annular layer is produced not on the assembly site, but in a manufacturing facility, and is thus designed to be dielectrically particularly high-grade.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] Exemplary embodiments of the invention will now be explained with reference to diagrams, in which:
[0027] FIG. 1 is a top view of an axial cross section through a first embodiment of a rotationally symmetrically configured surrounding body according to the present invention,
[0028] FIG. 2 is a top view of an axial cross section through a cable head fitted with the surrounding body according to FIG. 1 ,
[0029] FIG. 3 is a top view of an axial cross section through a second embodiment of a rotationally symmetrically designed surrounding body according to the present invention, and
[0030] FIG. 4 is a top view of an axial cross section through a rotationally symmetrically designed cable head provided with a third embodiment of the surrounding body according to the present invention.
WAYS OF EXECUTING THE INVENTION
[0031] In all figures the same reference numerals refer to identically functioning parts. A hollow surrounding body 1 shown in FIG. 1 is designed rotationally symmetrically and has a field control element 3 made of a material having elastomeric, nonlinear electrical properties and designed substantially as a hollow truncated cone and extended along an axis of rotation 2 in the direction of a coordinate r. The material contains apart from elastomer also microvaristors embedded in the elastomer as matrix, which microvaristors are advantageously formed by doped and sintered zinc oxide particles. Typical compositions, particle sizes and sintering conditions can be inferred from the initially mentioned prior art. The field control element 3 is formed in an inner surface of a likewise elastomeric hollow support element 4 , though consisting of an insulating material. Silicones, EPDM, natural rubber, nitrile rubber, thermoplastic elastomers or mixtures of various elastomers can be used as elastomers. The inner diameter D(r) of the field control element decreases along the axis of rotation 2 in the direction of the increasing coordinate r. Accordingly, the elastomeric field control element is expanded differently when pushed onto a cable end along the axis of rotation 2 and the electrical properties of the pushed-on field control element 3 then depend on the position on the cable.
[0032] This can be seen from FIG. 2 . In this figure a cable head 5 for a cable conducting operating voltages of a few 10 kV is illustrated. The cable has a cable section 6 with a cable conductor 7 conducting the voltage, an electrically conductive cable shielding 8 and cable insulation 9 arranged between the cable conductor 7 and the cable shielding 8 . The cable shielding 8 contains wires, which are removed from the cable insulation 9 and are fixed at the right end of the cable shielding, forming a coil of wire 10 . An electrically conductive coating 11 provided on the cable insulation 9 is stripped off as far as an offset edge 12 projecting over the coil of wire 10 . The cable conductor 7 bears at its end a cable shoe 13 . The surrounding body 1 is attached to a mantle surface formed by the cable shielding 8 , the coating 11 , an unshielded area 14 of the cable insulation 9 and the cable shoe 13 , and in such a way that the field control element 3 connects the coating 11 over the offset edge 12 to the cable shoe 13 lying on the potential of the cable conductor 7 and that the support element 4 occludes the cable section 6 fluid-tight. The inner diameter of the field control element 3 is evidently stretched more strongly in a section 15 enclosing the offset edge 12 and the unshielded area 14 of the cable insulation 9 than in a section 17 attached thereto and including a shielded area 16 of the cable insulation.
[0033] In the embodiment according to FIGS. 1 and 2 the inner diameter D(r) of the field control element 3 is linearly expanded along the axis of rotation 2 after production of the cable head is completed. The change in diameter may, however, take any other form and need also not extend over the entire length of the hollow field control element 3 , but possibly only over a preset section. If the maximum inner diameter of this hollow body section is designated by D max and if the minimum inner diameter is designated by D min ( FIG. 1 ), the ratio D min /D max can be between 0.2 and 1 with a given end seal. The expansion of the field control element 3 at the point with the minimum inner diameter D min can be between 2% and 80% after installation on the cable. Accordingly, the number of microvaristors per unit area of the field control element 3 is decreased and thus the electrical resistance and the dielectric constant of the field control element 3 at this point have changed compared to the resistance and the dielectric constant at the point with the maximum inner diameter D max . These changes in resistance and dielectric constant considerably benefit the field control of the cable end seal.
[0034] It is evident from FIG. 2 that the field control element 3 constitutes a through connection, such that earth potential and high-voltage potential are connected. This is an advantage for solving certain control tasks, in particular in the voltage range of up to several 10 kV and in the case of direct-current applications. Basically the field control element 3 can also be kept potential-free at one of its two ends.
[0035] A further possibility of varying the electrical resistance or the impedance of a cable element, such as of the cable head, along the axis of rotation 2 comprises a change of the wall thickness of the field control element 3 . With increasing wall thickness the cross section surface increases, that is, the resistance parallel to the axis of rotation reduces. FIG. 3 illustrates a second embodiment of the surrounding body 1 according to the invention for use in a cable head, in which the field-controlling, nonlinear electrical properties are further influenced by the change in expansion and the change in the cross section along the axis of rotation. For solving field control tasks, in which relatively strong field gradients occur, such as in cables with operating voltages of more than 100 kV, appropriately designed field-controlling surrounding bodies are particularly suited.
[0036] Yet another possibility for optimising field control in cable end seals or cable sleeves comprises the use of two field control elements arranged coaxially above one another and made of elastomeric material containing microvaristors. Here the field control elements 3 , 18 are directly superposed if required, but in general are separated from one another by an insulation layer 19 , as is shown in FIG. 4 in a third embodiment of the surrounding body according to the invention. The field control elements 3 , 18 can be of different lengths and can be offset in the longitudinal direction, so that e.g. the outermost field control element 18 projects out over the innermost element 3 . In addition to this, a layer 20 of electrically conductive material can be arranged between the field control element 18 and the insulating intermediate layer 19 . This layer is formed advantageously by an electrically conductive elastomer or by a conductive lacquer. This layer 20 is either embedded in an electrically insulating manner in an insulation layer 19 separating both field control elements 3 , 18 from one another, or is connected electrically conductively to the field control element 18 and due to its capacitive effect has a good field control function. Both field control elements 3 and 18 need not necessarily have the same electrical properties. Determined by different filler contents and by a different composition and sintering conditions of the microvaristors provided in the filler the electrical properties of both field control elements can differ quite substantially.
[0037] In order to separate the site of the highest electrical load from the offset edge 12 of the conductive layer 11 on the cable, it is recommended to apply an annular conductive layer 21 to the inside of the field control element 3 or to integrate it in the field-controlling material. Because of this layer the region of the highest electrical load does not coincide with the offset edge 12 , but—depending on the length of the conductive layer 21 —is shifted to the end of the cable.
[0038] The inventive surrounding body can be manufactured using processing machinery nowadays employed in elastomer compounding. The doped and sintered ZnO powder can be worked with a stirrer e.g. using LSR silicone as polymer matrix. When an EPDM or solid silicone is used the filler can be worked in the elastomer matrix by means of a rolling mill.
[0039] It is generally an advantage for the installation and application of the inventive surrounding body if the field control elements 3 , 18 and the insulation material of the support element 4 are produced together and can be drawn as one part over the cable end in the installation of the cable element designed as cable head 5 . Such a surrounding body 1 can be produced using production methods common in plastics processing, e.g. the injection-moulding process. An advantage here is that good adhesion of the different materials (field control element 3 , 18 , support element 4 , conductive intermediate layers 20 , 21 ) can be adjusted by the production process (pressure, temperature, vulcanising time and use of adhesives) among one another and thus good dielectrical strength of the electrically highly stressed limiting surfaces can be achieved. Furtermore, any contamination of the limiting surfaces during installation of the elements can be excluded.
[0040] The manufacturing the surrounding body 1 according to FIG. 1 can be carried out as follows: a ZnO granulate doped with oxides of typically Bi, Co, Cr, Mn and Sb and selectively additional elements, such as Al, B, Fe, Ni, Si, is sintered at temperatures between 900° C. and 1300° C. The sintering process can take place e.g. in a rotary kiln or in a conventional batch oven. After sintering the resulting microvaristor powder can be sieved to a desired particle size fraction of for example 100 μm. Optionally, metallic additives can then be mixed in and sintered on the microvaristors. The sieved powder is worked e.g. on a rolling mill into an elastomer (e.g. into an HTV silicone). Depending on the type of elastomer other additives (such as e.g. cross-linking additives, stabilisers) can be added in at this point. The volume proportion of the sintered powder in the field control material is typically between 20 and 45 percent. The resulting compound can now be filled by a conventional casting or injection-moulding procedure or a pressing process into the desired form the elastomer can be cross-linked in the form. The resulting cross-linked field control element 3 is cast in a second injection-moulding procedure or casting process with the insulating material (e.g. liquid silicone rubber) to form the surrounding body 1 .
[0041] Shielding necessary for external applications of the cable head can be cast directly with the support element 4 , but can alternatively also be cast in a separate production process and later pushed onto the cable head. The advantages of the separately produced shieldings lie in greater flexibility in different applications (e.g. with different degrees of environmental contamination) and thus in more cost-effective production methods.
[0042] Instead of an elastomer any shrinkable polymer can be used, preferably a thermoplast. The different concentrations of microvaristors per surface unit or unit area distributed over the axis and thus particularly precise field control is then achieved with pre-specified configuring of the inner surface when the surrounding body is deformed in a shrinking procedure.
Legend
[0000]
1 surrounding body
2 axis of rotation
3 field control element
4 support element
5 cable head
6 cable section
7 cable conductor
8 cable shielding
9 cable insulation
10 coil of wire
11 coating
12 offset edge
13 cable shoe
14 , 16 areas
15 , 17 sections
18 field control element
19 insulation layer
20 . 21 conductive layers | The surrounding body ( 1 ) serves to surround the end, a branching or a connecting point of a high-voltage cable. It has an element ( 3 ) with a nonlinear current-voltage characteristic line, which serves to control the electric field in the surrounding area. The field control element ( 3 ) contains a polymer and a filler embedded in the polymer und containing microvaristors, as well as at least a hollow body section extending along an axis ( 2 ) and designed flat, with an axially symmetrical inner surface conductive by deforming the surrounding body ( 1 ) to an outer surface of the cable. To ensure good field control in cables, which are operated at high voltages, the inner surface of the hollow body section is designed as a variation of the outer surface of the cable and in such a way that the field control in the surrounding area is achieved by altering the number of microvaristors per surface unit as a result of expansion and/or shrinking of the hollow body section after deforming. | 8 |
BRIEF SUMMARY OF THE INVENTION
BACKGROUND OF THE INVENTION
1. Field of the Invention
The instant invention relates generally to compositions for inhibiting vascular occlusion in humans and more specifically to compositions for inhibiting vascular occlusion which further contain nutritional supplements.
2. Description of the Prior Art
Compositions for inhibiting platelet aggregation are known in the art. For example, U.S. Pat. No. 5,401,730(Sauvage, L.R. et al., 28 Mar. 1995) discloses a method of treating a patient comprising the administration of a combination of acetylsalicylic acid (aspirin), citric acid and thiamine, optionally in further combination with zinc.
U.S. Pat. No. 4,491,574 (Seifter, E., 1Jan. 1985) discloses a therapeutic composition comprising aspirin in combination with vitamin A or a precursor of vitamin A to reduce toxicity and ulcerogenesis.
SUMMARY OF THE INVENTION
The present invention is concerned with a composition for inhibiting vascular occlusion in humans and more specifically to compositions for inhibiting vascular occlusion which further contain nutritional supplements.
A primary object of the present invention is to provide a single composition which contains both vitamins and a vascular occlusion inhibitor.
Another object of the present invention is to provide a vitamin supplement in combination with aspirin (acetylsalicylic acid).
An additional object of the present invention is to provide a vitamin supplement in combination with aspirin (acetylsalicylic acid) and nutritional minerals.
Another object of the present invention is to provide a vitamin supplement/vascular occlusion inhibitor which simplifies the process of treating cardiac care patients by combining aspirin and vitamins into a single formulation.
A further object of the present invention is to provide a vitamin supplement in combination with aspirin (acetylsalicylic acid) and one or more of herbal extracts, homeopathic compositions, red wine concentrates and amino acid supplements.
A further object of the present invention is to provide a method of treating a cardiac care patient by administering to the patient a vitamin supplement containing a vascular occlusion inhibitor such as aspirin.
Yet another object of the present invention is to provide a composition for reducing inflammation while providing nutritional supplements.
Another object of the present invention is to provide a composition for reducing fevers while providing nutritional supplements.
Yet another object of the present invention is to provide a composition for ameliorating pain while providing nutritional supplements.
Yet another object of the present invention is to provide a vitamin/mineral supplement in combination with aspirin for treating high risk pregnancies, with the aspirin useful for reducing the danger of eclampsia and pre-eclampsia.
Yet another object of the present invention is to provide a vitamin/mineral supplement in combination with aspirin, with the aspirin useful for reducing the danger of colorectal cancer.
A further object of the present invention is to provide a vitamin/mineral supplement in combination with aspirin for the combined effect of reducing fever, inflammation and/or pain while providing nutritional supplementation.
Another object of the present invention is to provide a vitamin/mineral supplement in combination with aspirin, with the aspirin useful for reducing the spread of viruses.
A further object of the present invention is to provide a vitamin/mineral supplement in combination with aspirin, with the aspirin useful for reducing heart attack damage, improving heart attack survival, reducing the incidence of second heart attacks and/or reducing death secondary to heart attacks.
Another object of the present invention is to provide a vitamin/mineral supplement in combination with aspirin, with the aspirin useful for reducing or preventing strokes and/or transient ischemic attacks.
A further object of the present invention is to provide a vitamin/mineral supplement in combination with aspirin, with the aspirin useful for reducing the likelihood and/or severity of migraine attacks.
Another object of the present invention is to provide a vitamin/mineral supplement in combination with aspirin, with the aspirin useful for reducing or preventing vascular dementia.
Yet another object of the present invention is to provide a vitamin/mineral supplement in combination with aspirin, with the aspirin useful for reducing the risk of cataract formation.
The foregoing and other objects, advantages and characterizing features will become apparent from the following description of certain illustrative embodiments of the invention.
The novel features which are considered characteristic for the invention are set forth in the appended claims. The invention itself, however, both as to its construction and its method of operation, together with additional objects and advantages thereof, will be best understood from the following description of the specific embodiments when read and understood in connection with the accompanying drawings. Attention is called to the fact, however, that the drawings are illustrative only, and that changes may be made in the specific construction illustrated and described within the scope of the appended claims.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
Various other objects, features and attendant advantages of the present invention will become more fully appreciated as the same becomes better understood when considered in conjunction with the accompanying drawings, in which like reference characters designate the same or similar parts throughout the several views.
FIG. 1 is the chemical structure for acetylsalicylic acid, also known as aspirin, the preferred vascular occlusion inhibitor in the composition of the present invention.
FIG. 2 is a diagrammatic view of various components which may find use in the present invention.
FIG. 3 is a chart illustrating various vitamins and minerals which can be effectively included in the composition of the present invention.
LIST OF REFERENCE NUMERALS USED IN THE DRAWING FIGURES
the chemical structure for acetylsalicylic acid (aspirin)
the phenyl ring which is the primary chemical moiety in acetylsalicylic acid 10
the carboxyl group attached to the phenyl group 12
the acetoxy group attached to the phenyl group 12, in the position ortho- to the carboxyl group 10
acetylsalicylic acid, the IUPAC name for aspirin 20
aspirin, the generic name for acetylsalicylic acid 18
a cardio/cerebrovascular patient care composition, the preferred utility for the compositions of the present invention
aspirin, the first major active component of the composition of the present invention
a plurality of vitamins, the second major active component of the composition of the present invention
one or more nutritional minerals, an optional minor component of the composition of the present invention
binder for holding the various components 24, 26, 28 together
fat-soluble vitamins which may be effectively employed in the compositions of the present invention
water-soluble vitamins which may be effectively employed in the compositions of the present invention
nutritional minerals which may be effectively employed in the compositions of the present invention
Vitamin A, including the retinoids and β-carotene
Vitamin D, actually a mixture of various sterols including ergocalciferol (vitamin D 2 ) and cholecalciferol (Vitamin D 3 )
Vitamin E, a mixture of various tocopherols and tocotrienols, of which d-α-tocopherol preferred
Vitamin K, including all compounds which exhibit a biological activity similar to that of phylloquinone
Vitamin C, also known as ascorbic acid
Vitamin B 1 , also known as thiamin
Vitamin B 2 , also known as riboflavin
Vitamin B 6 , the generic name for pyridoxine, its amine (pyridoxamine) and its aldehyde (pyridoxal)
Vitamin B 12 , also known as cyanocobalamin
niacin, the USP name for nicotinic acid, and its amide niacinamide (nicotinamide)
pantothenic acid
biotin
folic acid, also known as pteroylglutamic acid, or folate
selenium, an essential nonmetal mineral
zinc, an essential metal mineral
magnesium
calcium, an essential nonmetal mineral
iron, an essential metal mineral
manganese, a trace metal mineral
copper
chromium
cobalt
boron
phosphorus
iodine
potassium
molybdenum
vanadium
fluoride
chloride
nickel
tin
silicon
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Turning now descriptively to the drawings, in which similar reference characters denote similar elements throughout the several views, the Figures illustrate a vitamin supplement of the present invention.
With reference to FIG. 1, the preferred vascular occlusion inhibitor is aspirin (acetylsalicylic acid). The chemical structure of aspirin consists of a phenyl ring 12 substituted with a carboxyl group 14 and an acetoxy group 16, positioned ortho- to each other.
FIG. 2 illustrates, in general terms, various components which may be used in the compositions of the present invention, in this case illustrated as the specific embodiment of a cardio/cerebrovascular care composition 22. The composition contains the necessary components, vitamins 26 and a vascular occlusion inhibitor, in this case aspirin 24. Optional components include minerals 28 and binders 30, for example, when tablet form is desired.
FIG. 3 illustrates the various vitamins and minerals which can be effectively included in the compositions of invention. The vitamins can be divided into two broad groups, the fat-soluble 32 and the water-soluble 34 vitamins. Of the vitamins, vitamins A 38, D 40, E 42 and C 46 are preferred. Optionally, the composition can contain one or more minerals 36. Of the minerals, selenium 64, zinc 66, magnesium 68, calcium 70, iron 72, manganese 74, copper 76, chromium 78, potassium 88, nickel 98 and tin 100 are preferred, with selenium 64, zinc 66 and magnesium 68 most preferred. The compositions of the present invention are intended to include, without limitation, combinations of aspirin and vitamin(s), aspirin and mineral(s), and aspirin, vitamin(s) and mineral(s). As long as the composition contains at least one mineral or vitamin, all combinations of vitamins and/or minerals are within the scope of the present invention.
Platelet aggregation has been implicated in the process of thrombus formation, a contributor to vascular obstruction in humans. Thrombus formation involves a complex interaction of aggregated platelets and activated coagulation factors with a damaged vessel wall. Circulating platelets are normally nonadherent to endothelium or to each other, but when the endothelial lining of a vessel is damaged, the platelets adhere to exposed subendothelial collagen. This is the first step in the formation of hemostatic plugs, and requires participation of a protein made by endothelial cells called the von Willebrand factor (vWF). The vWF is found both in the vessel wall and in plasma, and binds during platelet adhesion to a receptor present on a glycoprotein of the platelet surface membrane.
Next, platelets are activated in reactions initiated by collagen and by thrombin formed at the injury site. These stimuli activate phospholipase C, an enzyme that hydrolyzes the membrane phospholipid, phosphatidyl inositol triphosphate. Products of this reaction activate protein kinase C and also increase the calcium concentration of platelet cytosol. As a result, a series of progressive, overlapping events ensue. The platelets change shape and develop long pseudopods. A receptor is assembled on the platelet surface membrane, and fibrinogen and other adhesive proteins bind to this receptor causing platelets to stick to each other. Arachidonic acid is liberated from membrane phospholipids and undergoes oxidation to products that include prostaglandin H 2 (PGH 2 ), which serves as an important cofactor for collagen-induced platelet activation, and thromboxane A 2 (TxA 2 ), which can act itself as as an additional platelet activator. The contents of platelets are secreted, including adenosine diphosphate (ADP) which can also stimulate platelet activation and recruit new platelets into the growing hemostatic plug.
After platelet aggregation, fibrinogen in the circulating blood is converted to fibrin to physically tie the hemostatic platelet plug in place. The platelet surface undergoes a reorganization that exposes procoagulant phospholipids needed for enzyme/cofactor complexes of blood coagulation to form on the platelet surface. Secretion of platelet factor V from platelet s-granules provides a key component for one of the enzyme/cofactor complexes. As a result, thrombin is generated in increasing amounts on the platelet surface, and converts fibrinogen into fibrin with the formation of fibrin strands that radiate outward from aggregated platelets helping to secure the platelet plug to the site of injury. Additionally, a mechanism within the platelets is activated which results in contraction of platelet actinomycin. This compresses and consolidates the platelet plug, further securing it to the site of injury.
In the in vivo regulation of thrombus formation, platelet aggregation is mediated by the PGH 2 derivative prostacyclin (PGI 2 ). Prostacyclin is also a vasodilator and is believed to render the vessel lining inert to platelet interactions. Thus, TxA 2 and PGI 2 have opposing physiological effects on platelet aggregation as well as on vascular caliber (TxA 2 induces vascular constriction while PGI 2 induces vascular dilation), and the degree of the physiological effect of each in the cardiovascular system on the regulation of thrombus formation and vascular caliber is determined primarily by their relative concentrations.
Accordingly, inhibition of platelet aggregation and vascular occlusion is a primary concern in cardiac and cerebrovascular care patients, both for treatment of, and prophylaxis of, thrombosis and vascular spasm. Cardiac care patients include, for example, potential and prior heart attack patients and potential and prior stroke patients. The most widely accepted substance for this purpose is aspirin (acetylsalicylic acid). In the arachidonic acid cascade, aspirin acts as a cyclooxygenase inhibitor, blocking the conversion of arachidonic acid to the PGH 2 precursor prostaglandin G 2 (PGG 2 ). Since PGG 2 is a precursor to both TxA 2 and PGI 2 , aspirin blocks both the aggregation inducing and aggregation inhibiting effects of these factors, respectively.
With regard to the amount of aspirin in the compositions of the inventions, a therapeutically effective and nontoxic amount can be readily determined by the ordinary skilled physician, with the precise amount depending on various factors, including, for example, size and health of the patient. Generally accepted values include from 0.5 mg of aspirin per Kg of body weight of the patient per day to 5 or more mg/Kg/a range most people, a range of from about 10 to about 1000 mg/day, and preferably from about 25 to about 500 mg/day, will often be appropriate, particularly in the range of from about 100 to about 250 mg/day. It is anticipated that the above-described aspirin concentrations will be most appropriate for use in compositions for treating cardio/cerebrovascular care patients. Aspirin is also well recognized to reduce fever, pain and inflammation. For use in fever reduction, pain control and inflammation reduction, concentrations will be somewhat higher.
With regard to the vitamins in the compositions of the present invention, this will also depend somewhat on the size, age, gender and health of the patient. Speaking generally, the vitamins will normally be from about 5% to about 1000% of the RDA for that vitamin, most often from about 25% to about 500% of the RDA. Of course, the RDA can vary considerably with the factors illustrated above. Almost any accepted vitamin may be included in the present compositions, for example, vitamins A, D, E, K, C, thiamin, riboflavin, niacin, niacinamide, B 6 , folate, B 12 , biotin and pantothenic acid can all be included. It is anticipated that the preferred vitamins will include, for example, vitamins A, D, E and C.
In general, the RDA for vitamin A will range from about 2000 International Units (IU) to about 5000 IU. The RDA for vitamin D will range from about 200 IU to about 400 IU. The RDA for vitamin E will range from about 5 IU to about 15 IU. The RDA for vitamin K will range from 5 μg to 80 μg. The RDA of vitamin C will range from about 30 mg to about 95 mg. The RDA for thiamin will range from about 0.3 mg to about 1.6 mg. The RDA for riboflavin will range from about 0.4 mg to about 1.8 mg. The RDA for niacin will range from about 5 mg to about 20 mg. The RDA for vitamin B 6 will range from about 0.3 mg to about 2.2 mg. The RDA for folate will range from about 25 μg to about 400 μg. The RDA for vitamin B-12 will range from about 0.3 μg to about 2.6 μg. There are no specific RDA levels for biotin and pantothenic acid. However a safe and adequate range for biotin is from 10 μg to 100 μg and an adequate range for pantothenic acid is 2 mg to 7 mg.
Vitamin A precursors (provitamin A, carotenoids) can also be used including β-carotene, α-carotene, cryptoxanthine and the like. The vitamin A esters and β-carotene are highly preferred forms of vitamin A. Vitamin D can be selected from, for example, cholecalciferol (D3), ergocalciferol (D2), and their biologically active metabolites and precursors such as, 1-α-hydroxy vitamin D, 25-hydroxy vitamin D, 1,25-dihydroxy vitamin D and the like. Vitamin D as cholecalciferol is highly preferred. d-α-Tocopherol and its esters are highly preferred as a source for vitamin E. Other sources of vitamin E include β-tocopherol, γ-tocopherol, the tocotrienols and their esters, tocopheryl nicotinate, and the like. Vitamin K can be selected from phylloquinone (K 1 ), menaquinone (K 2 ), menadione and their salts and derivatives. Vitamin K 1 , is highly preferred. It is noted, however, that vitamin K plays a role in clot formation and is known to interact with oral anticoagulant drugs to decrease their effect. Accordingly, for many utilities, vitamin K will not be used or will be present in low concentrations, as determined by individual patient need.
L-ascorbic acid is particularly preferred for the vitamin supplements of the present invention. However other forms of vitamin C, for example, L-ascorbic acid, D-ascorbic acid, DL-ascorbic acid, D-araboascorbic acid, dehydroascorbic acid, esters of ascorbic acid may also be used. The hydrochloride and nitrate salts of thiamin and thiamin alkyl disulfides such as the prophyidisulfide, tetrahydrofurfuryl disulfide, o-benzoyl disulfide can be used in the present invention. The hydrochloride and nitrate salts are highly preferred. The sources of riboflavin are selected, for example, from crystalline riboflavin coenzyme forms of riboflavin such as flavin adenine dinucleotide, flavin adenine mononucleotide, riboflavin 5'-phosphate and their salts. Riboflavin is highly preferred. For niacin they comprise, for example, nicotinic acid, nicotinamide (niacinamide), the coenzyme forms of niacin such as nicotinamide adenine dinucleotide, and nicotinamide adenine dinucleotide phosphate. Particularly preferred are nicotinamide and nicotinic acid. Vitamin B 6 can be selected from hydrochloride salts or 5'-phosphates of pyridoxine, pyridoxamine or pyridoxal. The preferred vitamin B 6 is pyridoxine hydrochloride. The folate can be in the form of folic acid, mono and polyglutamyl folates, dihydro and tetrahydro folates, methyl and formyl folates. Folic acid is a highly preferred form of folate. Sources of vitamin B 12 are, for example, cyanocobalamin, methylcobalamin, adenosylcobalamin, hydroxocobalamin and the like. Cyanocobalamin is highly preferred. Biotin for use in the vitamin and/or mineral supplements can be selected oxybiotin, biocytin, biotinol and the like. Biotin is highly preferred. For pantothenic acid the sources can be in the form of salts such as calcium pantothenate or as panthenol. Calcium pantothenate is a highly preferred source of pantothenic acid.
The optional mineral supplement component of the compositions of the present invention preferably comprises sources selected from calcium, phosphorus, magnesium, iron, zinc, iodine, selenium, copper, manganese, fluoride, chromium, molybdenum, potassium, and chloride. Additional minerals, though less preferred, include nickel, silicon, boron, tin, vanadium and cobalt. The minerals sources are preferably present in nutritionally relevant amounts, which means that the mineral sources used in the practice of this invention provide a nourishing amount of said minerals. Preferably, this amount comprises at least 5% of the RDA of these minerals, and more preferably, at least 10% of the RDA per unit dose of the finished supplement. Of course, it is recognized that the preferred daily intake of any mineral may vary with the user with greater than the RDA intakes being beneficial in some circumstances.
In general, the RDA for calcium will range from 400 mg for infants to 1200 mg for adults, depending somewhat on age. The RDA for phosphorus ranges from 300 mg to 1200 mg. The RDA for magnesium ranges from 40 mg to 400 mg. The RDA for iron ranges from 6 mg to 30 mg, depending somewhat on age and physiologic state. The RDA for zinc ranges from 5 mg to 19 mg. The RDA for iodine ranges for 40 μg to 200 μg. The RDA for selenium ranges from 10 μto 75 μg. There are no specific RDA levels for copper, manganese, fluoride, chromium, and molybdenum. However a safe and adequate range for copper is from 0.4 mg to 3.0 mg depending somewhat on age. An adequate range for manganese is 0.3 mg to 5.0 mg per day. A safe and adequate range for fluoride is 0.1 mg to 4.0 mg. A safe and adequate range from chromium is 10 μg to 200 μg. A safe and adequate range for molybdenum is 15 μg to 250 g. There are no specific RDA levels for potassium and chloride, but the estimated minimum requirement of potassium is from 500 to 2000 mg/day for adults and the estimated minimum requirement of chloride is from 180 mg for infants to 750 mg/day for adults.
Specific dietary allowances and estimated safe minimum requirements for nickel, silicon, boron, tin, and vanadium have not been established in humans. However, there is evidence of their function in other mammals and thus, possibly for humans as well. For cobalt, the known nutritional function is as part of cyanocobalamin (vitamin B 12 ). The supplement composition comprising use of any of these latter minerals should employ levels known to be safe without risk of toxicity.
The source of the mineral salt, both those with established RDA levels or with safe and adequate intake levels, as well as those with no as yet established human requirement, used in the practice of this invention can be any of the well known salts including carbonate, oxide, hydroxide, chloride, sulfate, phosphate, gluconate, lactate, acetate, fumarate, citrate, malate, amino acids and the like for the cationic minerals and potassium, calcium, magnesium and the like for the anionic minerals. However, the particular salt used and the level will depend upon their interaction with other supplement ingredients.
It will be understood that each of the elements described above, or two or more together, may also find a useful application in other types of applications differing from the type described above. These include, for example, cardiac care, myocardial infarction, transient ischemic attacks, strokes, blood clots, colorectal cancer, migraines, cataracts, immunity, Alzheimer's disease, arthritis, fever, pain, inflammation, pre-eclampsia and eclampsia.
While the invention has been illustrated and described as embodied in a disposable, absorbent article, it is not intended to be limited to the details shown, since it will be understood that various omissions, modifications, substitutions and changes in the forms and details of the formulation illustrated and in its operation can be made by those skilled in the art without departing in any way from the spirit of the present invention.
Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can, by applying current knowledge, readily adapt it for various applications without omitting features that, from the standpoint of prior art, fairly constitute essential characteristics of this invention.
What is claimed as new and desired to be protected by Letters Patent is set forth in the appended claims: | The present invention relates to a vitamin supplement containing from 5% to 1000% of the RDA of vitamins and a therapeutically effective amount of a vascular occlusion inhibiting compound which is preferably aspirin (acetylsalicylic acid). The vitamins are selected from vitamins A, D; E, K, C, thiamin, riboflavin, niacin, niacinamide, B 6 , folate, B 12 , biotin, pantothenic acid and mixtures thereof. The composition can be in capsule or tablet form, may further contain minerals, herbal extracts, homeopathics or other therapeutic substances, and finds particular utility with regard to cardiac care patients. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a high-performance carry lookahead adder (CLA) using an NMOS logic circuit.
2. Description of the Related Art
A microprocessor unit (MPU) is the core component used in personal computers, workstations, and various controller boards, and controls the function of a system by performing software. The core executing component of the MPU or microcontroller unit (MCU) is an arithmetic logic unit (ALU) for executing arithmetic operations, and the representative functional device of the ALU is an adder. Accordingly, implementation of a high-speed adder forms the basis of the construction of a high-speed MPU. The present invention is also applied to custom semiconductor integrated circuits having the MCU or ALU function.
First, the construction of a typical adder is explained. A half adder for performing a binary addition of data a and data b is illustrated in FIG. 1, whose functions are represented as S(sum)=a⊕b, C (carry)=a·b (Hereinafter, the added sum is referred to as "S", and the carry is referred to as "C".). FIG. 2 illustrates the construction of a full adder which can execute operations of carry inputs, and whose functions are represented as if P(i)=a(i)⊕b(i), G(i)=a(i)·b(i), then S(i)=P(i)⊕C(i), and C(i+l)=G(i)+P(i)·C(i).
FIG. 3 illustrates the construction of a 4-bit full adder which is composed of 4 full adder blocks. If the delay of a full adder is Δ, S(1), S(2), S(3), and S(4) have the delays of 1Δ, 2Δ, 3Δ, and 4Δ, respectively, resulting in that C(5) has the delay of 4Δ. Accordingly, if a 32-bit adder is constructed using the above full adders, it has the delay of 32Δ, and this causes the implementation of a high-speed adder to be impossible.
In order to solve this problem, a carry lookahead type adder has been developed, whereby an exclusive-OR value P(i) and a logic product value G(i) are produced from 3-bit data a 3:0! and b 3:0!, and then the sum S(i) and the carry C(i) are produced by logically combining P(i) and G(i). The carry C(i) is given as:
C(2)=G(1)+P(1)·C(1)
C(3)=G(2)+P(2)·C(2)=G(2)+P(2)·G(1)+P(2)·P(1).multidot.C(1)
C(4)=G(3)+P(3)·G(2)+P(3)·P(2)·G(1)+P(3).multidot.P(2)·P(1)·C(1)
C(5)=G(4)+P(4)·G(3)+P(4)·P(3)·G(2)+P(4).multidot.P(3)·P(2)·G(1) +P(4)·P(3)·P(2)·P(1)·C(1).
The above equations can be effected by a logic circuit of FIG. 4. Referring to the circuit of FIG. 4, the 4-bit full adder, which accompanied the delay of 4Δ, has been improved into a circuit capable of obtaining the same result through several logics.
However, the conventional logic circuit has the disadvantage that a carry generator used therein is constructed by CMOS logics using basic gates, and thus it produces a large amount of delay. As a result, the conventional logic circuit has a speed faster than that of the full adder, but it is still unsuitable for achieving a high-speed operation of several hundred MHz.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a high-performance carry lookahead adder (CLA) which can reduce the delay time of the whole adder by constructing a carry generator used therein with NMOS logics, thereby enabling a high-speed operation of a processor.
It is another object of the present invention to provide a carry lookahead adder which can effect a low power-consumption by reducing a static current flowing therethrough along with its high-speed operation.
Generally, an NMOS circuit is more advantageous than a CMOS circuit in operating speed, but it has disadvantageous characteristics in current consumption, noise margin, etc. However, since the speed of the whole MPU can be increased if NMOS logics are used in a unit where a high-speed operation is required, such as the arithmetic logic unit (ALU), a carry generating circuit employing such NMOS logics is used for constructing a 4-bit CLA. Also, the NMOS logics are used in constructing a high-performance ALU employing a 64-bit or 32-bit CLA circuit, and the CMOS logics are constructed as composite circuits, being not constructed with basic gates, resulting in the increase of the operating speed.
In one aspect of the present invention, there is provided a carry lookahead adder having a carry generator for receiving an exclusive-OR value P(i,i=1,2,3,4) and a logic product value G(i) of two data having predetermined bits, and an initial carry value C(1), and performing a function of G(4)+P(4)·G(3)+P(4)·P(3)·G(2)+P(4)·P(3)·P(2)·G(1)+P(4)·P(3)·P(2)·P(1)·C(1) to output a final carry value C(5), the carry generator for outputting the final carry value C(5) comprising:
a first NMOS transistor, connected between G(3) and a ground level, for receiving P(4) through its gate to execute an operation of P(4)·G(3);
second and third NMOS transistors, connected in parallel between G(2) and the ground level, for receiving P(3) and P(4) through their gates, respectively, to execute an operation of P(4)·P(3)·G(2);
fourth, fifth, and sixth NMOS transistors, connected in parallel between G(1) and the ground level, for receiving P(2), P(3), and P(4) through their gates, respectively, to execute an operation of P(4)·P(3)·P(2)·G(1);
seventh, eighth, and ninth NMOS transistors, connected in parallel between P(1) and the ground level, for receiving P(2), P(3), and P(4) through their gates, respectively, to execute an operation of P(4)·P(3)·P(2)·P(1)·C(1), and tenth and eleventh NMOS transistors, connected in series between G(4) and the ground level, for receiving C(1) and P(1) through their gates, respectively; and
twelfth, thirteenth, and fourteenth NMOS transistors, connected in parallel between G(4) and the ground level, for receiving G(1), G(2) and G(3) through their gates, respectively, to output C(5) by an OR operation of the respective logic product terms.
In another aspect of the present invention, there is provided a carry lookahead adder having a carry generator for receiving an exclusive-OR value P(i, i=1, 2, 3) and a logic product value G(i, i=1, 2, 3) of two data having predetermined bits, and an input carry value C(1), and performing a function of G(3)+P(3)·G(2)+P(3)·P(2)·G(1)+P(3)·P(2)·P(1)·C(1) to output a following bit carry value C(4) of a most significant bit carry, the carry generator for outputting the carry value C(4) comprising:
a first NMOs transistor, connected between G(2) and a ground level, for receiving P(3) through its gate to execute an operation of P(3)·G(2);
second and third NMOS transistors, connected in parallel between G(1) and the ground level, for receiving P(2) and P(3) through their gates, respectively, to execute an operation of P(3)·P(2)·G(1);
fourth and fifth NMOS transistors, connected in parallel between P(1) and the ground level, for receiving P(2) and P(3) through their gates, respectively, to execute an operation of P(3)·P(2)·P(1)·C(1), and sixth and seventh NMOS transistors, connected in series between G(3) and the ground level, for receiving C(1) and P(1) through their gates, respectively; and
eighth and ninth NMOS transistors, connected in parallel between G(3) and the ground level, for receiving G(1) and G(2) through their gates, respectively, to output C(4) by an OR operation of the respective logic product terms.
BRIEF DESCRIPTION OF THE DRAWINGS
The above objects, other features, and advantages of the present invention will become more apparent by describing the preferred embodiments thereof with reference to the accompanying drawings, in which;
FIG. 1 is a schematic circuit diagram of a typical half adder.
FIG. 2 is a schematic circuit diagram of a typical full adder.
FIG. 3 is a block diagram of a typical 4-bit full adder.
FIG. 4 is a logical circuit diagram illustrating the carry generator employed in a carry lookahead adder.
FIG. 5 is a schematic circuit diagram of a typical 4-bit carry lookahead adder.
FIG. 6 is a schematic circuit diagram of the Cout generator of FIG. 5 according to an embodiment of the present invention.
FIG. 7 is a schematic circuit diagram of the g4-adder of FIG. 5 according to an embodiment of the present invention.
FIG. 8 is a conceptional view explaining the leakage current problem caused by the circuit of FIG. 6.
FIG. 9 is a schematic circuit diagram of the Cout generator of FIG. 5 according to another embodiment of the present invention.
FIG. 10 is a timing diagram illustrating respective control signals and a carry output signal appearing at various points of FIG. 9.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The embodiments of the present invention will be explained in detail with reference to FIGS. 5 to 10.
FIG. 5 is a block diagram illustrating the construction of a typical 4-bit carry lookahead adder (CLA).
Referring to FIG. 5, respective gp-adders 10 receive data a 3:0! and b 3:0!, and generate exclusive-OR terms P(i) and logic product terms G(i), respectively. Carry generators, i.e., g2-adder 21, g3-adder 22, g4-adder 23, and Cout generator, generate carry outputs C(2), C(3), C(4), and C(5), respectively. An exclusive-OR (XOR) gate 30 generates a SUM 3:0!.
The g2-adder 21 and the g3-adder 22 for generating C(2) and C(3), respectively, among the carry generators may be constructed with composite CMOS logics to improve their operating speed. However, if the g4-adder 23 and the Cout generator 24 for generating C(4) and C(5), respectively, are constructed with the same composite CMOS logics, the amount of delay becomes greater than that of a circuit employing simple basic gates due to the serial delay of the NMOS logics and the serial delay of the PMOS logics.
At this time, since the delays of the terms SUM 3:0! are increased in the order of SUM 3!, SUM 2!, SUM 1!, and SUM 0!, the term SUM 3! corresponds to the critical path. In case of a 32-bit adder, the carry output C(5) will correspond to the utmost critical path.
According to the present invention, NMOS logics are employed in the g4-adder 23 and the Cout generator 24 for generating C(4) and C(5), respectively, and thus the delay of the whole critical path of the adder is reduced, resulting in the improvement of the whole operating speed.
Specifically, the g2-adder 21 and the g3-adder 22 among the carry generators are constructed with composite CMOS logics, while the g4-adder 23 and the Cout generator 24 are constructed with the NMOS logics.
FIG. 6 is a schematic circuit diagram of the Cout generator 24 for generating the final carry C(5). The Cout generator 24 performs a function of C(5)=G(4)+P(4)·G(3)+P(4)·P(3)·G(2)+P(4).multidot.P(3)·P(2)·G(1)+P(4)·P(3)·P(2).multidot.P(1)·C(1).
Referring to FIG. 6, the Cout generator 24 includes an NMOS transistor N88, connected between G(3) and a ground level line GND, for receiving P(4) through its gate to execute an operation of P(4)·G(3), NMOS transistors N86 and N87, connected in parallel between G(2) and the ground level line GND, for receiving P(3) and P(4) through their gates, respectively, to execute an operation of P(4)·P(3)·G(2), and NMOS transistors N83, N84, and N85, connected in parallel between G(1) and the ground level line GND, for receiving P(2), P(3), and P(4) through their gates, respectively, to execute an operation of P(4)·P(3)·P(2)·G(1). The operation of P(4)·P(3)·P(2)·P(1)·C(1) is performed by NMOS transistors N80, N81, and N82, connected in parallel between P(1) and the ground level line GND, for receiving P(2), P(3), and P(4) through their gates, respectively, and NMOS transistors N46 and N76, connected in series between G(4) and the ground level line GND, for receiving C(1) and P(1) through their gates, respectively. The detailed explanation of the NMOS transistor 46 will follow hereinafter.
If the respective logic product terms are generated as described above, an OR operation of the product terms and G(4) should be performed to output C(5). This OR operation is performed by the NMOS transistors N46 and N76, N77, N78, and N79, which are connected in parallel between G(4) and the ground level line GND, for receiving C(1), P(1), G(1), G(2), and G(3) through their gates, respectively. The NMOS transistor N46 is connected to the NMOS transistor N76 in series, so that the NMOS transistor N46 is firstly turned on by C(1) which is inputted most rapidly to achieve the high-speed operation.
The operation of the carry generator as constructed above will now be explained.
The respective product terms are applied to the respective gates of the NMOS transistors N77, N78, N79, N76, and N46. If any one of the product terms has a logic level "1", the G(4) input signal goes to a logic level "0", and the final carry signal C(5) has an inverted logic value of a node 1. That is, the logic value on the node 1 is inverted by an inverter I20 to be sensed as the final carry signal C(S). The role of the respective elements are as follows:
The NMOS transistors N46 and N76 connected in series are used for generating the term of P(4)·P(3)·P(2)·P(1)·C(1). Nodes 6 and 2, which are input terminals of the NMOS transistors N46 and N76, generates C(1) and P(4)·P(3)·P(2)·P(1). The node 2 becomes "1" when all of P(1), P(2), P(3), and P(4) are "1". The node 1 becomes "0" when both the node 6 and node 2 are "1", while it will be a `Don't Care` term otherwise.
A node 3 becomes "1" when all of P(4), P(3), P(2), and G(1) are "1". Thus, the node 1 becomes "0" when the node 3 is "1", while it will be a `Don't Care` term otherwise.
A node 4 becomes "1" when all of P(4), P(3), and G(2) are "1". Thus, the node 1 becomes "0" when the node 4 is "1", while it will be a `Don't Care` term otherwise.
A node 5 becomes "1" when both P(4) and G(3) are "1". Thus, the node 1 becomes "0" when the node 5 is "1", while it will be a `Don't Care` term otherwise.
As a result, the function of C(5)=G(4)+P(4)·G(3)+P(4)·P(3)·G(2)+P(4).multidot.P(3)·P(2)·G(1)+P(4)·P(3)·P(2).multidot.P(1)·C(1) can be performed to output the final carry signal Cout.
Here, the logic levels of "1" and "0" do not actually represent a supply voltage Vdd and the ground voltage GND. The voltage on the node 1 varies analogically due to the current paths formed by the PMOS inverter which follows the node 1 and the NMOS transistors N77, N78, N79, N49, and N76. The same explanation can be applied to the nodes 2, 3, 4, and 5.
The above-described circuit generally represents a simulation result that the operating speed thereof is faster than that of the conventional CMOS circuit in a similar manner as the precharged NMOS logic circuit.
FIG. 7 is a schematic circuit diagram of the g4-adder 23 for outputting the bit carry signal C(4) following the most significant bit carry signal. The g4-adder 23 performs a function of C(4)=G(3)+P(3)·G(2)+P(3)·P(2)·G(1)+P(3).multidot.P(2)·P(1)·C(1).
Referring to FIG. 7, the g4-adder 23 includes an NMOS transistor N24, connected between G(2) and the ground level GND, for receiving P(3) through its gate to execute an operation of P(3)·G(2), NMOS transistors N22 and N23, connected in parallel between G(1) and the ground level GND, for receiving P(2) and P(3) through their gates, respectively, to execute an operation of P(3)·P(2)·G(1), NMOS transistors N20 and N21, connected in parallel between P(1) and the ground level, for receiving P(2) and P(3) through their gates, respectively, to execute an operation of P(3)·P(2)·P(1)·C(1), and NMOS transistors N16 and N36, connected in series between G(3) and the ground level, for receiving C(1) and P(1) through their gates, respectively.
If the respective logic product terms are generated, an OR operation of the product terms and G(3) should be performed to output C(4). This OR operation is performed by the NMOS transistors N16 and N36, N37, and N38, connected in parallel between G(3) and the ground level, for receiving C(1), P(1), G(1), and G(2) through their gates, respectively. An inverter I20 connected to the output terminal of the carry signal C(4) inverts the carry signal C(3) to sense the inverted value of the carry signal C(4).
The operation of the g4-adder 23 as constructed above is similar to that of the circuit of FIG. 6, and thus the detailed explanation thereof will be omitted.
However, according to this circuit, a static current loss is produced in the event that G4="1", P1="1", G1="0", G2="0", G3="0", and C1="1", P2="0", P3="0", P4="0". Specifically, as shown in FIG. 8, by making α=0, and β=1, the condition that current flows constantly from the supply voltage line Vdd to the ground voltage line GND is imposed.
FIG. 9 is a schematic circuit diagram of the Cout generator which is proposed to prevent the above-described static current loss according to another embodiment of the present invention.
According to the Cout generator of FIG. 9, a NAND gate 1100 for NAND-gating a clock signal and an adder enable signal, and CMOS inverters which substitute the input-stage inverters I2, I4, I5 to I10 of FIG. 6 are constructed. Additionally, PMOS transistors 1101 to 1105, connected between the supply voltage and pull-up PMOS transistors, for receiving the output of the NAND gate 1100 are constructed. Also, on the output terminal of the Cout generator is additionally constructed a bus keeper B10 including an inverter I30, which latches the output terminal along with the inverter I20 in accordance with a latch enable signal Lach -- en, to heighten the driving force of the bus. The bus keeper B10 comprises a transmission gates 1106 and 1107 for receiving the latch enable signal Lach -- en through their gates, and the inverter I30 coupled to the input and output terminals of the inverter I20 through the transmission gates 1106 and 1107.
FIG. 10 is a timing diagram illustrating the respective control signals, i.e., the clock signal CLK, the adder enable signal ADD -- en, the latch enable signal Lach -- en, and the final carry signal C(5).
The additionally constructed PMOS transistors 1101, 1102, 1103, 1104, and 1105 in FIG. 9 are controlled by the clock signal and the adder enable signal ADD -- en. When both the clock signal and the adder enable signal become `high`, the PMOS transistors are turned on and provide the supply voltage to the CMOS inverters, thereby solving the above-described leakage current problem. Also, the transmission gates 1106 and 1107 are turned on only when the latch enable signal Lach -- en becomes `high`, and at this time, the final carry signal C(5) is outputted.
The carry generating circuit of FIG. 9 generates the carry signal at the same operating speed as the carry generating circuit of FIG. 6, but reduces its power consumption by 1/2 in comparison with the circuit of FIG. 6. Since in an idle state, the DC current flowing through the carry generating circuit of FIG. 9 becomes almost zero, the carry generating circuit can be efficiently used in the chip such as a CPU which consumes much power.
The circuit for generating the carry signal C(4) which follows the most significant bit carry as shown in FIG. 7 can also employ the PMOS transistors which are connected to the input-stage inverters and are controlled by the NOR gates, and the latches which are connected to the output terminal of the circuit, to achieve a low power-consumption.
As described above, according to the present invention, the carry generators having the largest delay time in performing 4-bit addition are implemented using NMOS logics, and thus a high-speed operation of the adder can be obtained. Further, by adding a dynamic circuit, a static current flowing through the adder is reduced to effect a low power-consumption. Furthermore, implementation of a high-speed ALU becomes possible by applying the present invention to a 32-bit or 64-bit carry lookahead adder.
While the present invention has been described and illustrated herein with reference to the preferred embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention. | A high-performance carry lookahead adder (CLA) which can reduce the delay time of the whole adder by constructing a carry generator used therein with NMOS logics, thereby effecting a high-speed operation of the adder along with a lower power-consumption. The carry generator receives an exclusive-OR value P(i, i=1,2,3,4) and a logic product value G(i) of two data, and an initial carry value C(1), and performs a function of G(4)+P(4)·G(3)+P(4)·P(3)·G(2)+P(4)·P(3)·P(2)·G(1)+P(4)·P(3)·P(2)·P(1)·C(1) to output a final carry value C(5). The carry generator includes a first NMOS transistor for executing an operation of P(4)·G(3), second and third NMOS transistors for executing an operation of P(4)·P(3)·G(2), fourth to sixth NMOS transistors for executing an operation of P(4)·P(3)·P(2)·G(1), seventh to eleventh NMOS transistors for executing an operation of P(4)·P(3)·P(2)·P(1)·C(1), and twelfth to fourteenth NMOS transistors for outputting the final carry signal C(5) by an OR operation of the respective logic product terms. | 6 |
BACKGROUND OF THE INVENTION
The present invention relates to the production of wood pulp by the green liquor semi-chemical pulping method. Green liquor semi-chemical pulping is a two-stage process. It uses green liquor cooking to soften the wood chips and mechanical refining to disintegrate the cooked chips into individual fibers. The present invention utilizes surface active agents having the following general structure: ##STR2## wherein a, b, and c are at least 1 but are such to produce an agent having a molecular weight of 500 to 30,000 with those having a molecular weight of 1,000 to 10,000 being preferred. The surface active agent is added during the green liquor semi-chemical pulping process.
Green liquor typically consists of Na 2 S, Na 2 CO 3 , and water. It is used to weaken the intercellular bonding by partial removal of hemicellulose and lignin. The more green liquor that is used, the more hemicellulose and lignin are removed, resulting in less mechanical energy required to refine the cooked chips. This energy savings is counter-balanced because the more hemicellulose and lignin that are removed, the lower the pulp yield. Conversely, the less green liquor used, the more mechanical energy is required and the higher the pulp yield. It is an object of this invention to increase the pulp yield by reducing the green liquor amount without increasing the mechanical energy.
U.S. Pat. No. 3,909,345 discusses and claims the use of surface active agents having the general formula:
R[(C.sub.2 H.sub.4 O)n (C.sub.3 H.sub.6 O)m)]y H
as additives to sulfate cooking liquor aids for the purpose of obtaining higher yields of pulp from a given wood chip charge. These agents permit a greater effectiveness of the cooking process relative to chips which prior to that invention were considered rejects and not pulpable.
While there is a degree of similarity between the invention of the '345 patent and that of the present inventors, the similarities cease as regards to the type of surface active agent utilized and the type of pulping process utilized.
The present invention utilizes surface active agents having the general structure: ##STR3## wherein a, b, and c are at least 1 but are such to produce an agent having a molecular weight of 500 to 30,000 with those having a molecular weight of 1,000 to 10,000 being preferred.
The green liquor semi-chemical pulping process differs from the kraft or sulfate pulping process described in the '345 patent. The kraft pulping process is a wholly chemical approach to pulping. Through the use of heat, pressure and chemicals the wood chips are disintegrated into fibers by cooking for about one hour for eventual use as linerboard for example. The typical chemicals utilized are sodium hydroxide (NaOH) and sodium sulfide (Na 2 S). In contrast, green liquor semi-chemical pulping is a two step process. The wood chips are first softened by the chemical processing involving about a twenty (20) minute cooking time then the softened wood chips are fiberized utilizing mechanical energy for eventual use as corrugated medium in boxboard for example. The typical chemicals comprising the green liquor which is used for softening the wood chips are sodium carbonate (Na 2 CO 3 ) and sodium sulfide (Na 2 S).
DESCRIPTION OF THE INVENTION
The present invention utilizes surface active agents having the general structure: ##STR4## wherein a, b, and c are at least but are such to produce an agent having a molecular weight of 500 to 30,000 with those having a molecular weight of 1,000 to 10,000 being preferred.
As with the '345 patent, the present surface active agents or combination thereof may be added to the green liquor prior to contact of such with the chips in an amount of about 0.001 to 1% based upon the dry weight of the wood chips. Preferably about 0.01 to 0.5% of the surface active agents based upon the dry weight of the wood chips is added to the green liquor. The surface active agents used in accordance with the present invention are available from BASF Wyandotte Corp., under trade names such as Pluronic L-62, L-92 and F-108.
The present invention is particularly suitable in green liquor semi-chemical pulp production by reducing the use of cooking liquor and amount of refining and increasing the yield from the pulping process.
From the available literature on the Pluronics, it was determined that:
L-62 had a molecular weight of approximately 2,188 and was composed of approximately 20% (CH 2 CH 2 O) and approximately 80% ##STR5## L-92 percentages were respectively about 20% and 80% with a molecular weight of 3,440; and
F-108 had percentages of 80% and 20% respectively with a molecular weight of 16,250.
In semi-chemical pulping, the pulping process is usually terminated when the amount of rejects in the pulp is reduced to an acceptable level. Substantial yield and quality advantages can be obtained when chips are processed to a higher lignin content.
Substantial economic benefits can be realized if increased yield can be accomplished while decreasing the amount of refining energy and decreasing the amount of green liquor utilized.
EXPERIMENTAL
The following mill study and results demonstrate the effectiveness of certain surfactants and blends thereof as pulping additives during green liquor semi-chemical pulping.
A semi-chemical pulp mill using waste kraft paper and semi-chemical pulp to manufacture corrugated medium will spend $140/ton and $55/ton, respectively on these two furnishes. For this reason there is a strong economical incentive to increase the use of semi-chemical pulp. The semi-chemical pulp mill was designed to process 500 tons/day but is used to process 550-575 tons/day and consequently, is short of cooking liquor. The mill uses green liquor to cook the chips for about 22.5 minutes. The cooked chips are then refined and washed.
A product comprised on an active basis of an aqueous solution containing 10% Pluronic L-62 and 7-1/2% Pluronic F-108 was added to the wood chips prior to cooking at a rate of about 2 lb/ton based on the pulp production. The mill produced green liquor semi-chemical pulp utilizing wood chips being pulped at the following conditions.
Cooking time: about 22.5 minutes
Cooking temperature: about 250° F.-350° F.
Green liquor: about 160 gal/min
Chips: about 670 tons/day at 45% moisture
At 2.62 horsepower day (HPD)/ton, the typical refining energy of the mill, the percentage of rejects before treatment with the composition of the present invention was 8.7%. After treatment with the present invention the percentage of rejects was 7.2%. This 1.5% reject reduction based on pulp was equivalent to a 17% reduction based on rejects.
The lower reject levels indicated that the chips were better penetrated by green liquor.
The refining energy at both pulp mill and paper mill was lower during the trial.
______________________________________ Pulp Paper Mill + Mill = Overall______________________________________Pre-Trial 2.62 7.39 10.01Trial 2.35 5.61 7.96Difference 2.05 HPD/ton______________________________________
The refining energy saving of 2.05 HPD/ton was estimated to be about $300,000/year.
The refining energy reduction was another indication that the chips were better penetrated by the green liquor.
Since chips were better penetrated by the green liquor, the green liquor dosage was reduced by 5 gal/min. The 5 gal/min reduction was equivalent to 3% of the overall green liquor dosage.
The reduction of the green liquor dosage resulted in increasing the yield from 72.7 to 75.1% based on oven dried weight of the chips. The yield increase was estimated to be 6,454 tons of pulp per year.
The 5 gal/min green liquor reduction was equivalent to a savings of 2.5 million gal/year.
In summary, the addition of the present invention reduced the use of cooking liquor and refining energy, and increased the yield of the green liquor semi-chemical pulping.
While this invention has been described with respect to particular embodiments thereof, it is apparent that numerous other forms and modifications of this invention will be obvious to those skilled in the art. The appended claims and this invention generally should be construed to cover all such obvious forms and modifications which are within the true spirit and scope of the present invention. | The present invention is directed to the use of certain ethoxylated compounds to increase the yield of green liquor semi-chemical pulping processes, the compound have the following structures: ##STR1## | 3 |
CROSS-REFERENCE TO RELATED APPLICATION(S)
This application is a continuation-in-part of U.S. patent application Ser. No. 11/566,306 filed Dec. 4, 2006, now U.S. Pat. No. 7,510,025 which is a continuation-in-part of U.S. patent application Ser. No. 10/622,710 filed Jul. 18, 2003, now abandoned the entire disclosure of each of which is hereby incorporated by reference herein for all purposes.
FIELD OF THE INVENTION
This invention concerns apparatus for drilling laser guided microbore tunnels and particularly a bore head for such apparatus.
BACKGROUND OF THE INVENTION
In our application Ser. No. 11/566,306 being a c-i-p of Ser. No. 10/622,710, we describe microbore operations which create horizontal bores 2-6 m below ground for the introduction of pipes from 300-600 mm in diameter. These bring services such as sewerage, mains water, mains gas and the like to buildings where the runs are short but perhaps crowded such as suburban housing or industrial estates.
The operation is preceded by the selection of an on-ground direction between two sites. A pit is excavated at each site and a laser is used to indicate the direction below ground level. Inclination of the beam then follows to ensure appropriate fall. Meanwhile a concrete base is cast on the pit floor or timbers are laid and the pit wall which is to receive the bore is faced with concrete and a circular aperture is formed in the wall using a plug.
The drilling platform is lowered on to the base and a target on the shaft of the bore head and platform are aligned as a unit with the laser spot. The platform is secured in the pit using peripheral jacks and the ancillary services such as hydraulic power and mains water and vacuum operation are brought to the pit.
The specification proposes various improvements to the equipment. In our co-pending Australian Application No. 2006907085 we describe ancillary equipment with which the platform and bore head of this invention are intended to be used.
In our Australian Patent No. 2003262292 we describe a bore head in which a pair of rams disposed radially at 90° to each other. These are attached to the cylindrical wall of the bore head and are grouped at the leading end in order to provide the requisite steering movement, namely 15 mm either side of centre, while it would be preferable to place the target as close to the cutter as possible to give to the operator the truest possible picture of the drilling axis, the rams prevent this and the target therefore placed in front of the rams. While the operator had a good view of the laser spot on the target, the adjustment of the drilling axis would frequently result in oversteer.
SUMMARY OF THE INVENTION
This invention concerns a boring head for laser guided drilling microbore tunnels using a liquid stream to remove soil, and an airstream to remove the soil and liquid mix, comprising a substantially cylindrical body with a leading end wall and a trailing end wall, an axial wall dividing the body into a component compartment and a flow compartment, the component compartment housing a steerable boring shaft which projects through the leading end wall to support a cutter a shaft bearing fixed to the axial wall near the trailing end, a liquid path through at least part of the shaft which exits beyond the leading end wall, a laser target mounted on the shaft close to the leading end wall and the cutter, and a camera mounted on the axial wall for shooting the target, the shaft being steered by rams mounted on the axial wall and acting at 90° to each other, up and down steering being provided by a first ram acting substantially parallel to the shaft and side to side steering being provided by a second ram acting transversely to the shaft, a passage through the flow compartment for liquid and air mix, a passage through the flow compartment for air.
The bearing may be a thrust bearing and the bearing housing may be bolted to the base. This housing may have an inlet which connects to the incoming water supply to form the slurry and an outlet which feeds water to the shaft interior. The ram mounts may be frames of inverted U-shape fixed to the base. The valve components which supply fluid to the rams may be arranged alongside the shaft so as to be accessible for servicing. Similarly the camera may be mounted on a stand fixed to the base.
When the components are grouped on a base, the attendant pipes and cables are easier to route and keep out of the way of the laser beam which must hit the target fixed to the shaft near the leading end thereof.
The end walls of the head may be semi-circular having a circular central major passage for return air and slurry and two minor passages parallel thereto of a cross-section which in total exceeds the cross-section of the major passage.
The central vacuum passage preferably ends in a coupling capable of connection to a pipe string which extends along the bore to the platform part and thence to the vacuum tank above the pit.
The bore head may be prepared for use by attaching to the base a semi-cylindrical cover with semi-circular end walls. The cover is removable for cleaning and servicing.
The bore head may be pushed by a carriage riding on a platform and may take drive from a motor mounted in the carriage in known manner.
The platform may have a pair of polished rails and the carriage may have a pair of slides for engaging the rails. The slides may each have a groove therein of keyhole section adapted to partially encompass the rail and minimise the lost motion.
The platform may have a pair of ram assemblies for advancing and retracting the carriage, each assembly comprising a pair of ganged rams, one extending in the bore direction and one in the reverse direction.
The drive from the motor to the bore head may include a universal coupling. The coupling is preferably sited close to the carriage. A universal coupling inside the bore head allows the cutter shaft to waggle and respond to steering forces selected by the operator.
The drive output from the motor may include a socket for receiving the ends of the rods which compose the string and the socket is spring loaded. This facilitates the coupling and uncoupling of the drill rods which is ongoing throughout the drilling operation.
BRIEF DESCRIPTION OF THE DRAWINGS
One embodiment of the invention is now described by way of example with reference to the accompanying drawings, in which:
FIG. 1 is a perspective of the platform and bore head with the cover removed for clarity.
FIG. 2 is an end view of the platform including the reel looking towards the bore.
FIG. 3 is an end view of the bore head showing the passages.
FIG. 4 is a partial section of the drill rod.
FIG. 5 is a plan view of variant of the bore head.
FIG. 6 is a side view of the variant of the bore head of FIG. 4 .
FIG. 7 is a schematic showing the hydraulic and electrical pathways.
DETAILED DESCRIPTION
Platform
Referring now to the drawings, especially FIGS. 1 and 2 , the platform bearers 2 are mutually connected by zig zag ties 4 . The bearers are of C-shaped cross-section and are directionally positioned in the pit 6 by L-section thrusters 8 . The bearers each support a stainless steel rail 10 of keyhole section. Carriage 12 extends across the width of the platform with a floor 14 on which is mounted a hydraulic drive assembly 16 .
The front end of the carriage has an upstanding pair of brackets 18 . A corresponding pair of brackets 20 extends from the rear of the platform. The cylinders of a pair of carriage rams 22 are connected side by side to the carriage. The connecting rods point in mutually opposite directions and react against brackets 18 and 20 thereby doubling the stroke of the rams. The platform rides on slides 24 ( FIG. 2 ) which embrace the rails and ensure accurate linear motion.
The drive assembly comprises hydraulic motor 26 which delivers rotation to coupling 28 through drive guard 30 . The guard 30 has laser window 32 through which laser generator 34 directs a beam. Beneath coupling 28 is vacuum spigot 36 which projects towards the bore. Spigot 36 leads to vertical, rigid vacuum tube 38 to which a flexible vacuum tube (not shown) is attached. The flexible tube carries drilling slurry to ancillary apparatus described in co-pending Application No. 2006907085.
The water from the slurry is obtained from an onsite piped supply. It is brought into the pit by a hose (not shown) which is coiled on reel 40 mounted above the drive assembly. As the drilling proceeds, the hose pays out and follows the boring head.
The drive coupling 28 has a spring loaded hexagonal socket 60 which can be displaced by an operator when inserting an extra drill rod. The drill string works in the same way as described in Australian Patent No. 2003262292. A universal coupling 62 takes drive from the carriage to the bore head.
The laser is directionally adjusted and then its inclination is adjusted to give appropriate fall. The platform is aimed by adjusting screw jack thrusters 8 until the laser beam strikes the centre of the target 64 in the bore head which is next described.
Bore Head
The bore head has a circular leading wall 66 and a trailing semi-circular wall 68 . A semi cylindrical body 70 made of sheet metal has a flat rectangular floor 72 upon which components are mounted. These are closed in by a semi cylindrical cover (not shown) which is secured to flanges 74 extending from walls 66 and 68 .
Body 70 is hollow but central tube 76 is 5 inches across (100 mm) and conducts air and slurry rearwardly while air supply tubes 78 , 80 allow air from the bore to pass through the walls 66 , 68 which would otherwise be a barrier. End walls 66 , 68 also contain shaft apertures for the cutter shaft 82 which extends through the bore head to the end of the drill string. The drill string in turn is driven by coupling 28 .
A thrust bearing housing 90 is bolted to the floor 72 . The cutter shaft 82 reacts against the thrust bearing. Universal coupling 92 allows the shaft to waggle up to 30 mm. The leading end carries cutter 94 . The cutter shaft is hollow from the universal coupling forwards and the leading end of the cutter shaft is surrounded by sleeve 96 (see FIG. 3 ) which is connected by inlet 98 to the external water supply pipe at the reel 40 . The shaft interior communicates with passages 100 in the cutter and water sparges from the cutter.
Steering Rams
A pair of inverted U-shaped mounts 102 are welded to the floor behind the leading end wall 68 . Each supports a ram 104 , 106 which acts on a sleeve which is a slide fit on shaft 82 . Rams 104 , 106 are disposed at 90° to each other and both are fed by mains pressure water via solenoid operated valves 108 , 110 , 112 , 114 as described in Australian Patent No. 2003262292. Both ends of the ram are connected to either feed or drain. The drained water leaving the rams is dumped into the slurry exit tube 76 .
The valves mounted on floor 72 are connected to the rams by flexible tubes 116 . A collar 118 on the shaft 82 supports target 64 marked with concentric rings. The target is viewed through a video camera 120 which supplies an image to a monitor located in the pit. The head is steered by draining water from one or both rams to bring the centre of the target to the static spot of laser light.
The ram stroke is 15 mm and partial stroke movement suffices to correct deviation in drilling. If the soil is uniform and not unduly stony, steering corrections may not be required for several minutes.
The space behind the cutter between the cutter and the leading wall 66 is purged of soil and water by the constant vacuum. When the bore has reached maximum distance which is about 120 m, the carriage is again reciprocated but upon each retraction the section of drill string and a length of vacuum tube is removed as a unit from the pit and the bore head emerges into the pit.
The platform and head are lifted out of the pit, reversed and lowered into the pit so that drilling can proceed in the opposite direction. When the bore links the two selected sites, a pipe of suitable diameter is inserted and the gap between the pipe and the bore is filled with a hardenable construction mix in which the buoyant air-filled pipe floats.
Referring now to FIGS. 1 and 4 , during drilling the bore head progresses by the insertion of a drill rod assembly between the coupling 28 on the universal coupling 62 and the bore head.
An assembly is shown in FIG. 3 and consists of a steel tube 130 with the same diameter as the central tube 76 . The ends of the tube are constructed for coaxial overlap and the drilling thrust is transmitted by the annular wall 132 rendered gas light by rubber o-ring 134 . The assemblies once engaged are locked together by pins 136 inserted into interfitting flanges 138 , 140 . Brackets 142 hold bearings which support a solid steel drive shaft 144 with a male hexagon socket 146 at one end and a female socket 148 at the opposite end. Pins 136 keep the string connected when the thruster reverses and pulls the bore head out of the bore. The carriage applies thrust through tube 130 . Drive shafts 144 bear no thrust.
FIGS. 4 and 5 show a variant which utilises the base to greater advantage. The thrust bearing 90 , universal coupling 92 , shaft 82 and cutter are arranged as in FIG. 1 and the shaft is free to waggle in an arc of about 30 mm. The steering rams are modified to allow the target 64 to be as close to the cutter as possible. The leading end of the shaft 82 passes through sleeve 96 which conducts water into the hollow centre of the shaft. The sleeve has a leading boss 150 and a trailing boss 152 , each of which contain a bearing 154 so that the sleeve remains static while the shaft 82 rotates. Each bearing is accommodated between a pair of seals 156 and the sleeve between the bosses acts as a water jacket 158 fed by port 98 from the water supply pipe.
The shaft has a central water bore 100 which allows water to reach the cutter 94 . A radial port 160 connects the water passage to the jacket. The leading boss 150 has an upwardly projecting lug 162 .
The mechanism from which the sleeve 96 depends is next described.
A pair of trunnions 164 disposed at the leading end at 90° to the shaft axis support a yoke 166 made of flat steel bar. The central position has a cut out 168 which is spanned by a rod 170 . The rod is a slide fit in the bore 172 of the upwardly projecting lug 162 . An arm 174 extends at 90° from the yoke and first ram 106 actuates the yoke like a bell crank, causing the shaft to move up and down in a small steering arc. Even so it is necessary to fit the rod in the yoke with flexible inserts to allow slight rocking of the rod. This prevents binding and leads to smooth steering.
The central part of the jacket 158 is surrounded by a metal collar 176 . Side to side steering is provided by the second ram 104 which reacts against post 178 and the collar 176 on the shaft. A spherical bearing (not shown) connects the ram to the post to permit up and down motion in the shaft of the order of 2-5 mm. The sideways steer motion is the same extent as the up and down motion.
The shaft itself is made of a stainless steel alloy whose surface is chromed. The shaft projects through the waggle aperture 182 which is kept shut against the ingress of slurry by steel washer 184 urged against the end wall by spring 186 .
Semi-circular hoops 188 extend over the hose for the reception of a semi-cylindrical steel cover plate. Removal of the cover is all that is necessary to render all the components accessible for inspection, cleaning and repair.
The camera 120 has ample room and an unobstructed view of the target 64 . The lens is forwardly facing and the cross wires of the target are removably facing and neither become dirty despite the passage of water continually through the conduits to the rams and through the shaft to the cutter head, the movement of the base head through sandy soil and the flow of slurry through the flow passages. The 24 v cables for the solenoid operated valves 108 - 114 and the camera cable 190 enter terminal box 192 and exit in an electrical socket 194 . Water enters the head at mains pressure through union 196 .
The arrangement of the tubes and leads is seen in the schematic shown in FIG. 7 . Union 196 on the trailing wall 68 of the bore head delivers mains water to the water jacket 158 and to each of the four valves 108 - 114 mounted on the base. Each valve has a water inlet 200 , a water outlet 202 , and a water drain 204 . The drain passes through the base and discharges into the slurry tube 76 .
Both ends of the ram are subjected to mains pressure. The solenoid control in the valve connects the selected end to drain and the piston moves in the desired direction. Leads 206 conduct 24v dc to the solenoids from terminal box 192 . Socket 194 which receives the plug of a cable which is fed through the bore following behind the bore head. Camera 120 is connected to the same terminal box.
We have found the advantages of the above embodiment to be:
1. Placing the laser target as close as possible to the cutter cures oversteer, and permits stable direction for the bore head. It is possible in suitable ground to drill for five drill rod lengths without steering correction.
2. Long drill runs are achievable without malfunction or damage to the bore head.
3. Cleanliness in the components compartment means that the operator can always have a clear image of the target.
4. The arrangement of the rams in the variant described allows the diameter of the bore to be reduced to mm. | Boring apparatus for drilling laser guided microbore tunnels uses a liquid stream to remove soil as slurry and an airstream to conduct the slurry away from the bore head. The cylindrical head houses a drill shaft steered by a pair of remotely controlled rams according to the position of a laser spot on a target fixed close to the end of the drill shaft. Small arcuate steering movements shift the cutter up and down through a first ram alongside the shaft working through a linkage. Side to side steering is provided by a second ram acting directly on the shaft. The components are mounted on an axial base wall which gives repair access and camera view of the target. A drilling platform has rams for advancing the cylindrical head. | 4 |
CROSS REFERENCE TO RELATED APPLICATION
This application claims priority under 35 U.S.C. §119 to German Patent Application No. 10 2007 032 498.9 filed Jul. 12, 2007, the entire contents of which are incorporated herein by reference.
FIELD OF THE INVENTION
The invention relates to a protection device for protecting a motor spindle from impact damage.
BACKGROUND OF THE INVENTION
Today the work spindles of many machine tools (above all, milling and grinding spindles, but also driven tool shafts on lathes, etc.) are in many cases implemented as motor spindles. With these, the actual work spindle, with bearing arrangement and electric drive as well as the tool holder with chucking system and release unit, internal lubricant feed, cooling etc., is combined into a compact drive assembly that is attached with screws or clamped to a feed carriage of said machine tool. As a result of a drive free of shear force or torsional play, the motor spindles feature, in comparison to conventional solutions having an external drive by means of couplings, belts or gears, the advantage of a greater running smoothness and fewer run-out errors, and have in addition, due to the lower rotating mass, shorter run-up times and braking times, with an improved workpiece surface quality being achievable together with simultaneously lower primary processing times. As a result of the high feed rates and accelerations, the mass of the spindle and of the feed carriage produces a kinetic energy that is substantially greater than the force from the feed drive, and can also not be diverted by means of a safety clutch at the feed shaft. For this reason, special protection measures must be met in order to protect the motor spindle from impact damage or the like. High-precision heavy-duty spindle ball bearings, in particular, can be damaged very quickly in the event of a collision caused by operator error or programming error; this is associated with considerable repair costs as well as lengthy machine downtimes for dismantling the motor spindle and installing a replacement spindle to be kept on hand.
Known from DE 195 27 561 A1 is an impact protection for a motor milling spindle of a machine tool, for which a work spindle with the entire bearing arrangement is arranged axially movable within a housing. The driveshaft of the motor is axially spaced apart from the work spindle, and is attached to it by means of a toothed coupling in order to transmit the torque of the motor. The work spindle is fixed within the housing axially by means of compression bushings. In the event of a collision, the work spindle together with the complete bearing arrangement can move along their longitudinal axis within the housing, with the compression bushings deforming plastically. This does indeed protect the bearing arrangement of the spindle, but after a collision the work spindle must be removed and disassembled in order to insert new compression bushings and to align the bearing arrangement again. In addition, the work spindle can move only in the direction of its longitudinal axis, and therefore is insufficiently protected from a lateral or oblique collision.
SUMMARY OF THE INVENTION
The purpose of the invention is to create a protection device for a motor spindle which permits not only an axial displacement but also a tilting motion of said motor spindle in the event of a lateral load and which enables return to the starting position in an installed state, at the lowest possible cost.
This problem is solved by means of a protection device having the features as set forth in the independent claim. Practical improvements and advantageous embodiments of the invention are the object of the dependent claims.
The protection device according to the invention is composed of an inner ring permanently joined to the motor spindle and an outer ring joined to the housing. To be understood as the housing shall be any suitable receiver for the motor spindle, such as the feed carriage or else the machine framework of a machine tool and the like. Therefore, the outer contour of the outer ring, rather than also necessarily being round, can be adapted to the respective machine. The inner ring is arranged to be axially movable and tiltable in the outer ring and is placed under axial preload in an elastically resilient manner against the outer ring by means of preloading members. The preloading members hold the inner ring within the outer ring with a predetermined preloading force, with this consequently fixing the motor spindle relative to the housing. The preload predetermined by means of the preloading members is configured such that the inner ring, for a normal load in accordance with the application, does not move in relation to the outer ring. Said preload can differ according to the intended use and construction of the machine tool. If, however, the force acting upon the motor spindle, e.g., in the event of a collision, exceeds the threshold value predetermined by the preloading members, the motor spindle can give way by means of a motion of the inner ring, with not only an axial shifting, but also a tilting motion of the motor spindle being possible in the event of a lateral or oblique force acting on the spindle axis. This optimally protects the motor spindle from damage even in the event of a collision having an effective force oblique to the central axis. In addition, a shifting of the inner ring relative to the outer ring causes the preload brought about by the elastically resilient preloading members to increase, thus dissipating kinetic energy from the feeding motion and causing the generation of a braking effect. Relative motion between the inner and outer ring can be detected by a suitable sensor and used as a signal to switch off the feed drive.
An additional advantage of the protection device according to the invention consists in the fact that the motor spindle, after being shifted due to a collision, can automatically move to its starting position again. After a possible collision, the elastically resilient preloading member causes the inner ring to be automatically shifted to its original position again, such that an elaborate disassembly and subsequent alignment is not required.
The preloading members can advantageously be configured as pressure springs that press an end face of the inner ring against an annular supporting surface of the outer ring. The preloading members can, however, also be configured as elastic-resilient pressure elements or as hydraulic or pneumatic cushions and the like.
In order to improve damping and in order to avoid oscillation, additional radial damping members can be arranged between the inner ring and outer ring. These additional damping members can be used to increase the friction between the inner and outer ring in a defined manner in order to, if necessary, suppress oscillation produced by means of machining force or increased speed. The damping members can be composed, e.g., of several radial retaining elements upon which springs bear, which elements are advantageously movably guided in several radial drilled holes distributed about the circumference of the inner ring, and are intended to engage with indentations in the outer ring. Only when a threshold force has been exceeded are the retaining elements pressed against the force of the springs, by means of which the inner ring can be released. Here also, either a simultaneous release of all retaining elements from the indentations or else also only a partial release in order to tilt the motor spindle is possible. The retaining elements can also serve to support the torque of the motor spindle relative to the housing.
In an advantageous configuration of the invention, the preloading members on the outer ring and/or the damping members on the inner ring are arranged in a uniform distribution about the circumference in order to receive the same releasing moment for any direction of force within the plane (within the X/Y plane) perpendicular to the central axis (Z axis) of the motor spindle. However an asymmetrical arrangement can also be used to deliberately achieve a differentiated release behavior (different in the X and Y direction), should this be required due to the design of the machine tool.
BRIEF DESCRIPTION OF THE DRAWING
Additional specific features and advantages of the invention arise from the following description of a preferred embodiment based on the drawing, which shows one part of a motor spindle having one embodiment of a protection device.
DETAILED DESCRIPTION OF THE INVENTION
The motor spindle ( 1 ) schematically depicted in FIG. 1 is arranged in a housing ( 2 ) of a machine tool or the like. Said housing ( 2 ) can be, e.g., a feed carriage part, a machine framework or another part of a machine tool. The motor spindle ( 1 ) comprises a spindle housing ( 3 ) in which a work spindle ( 4 ) is rotatably mounted by means of bearings, not represented, about a central axis ( 5 ). The motor spindle ( 1 ) also features, in a known way, a drive motor arranged in the spindle housing ( 3 ), an integrated tensioning device with release unit, an internal lubricant feed, a cooling system etc., and consequently forms a complete drive assembly employed primarily in milling or grinding machinery as a drive unit for the tools, but also for driven tool shafts for lathes, etc.
The motor spindle ( 1 ) is held within the housing ( 2 ) by means of an inner ring ( 6 ) permanently joined to the motor spindle ( 1 ) and an outer ring ( 7 ) permanently arranged in the housing ( 2 ). The inner ring ( 6 ) is arranged in the outer ring ( 7 ) in a way permitting axial displacement and tilting displacement and is placed under axial preload against the outer ring ( 7 ) in an elastically resilient manner by means of preloading members ( 8 ). The inner and outer rings create an interface between the machine tool and motor spindle that serves to protect the motor spindle from impact damage.
For the embodiment shown, the outside of the inner ring ( 6 ) features an annular flange ( 9 ), with the side facing the outer ring ( 7 ) including a bearing surface ( 10 ) perpendicular to the central axis of the inner ring ( 6 ) in order to bear against an annular supporting surface ( 11 ) on an inner ledge on one side of the outer ring ( 7 ). The other side of the outer ring ( 7 ) comprises a diagonal inner surface ( 12 ). By means of a semicircular-shaped rounding ( 13 ) on the outside of the annular flange ( 9 ), the inner ring ( 6 ) is additionally supported against a correspondingly rounded bearing face ( 14 ) of the outer ring ( 7 ). Here the preloading members ( 8 ) are executed as compression springs which are arranged on the outer ring ( 7 ) in a uniform distribution about its circumference. The preloading members ( 8 ) executed as compression springs are mounted between the head ( 15 ) of a screw ( 16 ) fixed in the outer ring ( 7 ) and an inner end face ( 17 ), to the left in the drawing, of the inner ring ( 6 ). This causes the inner ring ( 6 ) to be pressed by means of the preloading members ( 8 ) against the outer ring ( 7 ). The screws ( 16 ) are screwed into the outer ring ( 7 ) in threaded holes ( 18 ) running perpendicular to its supporting surface ( 11 ). The preload force of the preloading members ( 8 ) executed as compression springs can thus be adjusted by screwing in or unscrewing the screws ( 16 ).
Additionally provided in the annular flange ( 9 ) of the inner ring ( 6 ), distributed about the circumference, are several radial drilled holes ( 19 ) with spring-loaded radial retaining elements ( 20 ). The pin-shaped retaining elements ( 20 ) feature a ball-shaped free end in order to engage with dome-shaped indentations ( 21 ) of the outer ring ( 7 ). The retaining elements ( 20 ) are movably guided perpendicular to the central axis of the inner ring ( 6 ) in the radial drilled holes ( 19 ) and are pressed outward by means of springs ( 22 ). Screws ( 23 ) hold the retaining elements ( 20 ) captive within the drilled holes. In addition, the screws here can be used in order to change the preload of the locking pins.
For the embodiment illustrated in the drawing, the spindle housing ( 3 ) of the motor spindle features an annular flange ( 24 ), onto which the inner ring ( 6 ) can be screwed. However, the inner ring can also, e.g., be shrunk onto the spindle housing or be designed as integral with it. The outer ring ( 7 ) is permanently attached to the housing ( 2 ) by means of a cover disk ( 25 ). The outer ring ( 7 ) also can be attached to the housing ( 2 ) by another means or can be designed as integral with it. | The invention relates to a protection device for a motor spindle ( 1 ) arranged in a housing ( 2 ), particularly of a machine tool, having an inner ring ( 6 ) fixedly joined to the motor spindle ( 1 ) and an outer ring joined to the housing ( 2 ). The inner ring ( 6 ) is arranged in the outer ring ( 7 ) in a way permitting axial motion and a tilting motion, and is placed under elastically resilient preload against the outer ring ( 7 ) by means of preloading members ( 8 ). | 8 |
BACKGROUND OF THE INVENTION
This invention relates to the field of scroll saws and a blinder to shield the operator's vision from the rapid up and down movement of the upper saw blade arm.
Prior art devices known to the inventor include those described and shown in the following United States patents:
U.S. Pat. No. 4,616,541 discloses a scroll saw having a blade guard 123 to protect the user of the saw blade from injury and to also hold the workpiece on the table.
U.S. Pat. No. 4,455,909 discloses a hacksaw machine which discloses a pair of spaced apart swinging arms having a hacksaw blade connected between the front ends of the swinging arms, the rearward ends of one or both biased by a draw spring to apply an adjustable tension on the saw blade, the swinging arms being mounted in a U-shaped frame.
U.S. Pat. No. 4,204,446 discloses a power hand saw, comprising a vertically extending saw blade which reciprocates up and down above the work table, in which the operating mechanism is below the work table. A tubular safety shield is mounted above the work table to receive the reciprocating saw blade within its vertical passageway, the front portion of the tubular safety shield being cut away for better visibility of the reciprocating saw blade.
U.S. Pat. No. 2,870,837 discloses a high speed pivoted cutting machine for use in repairing shoes, having a reciprocating blade and a protective guard which covers the blade but not the outer end of the upper arm. The guard is to protect the hand and fingers of the operator from coming in contact with the blade.
U.S. Pat. No. 2,764,189 discloses a power saw having a saw blade which extends above the work table and reciprocates up and down in the vertical direction, the operating mechanism being below the work table. A guard is provided above the work table to protect the hands and fingers of the operator from contact with the blade.
U.S. Pat. No. 2,350,247 discloses a machinery guard to protect the hands and fingers of a workman from contact with a reciprocating blade or tool.
U.S. Pat. No. 1,447,987 discloses a safety guard for presses, such as a metal stamping press, which encloses the work piece but which is of transparent or mesh material so the workman can see through the guard to observe operation of the press arm and stamping head as it contacts and presses against the work piece.
U.S. Pat. No. 1,102,544 discloses an embroidery trimming machine having a guide to prevent the cutter from cutting too close to the embroidery and also prevents movement of the embroidery too far under the guide.
The improved scroll saw with a blinder in accordance with this invention solves a problem which none of the prior art guard devices address, namely the visual distraction and tiring effect of having the continuous up and down movement of the outer end of the upper saw blade arm in the field of vision of the operator. The blinder in accordance with this invention includes a shield which is positioned in front of the outer end of the upper saw blade arm, having a vertical dimension long enough to span the distance the outer end of the upper saw blade arm travels upwardly and downwardly during operation of the reciprocating saw blade.
The blinder shield is held stationary by mounting it to a non-movable part of the scroll saw frame, such as the horizontally extending hold down arm to which the vertical shaft of the hold down foot assembly is connected, or to the vertical shaft of the hold down foot assembly itself.
The blinder shield is preferably arcuate in shape, having a convex surface facing outwardly and away from the outer end of the upper saw blade arm and a concave surface facing inwardly and toward the outer end of the upper saw blade arm. The blinder shield curves around to block the operator's field of vision on each side of the outer end of the upper saw blade arm as it moves up and down during operation of the reciprocating saw blade.
SUMMARY OF THE INVENTION
It is an object of the invention to provide a scroll saw with a blinder to block the movable outer end of the upper saw blade arm from the field of vision of the operator of the scroll saw to prevent the visual distraction and tiring effect which occurs when up and down movement of the outer end of the upper saw blade arm is continuously viewed by the operator in his peripheral vision as he continuously keeps his eyes focused on the work piece itself in cutting engagement with the saw blade.
It is an object of the invention to provide a scroll saw with a blinder to block the movement of the outer end of the upper sa blade arm from the field of vision of the scroll saw operator, wherein the blinder includes a shield which is positioned in front of the movable outer end of the upper saw blade arm and a supporting member to support the shield in such position, the supporting member being secured to a non-movable portion of the scroll saw assembly.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a side elevation view of a scroll saw with a blinder in accordance with this invention
FIG. 2 is a top plan view of the scroll saw and blinder of FIG. 1.
FIG. 3 is an elevation view from the rear of the scroll saw and blinder of FIG. 1.
FIG. 4 is an end elevation view of the machine pulley and eccentric drive shaft to operate the drive link member and lower walking beam arm connected thereto.
FIG. 5 is a side elevation view of the drive link member.
FIG. 6 is a side elevation view of the blinder in accordance with this invention shown connected to the vertical shaft of the hold down member by a compression bracket.
FIG. 7 is a top plan view of the compression bracket with its tightening bolt in place
FIG. 8 is a top plan view of the compression bracket with its tightening bolt removed.
FIG. 9 is a section view taken on line 9--9 of FIG. 8.
FIG. 10 is a side elevation view of the blinder in accordance with this invention showing a modified connecting arm to secure the blinder to a stationary member of the scroll saw.
DESCRIPTION OF PREFERRED EMBODIMENT
A scroll saw and blinder combination in accordance with the present invention comprises a scroll saw 2 having a pair of spaced apart reciprocating arms which hold the scroll saw blade 4 therebetween for reciprocating movement, including an upper walking beam member 6 and a lower walking beam member 8.
The upper walking beam member 6 has an upper blade holder 10 at its forward free end to receive and hold the upper end 12 of the saw blade 4. The lower walking beam member 8 has a lower blade holder 14 at its forward free end to receive and hold the lower end 16 of the saw blade 4.
The upper walking beam member 6 is pivotally mounted at a pivot point 18, which is inwardly of the upper walking beam member 6 and forwardly from its rearward free end 20, to and sandwiched between the pair of horizontally extending spaced apart upper legs 22a and 22b of the scroll saw frame 24 by a pivot pin 26.
The lower walking beam member 8 is pivotally mounted at a pivot point 28, which is inwardly of the lower walking beam member 8 and forwardly from its rearward free end 30, to and sandwiched between the pair of horizontally extending spaced apart lower legs 32a and 32b of the scroll saw frame 24 by a pivot pin 36.
The forward free ends of the upper and lower walking beam members 6 and 8, and the scroll saw blade 4 held therebetween, are reciprocated up and down by an electric motor 38 having a drive pulley 40 connected to drive machine pulley 42 by a drive belt 44. An eccentric drive shaft 46 is connected to the machine pulley 42 for rotation therewith. The eccentric drive shaft 46 includes a diagonally extending section 48 and an offset drive lug 50 received in the central aperture of a first roller bearing 52 secured in the lower recess 54 of a drive link member 56.
The drive link member 56 has a second roller bearing 58 secured in the upper recess 60 of drive link member 56. The lower walking beam member 8 is connected to the drive link member 56 at a drive connecting point 62 inwardly of the lower walking beam member 8 and rearwardly from its forward free end, by a drive pin 64 extending laterally therefrom and received in the central aperture of the second roller bearing 58 in the upper recess 60 of the drive link member 56.
The drive pulley 40 of the motor 38 rotates the machine pulley 42 and eccentric drive shaft 46, whose offset drive lug 50 rotates in an offset or outer orbit around the central axis of the drive shaft 46 and machine pulley 42. As the drive lug 50 rotates in such offset or outer orbit, it moves the drive link member 56 and its second roller bearing 58 in its upper recess 60 upwardly and downwardly. The lower walking beam member 8, whose drive pin 64 is received in the central aperture of the second roller bearing 58, is thereby moved upwardly and downwardly to also reciprocate the saw blade 4 connected to the forward free end of lower walking beam member 8 upwardly and downwardly as well as causing the forward free end of the upper walking beam member 6 to which the upper end of the saw blade 4 is connected to also move upwardly and downwardly.
The upper and lower walking beam members 6 and 8 and saw blade 4 held therebetween are reciprocated upwardly and downwardly at a rapid rate. A workman who is working with a workpiece on the work table 66 in cutting engagement with the scroll saw has the rapidly moving forward end of the upper walking beam member 6 constantly in his field of vision. Such rapid up and down movement of the forward end of the upper walking beam member 6 is not only a distraction for the workman but it becomes a tiring annoyance, it can cause dizziness as well as fatigue and may even approach the level of having a hypnotic effect on some workmen.
To eliminate this problem, a stationary blinder 68 is positioned forwardly of the rapidly moving forward free end of the upper walking beam member 6 which blocks such rapid up and down motion of the forward free end of the upper beam member 6 from the workman's view.
The blinder 68 comprises a shield member 70 having an imperforate blinder wall with a vertical or longitudinal dimension greater than the travel distance of the forward free end of the upper walking beam member 6 as it is moved upwardly end downwardly by the drive mechanism and connections described above. The vertical or longitudinal dimension of the shield member 70 is preferably about six inches and positioned relative to the forward free end of the upper walking beam member 6 so the upper edge 72 of the shield member 70 is above the uppermost distance the forward free end of the upper beam member 6 travels in its up and down movement, and so the lower edge 74 of the shield member 70 is below the lowermost distance the forward free end of the upper beam member 6 travels in its up and down movement.
The shield member 70 has a horizontal or lateral dimension greater than the width of the forward free end of the upper beam member 6 and preferably three times its width or more. The horizontal or lateral dimension of the shield member 70 is preferably about three inches or wider.
The shield member 70 may have planar front and rear surfaces, or in a preferred embodiment the front and rear surfaces are curved or arcuate, the front or forwardly facing surface 76 being convex and the rear or rearwardly facing surface 78 which faces the forward free end of the upper walking beam member 6 being concave. The arcuate front and rear surfaces 76 and 78 extend in arcuate paths which surround the vertical or up and down travel path of the saw blade 4 and of the forward free end of the upper beam member 6.
The shield member 70 is held in the position as described by a horizontally extending support arm 80 bolted or welded at its forward end to the rear surface 78 of the shield member 70, the rearward end of the horizontal support arm 80 being secured to the vertical shaft 82 of the hold down foot 84 which holds the work piece to the work table 66 and keeps it from jumping as it is being cut by the scroll saw blade 4.
The vertical shaft 82 of the hold down foot 84 is secured to the forward end of the horizontally extending hold down arm 86 whose rearward end is bolted to the outwardly facing side 88 of the forward end of the upper horizontal leg 22a of the scroll saw frame 24. The horizontally extending hold down arm 86 is held in fixed position and it extends forwardly alongside the movable upper walking beam member 6. Throughout its movement upwardly and downwardly from its pivotal connection between the upper legs 22a and 22b of the scroll saw frame 24, the upper walking beam member 6 rises above and descends below the fixed level of the horizontally extending hold down arm 86 a substantially equal distance in each direction.
The rearward end of horizontal support arm 80 which holds the shield member 70 in place may be secured to the vertical shaft 82 of the hold down foot 84 in a number of different ways.
In one embodiment, a compression bracket 90 is provided comprising a body portion 92 having a top wall 94, a bottom wall 96, a closed forwardly facing end wall 98 and a rearwardly facing end wall 100 with a spread apart slot 102 opening thereto extending from the top wall 94 to the bottom wall 96 and extending inwardly of the body portion 92 to open to a vertically extending cylindrical recess 97 which opens at one end to the top wall 94 and at its opposite end to the bottom wall 96 of the compression bracket 90.
The compression bracket 90 is secured to the rearward end of the horizontal support arm 80 of the shield member 70 by threading it into an internally threaded aperture of the compression bracket 90 opening to the forwardly facing end wall 98. The compression bracket 90 is secured to the vertical shaft 82 of the hold down foot 84 by extending the vertical shaft 82 through the cylindrical recess 97 of the compression bracket 90. A bolt 104 extends through an unthreaded oversize aperture 106 in the body portion 92 of the compression bracket 90 which extends from its side wall 108 and opens to the spread apart slot 102, the bolt 104 having its outer end portion threaded and received in an internally threaded aperture 110 which extends from the slot 102 through the body portion 92 on the opposite side of the slot from aperture 106, coaxial with aperture 106, and opening to the opposite side wall 112 of the body portion 92 of the compression bracket 90.
The bolt 104 has a hand grasp knob 114 on its opposite end for rotating the bolt 104. The inwardly facing surface of the knob 114 bears against the surface of the side wall 108. When the knob 114 is rotated in one direction, its threaded end draws the portion of the body portion 92 of the compression bracket 90 through which the threaded aperture 110 extends toward the portion through which the unthreaded aperture 106 extends, thus narrowing the spread apart slot 102 and thus constricting the cylindrical recess 97.
The vertical shaft 82 of the hold down foot 84 is received in the cylindrical recess 97 of the compression bracket 90 to secure the support arm 80 of the shield member 70 to the vertical shaft 82 of hold down foot 84. The diameter of the cylindrical recess 97 before being constricted by tightening rotation of the bolt 104 corresponds to the diameter of the vertical shaft 8 of the hold down foot 84, and is slightly larger to receive the shaft 82 therein. When cylindrical recess 97 is constricted by rotating bolt 104 in the tightening direction, the shaft 82 is gripped tightly therein to hold the support arm 80 of the shield member 70 securely in place.
In another embodiment, the support arm 80 of the shield member 70 is secured directly to the horizontally extending hold down arm 86 by a cooperative pair of fastening strips having releasable interconnecting means thereon, such as the loop surface strip 116 secured to the upwardly facing flat top wall 118 of a modified support arm 800 which is flat or planar and the hook surface strip 120 secured to the downwardly facing flat bottom wall 122 of the hold down arm 86.
The loop surface strip 116 includes a plurality of tiny loop members 124 projecting from its outwardly facing surface. The hook surface strip 120 includes a plurality of tiny hook members 126 projecting from its outwardly facing surface to hook and releasably interconnect with the corresponding plurality of tiny loop members 124 of the strip 116 when brought into facing engagement therewith. | A scroll saw having a blinder to shield the rapid up and down movement of the saw blade and outer end of the saw blade arm from the view of the operator, comprising a shield member supported at a spaced apart distance in front of the saw blade arm having a vertical dimension large enough to span the vertical movement of the saw blade arm and block the view of such movement from the operator in front thereof. The shield member is supported in such position by a support arm held by a bracket secured to the vertical shaft which connects the hold down shoe to the elongated stationary arm of the scroll saw. | 8 |
FIELD OF THE INVENTION
The present invention relates to the process of making paper. Specifically disclosed is a method for improving the retention and drainage properties of the aqueous pulp slurry during the production of paper.
BACKGROUND OF THE INVENTION
Paper or paperboard is made by producing an aqueous slurry of cellulosic wood fiber, which may also contain inorganic mineral extenders or pigments, depositing this slurry on a moving papermaking wire or fabric, and forming a sheet from the solid components by draining the water. This process is followed by pressing and drying sections. Organic and inorganic chemicals are often added to the slurry before the sheet forming process to make the papermaking process less costly or more rapid, or to attain specific properties in the final paper product.
The paper industry continuously strives to improve paper quality, increase process speeds, and reduce manufacturing costs. The dewatering, or drainage, of the fibrous slurry on the papermaking wire is often the limiting step in achieving faster process speed. This is also the stage in the paper papermaking process which determines many paper sheet final properties.
Typically, a fibrous slurry is deposited on the papermaking wire from the headbox at a consistency (fiber and filler solids content) of 0.5 to 1.5%; the resultant fibrous mat that is removed from the wire at the couch roll and transferred to the pressing section is approximately 20% consistency. Depending upon the machine size and speed, large volumes of water are removed in a short period of time, typically 1 to 3 seconds. The efficient removal of this water is critical in maintaining process speeds.
Chemicals are often added to the fibrous slurry before the papermaking wire to improve the drainage performance on the machine wire. These chemicals and chemical programs are called drainage aids. Additional benefits, such as fines retention, are also obtained.
Papermaking retention aids are used to increase the retention of fine furnish solids in the web during the turbulent process of draining and forming the paper web. Without adequate retention of the fine solids, they are either lost to the process effluent or accumulate to excessively high concentrations in the recirculating white water loop and cause production difficulties including deposit buildup and impaired paper machine drainage. Additionally, insufficient retention of the fine solids and the disproportionate quantity of chemical additives which are adsorbed on their surfaces reduces the papermaker's ability to achieve necessary paper quality specifications such as opacity, strength, and sizing.
GENERAL DESCRIPTION OF THE INVENTION
This invention describes a method for draining water from the pulp slurry in order to facilitate paper formation by the addition of a cationic starch after the alum and polyacrylamide are added to the slurry. The addition order of the cationic starch is critical in the application of this invention; its addition at other feed points or in a different sequential order does not provide the significant improvements in drainage.
Cationic starch is commonly used in the papermaking process to increase interfiber bonding and to obtain paper strength properties or is used to emulsify synthetic internal sizing agents, such as alkenyl succinic anhydride (ASA). Starch is added to the thick stock, in the machine chest or stuff box, before the addition of wet-end process chemicals such as drainage aids. Alum and ionic polyacrylamide (PAM), typically anionic polyacrylamide, are also commonly used in alkaline papermaking to achieve improvements in drainage and fines retention. These are usually added near the fan pump or headbox, before the pulp slurry is deposited on the papermaking wire.
Alum and ionic PAM are understood to operate by a "patch model mechanism", as reviewed in PULP AND PAPER--CHEMISTRY AND CHEMICAL TECHNOLOGY, Chapter 17, "Retention Chemistry", James P. Casey, Third Edition, Volume III. As discussed in this chapter, alum operates as the low molecular weight cationic material or coagulant, and ionic PAM acts as the flocculant.
The coagulant must be added before the flocculant for effective drainage/retention performance. Laboratory evaluations of this system consisted of the addition of alum, followed by the addition of the ionic PAM, followed last by the cationic starch. A mill feed system comprises the alum being added at the fan pump, ionic PAM added after the fan pump or before the screen, and cationic starch added before or after the primary screen.
The starch added after the alum and PAM is independent of any starch previously added to the thick stock. The amount of starch added is in addition to the starch added to provide strength or emulsify internal size.
RELEVANT ART
U.S. Pat. No. 4,066,495 covers the use of a cationic starch followed by the addition of an anionic PAM for improved retention. Starch is generally added before the polymers.
U.S. Pat. Nos. 4,470877 and 4,548,676 (a continuation of the former) discuss the manufacture of gypsum board. Alum is used in acid conditions to buffer pH, and is used in alkaline conditions to acidify silicone surfactants. Cationic starch is used to emulsify internal size, and is added before the anionic PAM. The anionic PAM provides retention and drainage benefits. A synthetic cationic flocculant is also added before the anionic PAM to provide retention benefits. The cationic starch is added before the PAM and is used to emulsify internal size.
U.S. Pat. No. 4,798,653 covers the use of a cationic colloidal silica sol and an anionic PAM for retention and drainage.
U.S. Pat. No. 4,824,523 relates to the method of producing paper by the addition of a retention-dry strength system. This system consists of (I) a cationic starch; (II) an anionic PAM polymer; and (III) a non-starch cationic synthetic polymer. Cationic starch is not sufficiently charged to provide charge neutralization capabilities similar to alum, and thus an alum/PAM system is much more effective than a cationic starch/PAM system for drainage/retention. The cationic starch is providing dry strength in this system, with minimal effect on charge neutralization. The alum in this invention is to neutralize charge only, and provides no strength properties. Cationic starch can be utilized in this invention as the initial additive as discussed, with no effect on drainage. A cationic polymer is added last, and is specified to be non-starch.
U.S. Pat. No. 4,925,530 describes the separation of fiber and filler and treating them separately for increased strength. The fiber is treated with an ionic coagulant or flocculant; the filler is then treated with a starch of opposite charge. The treated fiber and fillers are then mixed to produce a sheet of increased strength.
U.S. Pat. No. 4,927,498 covers the improved retention and drainage with the addition of an anionic polyaluminosilicate microgel followed by the addition of cationic PAM or starch.
U.S. Pat. No. 5,127,994 discloses improved retention and drainage with the addition of an aluminum compound, a cationic PAM, and polymeric silicic acid. This system utilizes a cationic PAM, followed last by an anionic component--the polysilicic acid.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows the improvement in drainage using the addition of alum, anionic PAM and cationic starch
FIG. 2 shows the effect on drainage using the addition of alum, anionic PAM and different cationic starches.
FIGS. 3 and 4 are comparisons of the drainage effect between the addition of alum and anionic PAM and the addition of alum, anionic PAM and cationic starch.
DETAILED DESCRIPTION OF THE INVENTION
The cationic starch encompassed by the present invention can be derived from corn, potatoes, wheat, rice, or tapioca. Optimal results are obtained with an amylopectin based (branched structure) cationic starch derived from the listed sources, preferably a cationic waxy maize (amylopectin based corn starch ). Cationicity is imparted during manufacture by reaction of the starch with tertiary or quaternary amines. The total level of cationicity is defined by degree of substitution (DS) or average number of amine groups substituted for hydroxyl group per anhydroglucose unit of starch. The DS may range from 0.01 to 0.10; optimal results are obtained with a DS of 0.02 to 0.04. The cationic starch is first hydrated and dispersed in water before addition to the paper-making furnish. Either starches that require gelatinizing or "cooking" at the use location, or pre-gelatinized, cold-water dispersion starches can be used. Preferably the starch dispersion will contain about 0.1 to 10 weight % cationic starch. Typically, 10 to 30 pounds per ton active starch are added to the thick stock. As an additive for use with alum and PAM to improve drainage, levels range from 2.5 to 30 pounds per ton based on furnish consistency.
The alum utilized is technical grade aluminum sulfate, also known as papermakers alum. Other alum species, such as polyaluminum chloride (PAC), and the like may also be employed. Dosage levels utilized correlate with those used at actual mills, typically 5 to 15 lbs per ton based upon the pump slurry, or furnish, consistency.
The PAM utilized can be cationic or anionic, preferably anionic, with a mole % anionic monomer ranging from 1 to 60%, preferably 30 to 40%, and an intrinsic viscosity ranging from 5 to 30 dL/gram, preferably 15 to 25 dL/gram. The anionic monomer can be of those commonly used, and include but are not limited to acrylic acid or methacrylic acid. The anionic PAM can be either powder (100% active) or water-in-oil emulsion (30 to 40% active). Powder polymer levels range from 0.25 to 1.5 pounds per ton, with optimal results at 0.1 to 5.0 pounds per ton; emulsion levels range from 0.2 to 20 pounds per ton, with optimal results at 1.5 to 3 pounds per ton.
Visual observations during laboratory tests demonstrate floc formation of moderate size after the addition of the PAM; the further addition of cationic starch provides an even larger floc. This floc is then somewhat reduced in size by the additional mixing of the beaker agitator and sheet mold plunger. The resultant floc is still larger in size and more defined ("tighter") than a floc from an alum/PAM system. These visual observations would indicate the formation of a larger floc that is sheared into a "microfloc", producing channels or gaps in the fibrous mat during dewatering which provides a physical opening for the water to drain through, thus resulting in the documented faster draining times.
This invention exhibits the greatest utility in paper-making processes where heavier papers (>75 lbs/3300 ft 2 ) are being produced. This is because a thicker fibrous mat is used, which more significantly impedes water drainage.
EXAMPLES
Laboratory drainage evaluations were conducted on a British Standard Drainage device. (TAPPI test procedure number T-221 Om 88). Determinations are made initially with various volumes of pulp furnish to determine the appropriate volume of furnish which will produce a sheet of the desired basis weight. This volume is used in all testing, and is agitated in a separate container at a specific shear rpm consistent with the mill's processing conditions. The component test dosages are added and allowed to mix for 15 seconds each. This treated volume is then added immediately to the drainage device, where water is then added manually to the grooved line (approximately 6.9 liters total volume). This slurry is then mixed with the device plunger for 4 cycles. The draining lever is then depressed while simultaneously starting a timer capable of measuring to 0.1 seconds. The pulp slurry will then drain from the device, and is observed for fibrous mat formation on the device wire. The timer is stopped when all water has drained from the cylinder to the point where the fibrous mat formed has lost its gloss or sheen (simulating a dry line on a paper machine). The time of dewatering or drainage is noted for all component dosages. Drainage times were not converted to 60 gram/sq m OD (oven dried) per TAPPI T-221. The fibrous mat is removed for press and oven drying, and can then be utilized for additional paper property testing.
The following data will demonstrate the paper-making drainage efficacy of this invention.
Example 1
Bleached, kraft, softwood alkaline furnish from a west coast mill, refined to a 350 to 400 CSF (Canadian Standard Freeness), was evaluated for drainage improvements on the British Standard device at an equivalent 125 pound per 3300 square feet basis weight. The results are shown in Table I. The examples show the order of addition of the three components, as read from left to right.
TABLE I______________________________________ COMPONENT DRAIN DOSE, TIME,COMPONENT SYSTEM LB/TON SECONDS______________________________________BLANK -- 65.01) ALUM/ANIONIC PAM #1 7.5/3.0 36.8 (EMULSION) 10/3.0 32.2 15/3.0 25.72) ALUM/CATIONIC 7.5/5.0/3.0 28.1 STARCH #1/ 10/5.0/3.0 27.2 ANIONIC PAM #1 15/5.0/3.0 24.63) ALUM/ANIONIC PAM #1/ 7.5/3.0/5.0 25.2 CATIONIC STARCH #1 10/3.0/5.0 22.1 15/3.0/5.0 17.6______________________________________
Graphed data is illustrated in FIG. 1.
Treatment 3 demonstrates the drainage improvement of the invention.
Cationic starch #1 is a cationic amylopectin corn starch (waxy maize) with a % Nitrogen of 0.32%.
Anionic PAM is a 30% charge moiety with an intrinsic viscosity (IV) of 22 dl/gram.
Example 2
Pulp furnish from Example 1 was evaluated using various cationic starches. Results are shown in Table II.
TABLE II______________________________________ COMPONENT DRAIN DOSE, TIME,COMPONENT SYSTEM LB/TON SECONDS______________________________________1) ALUM/ANIONIC PAM #2 5/1/5 24.7 (POWDER)/ 7.5/1/5 23.9 CATIONIC STARCH #2 10/1/5 20.62) ALUM/ANIONIC PAM #2 5/1/5 32.0 CATIONIC STARCH #3 7.5 /1/5 26.8 10/1/5 21.93) ALUM/ANIONIC PAM #2/ 5/1/5 36.4 CATIONIC STARCH #4 7.5/1/5 31.7 10/1/5 26.64) ALUM/ANIONIC PAM #2/ 5/1/5 34.1 CATIONIC START #5 7.5/1/5 27.7 10/1/5 24.25) ALUM/ANIONIC PAM #2/ 5/1/5 36.1 CATIONIC STARCH #2 7.5/1/5 29.8______________________________________
Graphed data is illustrated in FIG. 2.
This data illustrates the claim of improved drainage with this invention.
Cationic starch #2 is a amylopectin based corn starch (waxy maize) similar in structure to cationic starch #1.
Cationic starch #3 is a corn starch mixture of amylose and amylopectin.
Cationic starch #4 is a corn starch of primarily amylose.
Cationic starch #5 is a potato starch of primarily amylose.
Anionic PAM #2 is a powder with a 30% charge moiety and an IV of 17.0.
Example 3
Bleached, kraft, hardwood/softwood alkaline pulp from an eastern United States mill, refined to a 400 to 450 CSF, was evaluated for drainage improvements on the British Standard device at an equivalent 100 pound per 3300 square feet. Results are shown in Table III.
TABLE III______________________________________ COMPONENT DRAIN DOSE, TIME,COMPONENT SYSTEM LB/TON SECONDS______________________________________ALUM/ANIONIC PAM #3 5/3 38.7(EMULSION) 7.5/3 27.2 10/3 23.0ALUM/ANIONIC PAM #3/ 5/3/5 26.1CATIONIC STARCH #1 7.5/3/5 23.1 10/3/5 22.5______________________________________
This data is illustrated in FIG. 3.
Anionic PAM #3 contains a % charge moiety of 30% and an IV of 18.0 dl/gram.
Example 4
Bleached, kraft, hardwood/softwood alkaline furnish from a north-east mill, refined to a 300 to 350 CSF, was evaluated for drainage response on the Canadian Standard Freeness device (the design of this device indicates a faster drainage response at a higher mls value ). Results are shown in Table IV
TABLE IV______________________________________ COMPONENT DRAIN DOSE, RATE,COMPONENT SYSTEM LB/TON mis______________________________________BLANK -- 355ALUM/ANIONIC PAM #3 5 /1.5 487 5/2.25 517 5/3.0 542 5/3.75 547ALUM/ANIONIC PAM #3/ 5/1.5/5 527CATIONIC STARCH #1 5/2.25/5 567 5/3.0/ 5 571______________________________________
This data is illustrated in FIG. 4.
While this invention has been described with respect to particular embodiments thereof, it is apparent that numerous other forms and modifications of this invention will be obvious to those skilled in the art. The appended claims and this invention generally should be construed to cover all such obvious forms and modifications which are within the true spirit and scope of the present invention. | A method of improving the drainage characteristics of a pulp slurry in a papermaking operation utilizing the sequential steps of adding alum, ionic polyacrylamide and cationic starch. The cationic starch can be added to the slurry prior to or after the primary screen. | 3 |
GOVERNMENT RIGHTS
The United States Government has rights in this invention pursuant to Contract No. DE-AC04-76DP00789 between the U.S. Department of Energy (DOE) and AT&T Technologies, Inc. (Sandia).
BACKGROUND OF THE INVENTION
1. Field of Invention
This invention relates generally to the fabrication of high-frequency (or pulsed), high-voltage connectors and, more particularly, to modification of coaxial cable ends to serve as connectors to unite cables with electrical fittings. Disclosed are a method for making the connectors, molds for use with the method, and the connectors, themselves.
2. Description of the Related Art
In a field of high-voltage connectors, it is frequently necessary to adjoin coaxial cables consisting of a central electrical conductor surrounded by a nonconducting or poorly conducting dielectric and an outer conductor which surrounds the dielectric. Ordinarily, the dielectric permits the conducting core of the cable to be insulated electrically from the electric potential of the outer conductor. In high-voltage environments, including in applications involving pulse power, there is a significant risk that when two conductors of opposite respective polarities are placed in sufficiently close proximity to each other, electromagnetic breakdown will occur in the air or other insulating dielectric medium between the conductors resulting in a spark or electromagnetic arc, thus allowing the difference in potential to be neutralized. Thermoplastics, such as high-density polyethylene (HDPE) are common and effective dielectrics for uses associated with high-voltage pulsed power.
One purpose of the dielectric insulator surrounding the conductor material is to provide insulation capable of preventing sparking or arcing. Another purpose is to furnish proper characteristics of impedance determined by the specific composition of the dielectric material, its inner diameter and its outer diameter. Relationships between impedance, dielectric constants and the dimensions (including thickness) of particular dielectrics are well known to those skilled in the art of high voltage connections. It is sufficient to mention here only that it is important to maintain the integrity of the characteristic coaxial impedance of high-voltage cable when splicing cable pieces together or joining cables to fixtures.
The insulating effectiveness of cable dielectric can be seriously compromised where cables are joined to one another or to components. This is due, in part, to the fact that, typically, such connections are not airtight, and gas-filled discontinuities in cable dielectric provide favorable conditions for arcing. This is due to the propensity of air, or other gases, in the presence of high voltages, to break down and allow discharge to occur.
Another concern related to arcing may involve gas bubbles in the dielectric of high-voltage cable. The presence of bubbles in the cable dielectric can increase the risk of an are, much in the same way that a continuous air path across a junction can provide conditions for a spark, although to a lesser extent. In high-voltage applications, it is critical that gas bubbles or other discontinuities in the dielectric insulation be minimized or eliminated. Effective methods for fabricating safe connectors, therefore, cannot permit the continuity and integrity of the cable dielectric to be compromised.
The most commonly used approach to avoid arcing in proximity to high-voltage with a "socket" bearing an opposite configuration. The taper provides for a relatively longer distance, between the central metal conductor and the region outside of the dielectric insulator than a connection where an untapered cable end abuts another untapered cable or fitting. This increased distance relative, for example, to the distance of the radius of the dielectric, allows for a decreased likelihood of discharge due to breakdown of the medium filling the space between the two cable dielectrics. This tapering method has been demonstrated to be an effective connecting technique, as the path length in air between the dielectric surfaces is effectively lengthened. George L. Ragan, Microwave Transmission Circuits, McGraw-Hill Book Company, Inc., 1948, p. 260.
Fabrication of the tapered end is typically accomplished by cutting away the dielectric cable housing using a tool similar to a large pencil sharpener. Although this method has long been an accepted and preferred technique, certain drawbacks exist. For example, the sharpening technique can cause tearing of the dielectric in the region where it adjoins the inner conducting cable, thereby potentially causing gas pockets between the conductor and the dielectric in a location where the electric field is highly concentrated. Also, the sharpening method commonly used often results in a slightly oval cut, which is especially noticeable at the large end of the taper. This can cause difficulty later in securely fastening the tapered end of the dielectric cable into the receptacle of a fitting. Furthermore, it can potentially cause gas pockets to occur between the dielectric of the fitting and that of the connector, thereby increasing the risk of electromagnetic breakdown.
A different approach to minimizing arcing risk in high-voltage connections is to encase the connections in high-pressure gas-filled containers. This disclosure is primarily concerned with dielectrics such as HDPE and other thermoplastics, however, it is instructive to mention also that gases such as nitrogen, given favorable condition of pressure and temperature, can act as efficient dielectric insulators. In high-pressure, high-voltage connections, the high gas pressure in the region of the cable juncture increases gas density in the location of the cable dielectric discontinuity, and the effective amount of gas which would have to undergo electromagnetic breakdown in order for a spark to occur is increased.
In either case, it is necessary and desirable to be able to modify cable ends for high-voltage connections so that they can satisfactorily be mated to fittings used for adjoining the cables to other cables or to fixtures. This includes having the capability to make coaxial cable dielectrics conform to particular shapes favorable for use as cable connectors. Disclosed here is a new method for fabricating cable connectors capable of minimizing the risk of arcing in high-voltage, and in some cases high-pressure, environments. Also disclosed are molds used in the method, and connectors fabricated using the invention method.
BRIEF SUMMARY OF THE INVENTION
The needs noted above are met by the method and apparatuses of the invention wherein the electrical cable ends are modified, and connectors are manufactured, by heating the dielectric insulating medium surrounding the center conductor in a cable sufficiently to soften the dielectric, and then pressing it into a mold such that the dielectric medium is shaped into a desired configuration conforming to the shape of the mold.
Accordingly, it is an object of the present invention to provide a method for fabricating an electrical cable conductor comprising the steps of heating the end of a cable, sufficiently to soften the dielectric insulator surrounding the conducting core of the cable, and pressing the heated cable into a mold such that a portion of the conducting core of the cable passes through a central orifice in the mold, and thereby shaping the malleable dielectric medium into a desired configuration.
It is another object of the present invention to provide a means to vent gas trapped inside the mold or gas bubbles squeezed out of the softened dielectric medium as it is pressed into the mold.
It is yet another object of the present invention to provide electrical cable connectors manufactured using the described method.
It is yet another object of the present invention to provide molds which may be used in conjunction with the method of the invention.
Upon further study of the specification and appended claims, further objects and advantages will become apparent to those skilled in the art.
These objects have been obtained by providing the method and apparatuses of the present invention.
BRIEF DESCRIPTION OF THE DRAWING(S)
FIG. 1 depicts one configuration of a mold used in the method of the invention.
FIG. 2 depicts a mold with gas vents used in the method of the invention.
FIG. 3 depicts the appearance of a cable after the end has been molded using the method of the invention.
FIG. 4a depicts a mold with cable therein and showing alternate venting method.
FIG. 4b depicts the mold and cable of FIG. 4a, but further illustrates particular angles which affect the operation of the alternate venting method.
DETAILED DESCRIPTION OF THE INVENTION
Users of high-voltage cables often require the capability to mate such cables to other cables or to fixtures utilizing premanufactured fittings made from TEFLON™ (tetrafluoroethylene Fluorocarbon polymer) or some other substance. Typically, the fittings receive the cable ends directly according to methods well known in the art of electrical connections and whereby a fitting comprises the female end of a connection and a cable comprises the male end of the connection. An example of such a connection is where in-line cables are spliced using a turnbuckle or other fitting. The nature of the art gives rise to the need to adapt the end of a high-voltage cable so that it might appropriately adjoin the fitting giving a satisfactory electrical union. Such a union must, according to the circumstances of use, maintain impedance integrity and exhibit an acceptably low risk of generating a short or permitting an are to occur across the break in cable insulation continuity which results from adjoining the cable to either another cable or to a fixture via the fitting.
Oftentimes, connections between cables and fittings must be made by personnel in the field who require the capability to cut cable to a desired length and then conveniently to mate the cable to a particular fitting. The present invention provides a method for making appropriate modifications to cable ends thereby rendering them suitable for adjoining to fittings. The invention also provides novel molds for use with the method, and finally, provides the modified cable ends (connectors), themselves. Although, the invention is well-suited for field applications, the principals disclosed herein may be used in factory applications, as well.
The invention concerns making modifications to coaxial cable comprised of a central electrical conductor or wire surrounded by a dielectric insulator made of a material capable of being rendered malleable or soft with the application of heat. Thermoplastics are frequently used as dielectric insulators in coaxial cable, and one of the most common coaxial cable insulators is high-density polyethylene (HDPE). External to the dielectric insulator is a second conductor which typically takes the form of a wire mesh forming a tube surrounding the dielectric portion of the cable. Finally, the external mesh conductor is frequently encased in a "jacket" of rubber, plastic or some other material capable of providing insulation and protection against weathering.
According to the preferred embodiment, the outer casing and external mesh conductor are peeled back to reveal the outer surface of the dielectric insulator of a cable to be modified according to the method if this invention. In addition, a small portion of the dielectric insulator may be cut away from the central electrical conductor yielding easy, unobstructed access to the conductor.
Next, the revealed portion of the cable dielectric is heated uniformly, for example, using a heat gun, until the dielectric is softened and malleable. For HDPE, the dielectric should be heated until it appears relatively clear. The cable with softened dielectric is then pressed into a mold and the dielectric is thereby shaped into a desired configuration. The mold may be made of metal, ceramic or some other material capable of withstanding the temperatures and pressures characterizing the method of the invention. In the case of an aluminum mold, improved results have been demonstrated where the mold is likewise heated prior to the pressing step.
As will be discussed more fully below, it is desirable for the mold to have a centrally positioned opening through which a portion of the center conductor of the cable may be allowed to pass during the pressing stage. This serves as a guide to ensure satisfactory alignment of the dielectric in the mold with respect to the center conductor, and it allows the center conductor to protrude from the molded portion of the dielectric.
Finally, after the dielectric has cooled and set, the mold is removed, leaving a molded cable connector bearing a desired shape suitable for adjoining to a selected premanufactured fitting.
Shown in FIG. 1, from an oblique angle, is a mold suitable for practicing the invention. The mold is generally cylindrical in configuration and is capable of receiving and shaping the end of a cable according to the method of this invention. The mold illustrated in FIG. 1 is characterized by an inlet (5), leading to a molding receptacle 10), which ends in a terminus. In the case of the illustration, the terminus takes the form of a terminal wall (15), however, in other embodiments, the actual shape of the terminus will be dictated by the desired shape of the mold. In the center of the terminus is an orifice (20).
According to the method of the invention, the cable dielectric, exposed and heated to malleability as described above, is pressed into the mold via the inlet (5). The softened dielectric then fills the receptacle (10), conforms to the shape of the receptacle, and is allowed to cool. During the pressing process, the center conductor is pushed through the orifice (20) so that a portion of the conductor extends beyond the mold.
FIG. 2 illustrates a cross-section of an alternate mold construction containing vents. It has been observed that gas bubbles (typically air) may occur or develop in the dielectric medium either as a result of the original dielectric manufacturing processes, or due to the heating and pressing activities described in this disclosure, or simply due to the presence of gas in the mold prior to its being filled with malleable dielectric. Gas bubbles in the dielectric compromise the continuity of the dielectric insulator, and as such, pose an increased risk of arcing across the dielectric. These gas bubbles can be forced out of the heated dielectric medium as a consequence of the pressure exerted on the heated dielectric in the mold. Therefore, there is a benefit in providing vents in the mold through which gas forced out of the dielectric medium, or occupying the space in the receptacle, may be allowed to exit.
According to the arrangement in FIG. 2, the central orifice (20) is again located in the center of a terminal wall (15). Also in the terminal wall are several holes or vents (25) which provide openings between the inside of the receptacle (10) and the outside of the mold. In the preferred embodiment of this mold configuration, there is at least one such vent capable of providing passage through which gas may pass out of the mold as the malleable dielectric is compressed in the receptacle. The optimum number of vents are a matter of routine experimentation, and will depend on the size of the mold and the conditions under which it is used.
FIG. 3 illustrates, from an oblique angle, the appearance of a cable after it has been modified using the method of this invention. In particular, the cable shown in the Figure depicts an end molding which has been fashioned using a vented mold similar to that shown in FIG. 2. As illustrated, the outer braid conductor (30) of a coaxial cable has been pulled back to reveal the dielectric insulator (35) of the cable. The insulator has been heated, and the cable has been pressed into a vented mold, allowed to cool and removed from the mold, all according to the method of the invention described herein. The illustrated untapered end molding might be suitable, for example, for use with an encased high-pressure fitting such as was mentioned previously.
It is important to note that HDPE, for example, expands when heated and contracts when cooled. Accordingly, the mold should have inner dimensions slightly larger than the exact dimensions required for the cable end molding. Also, it is necessary for the mold receptacle to be designed so that the end molding that results will have proper dimensions in order to mate satisfactorily with a desired fitting.
The resulting end molding shown in FIG. 3 is characterized by a molded portion of the thermoplastic dielectric (40) which conforms to the dimensions of the receptacle of the mold used. A small amount if dielectric material is extruded in the course of the pressing step and results in the band of excess plastic (45) shown in the Figure. This can later be carefully removed with a knife, if desired or necessary. In the course of the pressing step, the extrusion of excess softened dielectric material from behind the inlet of the mold is an indication that the softened dielectric has been compressed sufficiently to fill and attain the shape of the receptacle. Additional excess plastic (48) is shown in FIG. 3 to have been extruded from vent holes in the mold, optimally, after gas has escaped through the vents. This plastic can, likewise, be cut away, as needed. Finally, the Figure shows where the conducting core (50) of the coaxial cable protrudes from the portion of the dielectric medium which has been molded using the method of the invention.
FIG. 4a depicts the cross section of an alternate mold configuration which can be used to generate a cone-shaped cable end molding. Also shown in the Figure is the positioning of a cable inside the mold prior to the pressing step. In the arrangement in FIG. 4a venting of gas is by a means different from that already described. In this case, rather than providing additional holes in the mold to allow gas to escape, the shapes of the mold receptacle and the pre-trimmed dielectric provide passages through which gas can escape during the pressing step.
As illustrated, the mold receptacle (10') bears a roughly conical shape and the terminus of the mold does not take the form of a terminal wall, although the central orifice (20') is present. The conducting core (50) of the cable passes through the central orifice (20') as described previously. Of particular importance, however, is the fact that there is sufficient space between the outside perimeter of the cable core (50) and the outside perimeter of the orifice (20') to create a gap through which gas may be allowed to pass.
As further illustrated in FIG. 4a, the cable dielectric has been trimmed in order to give it a roughly conical shape, as well. This trimming may be accomplished using the "giant pencil sharpener" described in the background section of this disclosure, or by other appropriate means known to skilled practitioners of the art. As depicted in the Figure, the cable dielectric, therefore, is comprised of an untrimmed portion (55) and a trimmed portion (60). The Figure further illustrates that, in this particular embodiment, the conical shape of the dielectric is truncated. Also, as further elaborated pictorially in FIG. 4b, the vertex angle (A) of the roughly conical configuration of the mold receptacle (10') is greater than the vertex angle (B) of the roughly conical configuration of the trimmed portion (60) of the dielectric.
The difference in vertex angles of the roughly conical configurations of the trimmed portion of the dielectric and the mold receptacle results in an effect whereby gas is vented from the mold both in a forward direction (65) and a rearward direction (70) with respect to the cut end of the cable as the cable and mold are pressed together. More specifically, the forward venting is through an opening created between the perimeter of the central orifice and the perimeter of the central conductor as the conductor passes through the orifice; the rearward venting is through the opening created between the perimeter of the mold inlet and the outside perimeter or boundary of the dielectric. Different degrees of venting can be achieved depending on the shape or position of the truncation.
The foregoing description of the invention has been presented for purposes of illustration. It is not intended to be exhaustive or to limit the invention to the precise forms disclosed. Obvious modifications or variations are possible in light of the above teachings. The embodiments were chosen and described in order to best illustrate the principles of the invention and its practical application to thereby enable one of ordinary skill in the art to best utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated, as long as the principles described herein are followed. Thus, changes can be made in the above-described invention without departing from the spirit and scope thereof. It is also intended that the scope of the invention be defined by the claims appended hereto. The invention is intended to encompass all such variations as fall within its spirit and scope. | End moldings for high-voltage cables are described wherein the dielectric insulator of the cable is heated and molded to conform to a desired shape. As a consequence, high quality substantially bubble-free cable connectors suitable for mating to premanufactured fittings are made. Disclosed are a method for making the cable connectors either in the field or in a factory, molds suitable for use with the method, and the molded cable connectors, themselves. | 7 |
BACKGROUND OF THE INVENTION
The present invention is related to a cordless headphone.
As a headphone stereophonic system, for instance, a cassette tape player is connected with a headphone by way of a cordless manner.
FIG. 1 is a perspective view for illustrating an outer view of one typical cordless type cassette tape player. In this drawing, reference numeral 1 shows a cassette tape player, and reference numeral 6 indicates a receiver exclusively used for this headphone.
Then, in the cassette tape player 1, an audio signal "R" of a right channel and an audio signal "L" of a left channel are reproduced from a cassette tape (not shown) in a stereophonic system during the reproducing operation. These right/left channel signals R/L are converted into FM signals SR/SL having preselected carrier frequencies, and then these FM signals SR/SL are transmitted to the receiver 6.
Then, in the receiver 6, when the FM signals SR and SL transmitted from the cassette tape player 1 are received, audio signals R and L are demodulated from these FM signals SR and SL, and then these audio signals R/L are supplied via a headphone cord 7C to right/left acoustic units 7R/7L of a headphone 7 so as to be converted into stereophonically reproduced sounds.
It should be noted that the distance over which the receiver 6 may be separated from the cassette tape player 1 during the stereophonic operation is within a range from 1 m to 3 m, for example, approximately 1.5 m.
FIG. 2 and FIG. 3 represents one example of signal processing systems for the above-described cordless type cassette tape player 1 and receiver 6. In the cassette tape player 1, the right/left-channel audio signals R/L are reproduced from a magnetic tape 2 of the tape cassette by reproducing heads 11L/11R during the reproducing operation. These audio signals R/L are supplied via reproducing equalizer amplifiers 12R/12L and preemphasis circuits 13R/13L to FM modulating circuits 14R/14L so as to be converted into FM signals SRT/SLT.
In this case, the carrier frequencies fRT/fLT of the FM signals SRT/SLT are selected to be, for example,
fLT=11.29 MHz
fRT=11.75 MHz.
Then, these FM signals SRT and SLT are supplied to a mixer circuit 15, and an oscillation signal S16 having a preselected stable frequency f16 (for instance, f16=249.75 MHz) is produced from an oscillating circuit 16. This oscillation signal S16 is supplied to the mixer circuit 15.
Thus, the FM signals SRT and SLT are added to each other in the mixer circuit 15, and then the added signal is frequency-converted by the oscillation signal S16. As a result, these FM signals SRT/SLT are frequency-converted into such FM signals SR/SL having the following carrier frequencies fR/fL:
fL=f16-fLT=238.46 MHz
fR=f16-fRL=238.0 MHz.
Then, these FM signals SR and SL are supplied via a bandpass filter 17 and an output amplifier 18 to a transmitter antenna 19 in order to be transmitted to the receiver 6.
On the other hand, in the receiver 6, the FM signals SR/SL transmitted from the cassette tape player 1 are received by the headphone cord 7C (namely, headphone cord 7C may be operated as an antenna), the received FM signals SR/SL are supplied via a bandpass filter 61 and a RF (radio frequency) amplifier 62 to a mixer circuit 63, and also a local oscillation signal S64 is supplied from a local oscillating circuit 64.
In this case, it should be understood that the frequency f64 of the local oscillation signal S64 is selected to be, for instance,
f64=248.7 MHz.
In this manner, these FM signals SR and SL are frequency-converted by the mixer circuit 63 by using the local oscillation signal S64 into intermediate frequency signals SRI and SLI having frequencies fRI and fLI given as, for instance,
fLI=fL-f64=10.24 MHz,
fRI=fR-f64=10.7 MHz.
Then, these intermediate frequency signals SRI and SLI are supplied via intermediate frequency circuits 65R and 65L containing filters and limiter amplifiers to FM demodulating circuits 66R and 66L, respectively, so as to demodulate audio signals R and L. These audio signals R/L are supplied to the "hot" sides of the acoustic units 7R and 7L via a signal line constituted by deemphasis circuits 67R/67L, output amplifiers 68R/68L, and RF choke coils 69R/69L. Also, at this time, the "cold" sides of the acoustic units 7R and 7L are connected through another RF choke coil 69G to the ground.
As a consequence, the audio signals R and L reproduced by the cassette tape player 1 can be heard by the headphone 7.
In this case, the dimension of the receiver 6 may be defined by, for instance, 50 mm (height)×20 mm (width)×10 mm (thickness). When the cassette tape music is played, since the cassette tape player 1 is connected to the receiver 6 in the cordless manner, while this cassette tape player 1 is stored in a bag, the receiver 6 may be put into a chest pocket of a jacket for example. Therefore, when the tape music is reproduced while the user goes to his office, or the user walks, there is no cord connected between the cassette tape player 1 and the receiver 6 to disturb the user operation.
Also, since the carrier frequencies fR/fL of the FM signals SR/SL transmitted from the cassette tape player 1 to the receiver 6 are selected to be, for example, fL=238.46 MHz and fR=238.0 MHz, namely higher than the frequency bands from 76 MHz to 222 MHz generally used in the FM broadcasting system and the television broadcasting system, these FM stereophonic signals SR/SL will not be adversely influenced by electromagnetic wave interference from broadcasting electromagnetic waves or reflections from surfaces in cities.
In the above-described cordless type headphone stereophonic system, the connection between the cassette tape player 1 and the exclusively used receiver 6 is made as a "cordless" connection, whereas the connection between the headphone 7 and this receiver 6 is not made as the "cordless" connection, but is established by the headphone cord 7C.
Therefore, it is conceivable to assemble the receiver 6 with the headphone 7 so as to eliminate the necessity of the headphone cord 7C. However, if so, then this headphone cord 7C can be no longer used as the reception antenna when the receiver 6 receives the FM signals SR and SL. Accordingly, another reception antenna must be employed.
As a result, for instance, as represented in FIG. 4, or FIG. 5, in order to obtain a high signal reception sensitivity, it is also conceivable to design this receiver 6 as a diversity reception system. In other words, in the receiver 6 shown in FIG. 4, the FM signals SR/SL are received by two sets of antennas 7A/7B and two sets of signal receiving circuits 6A/6B to derive two sets of audio signals R/L. These two audio signals R/L are supplied to a switch circuit 81. Also, reception levels of the receiving circuits 6A and 6B are detected by a detecting circuit 82 to output detection signals. A switch circuit 81 is controlled based on the detection signals.
In this manner, either the audio signal R, or the audio signal L, which is derived from the receiving circuit having the high reception level, is selected and derived from the switch circuit 7 among two sets of the audio signals R and L from the receiving circuits 6A and 6B. As a consequence, the better audio signals R and L can be continuously obtained irrespective of to the directional relationship between the cassette tape player 1 and the receiver 6.
Also, in the receiver 6 shown in FIG. 5, both the reception signal of the antenna 7A and the reception signal of the antenna 7B are switched at a frequency more than two times higher than the maximum frequencies of the audio signals R and L by a oscillation signal derived from an oscillating circuit 84, and then the switched reception signal is supplied to the receiving circuit 6A.
As a result, even when the level of one of the FM signals SR/SL received by the antenna 7A or the antenna 7B is low, if the level of the other FM signal is sufficiently high, then the better audio signals R/L can be produced from the FM signal received by the other antenna.
As previously explained, in accordance with the diversity reception type receiver 6, since the audio signals R/L produced from such an FM signal having the higher reception level among two sets of the FM signals SR/SL is used, the audio signals R/L can be obtained under better condition to reproduce better stereophonic sounds.
However, in the case of the diversity reception type receiver shown in FIG. 4, since a total number of circuit components is greatly increased, higher cost would be required. Also, since the total number of circuit components is increased, when this receiver 6 is assembled with the headphone 7 in an integral manner, the dimension of the headphone 7 would be increased, and further the weight of this headphone 7 would increase, which could impede the easy operation of the headphone.
On the other hand, in the diversity reception type receiver shown in FIG. 5, both the cost and the dimension of this receiver are not greatly increased, as compared with those of the diversity reception type receiver indicated in FIG. 4. However, since the audio signals R/L are partially derived from the FM signals SR/SL having the low reception levels, the S/N ratio and the clarity of the audio signals R/L supplied to the headphone 7 would be deteriorated.
SUMMARY OF THE INVENTION
The present invention has been made to solve the above-described problems, and therefore has an object to provide a cordless headphone capable of realizing a so-called "cordless connection" between a signal receiving circuit and an acoustic unit.
To achieve this object, a headphone, according to the present invention, is featured by comprising:
a first antenna for receiving an FM signal produced by FM-modulating a carrier signal by an audio signal;
a second antenna for receiving the FM signal;
a first tuning circuit to which the reception signal of the first antenna is supplied;
a second tuning circuit to which the reception signal of the second antenna is supplied, including a tuning coil which is transformer-coupled with tuning coil of the first tuning circuit;
a mixer circuit for frequency-converting the output signal of the second tuning circuit into an intermediate frequency signal;
an FM demodulating circuit for FM-demodulating the intermediate signal to obtain the audio signal; and
an acoustic unit for entering therein the audio signal derived from the FM demodulating circuit and for converting this entered audio signal into a reproduction sound.
As a consequence, the connection between the signal receiving circuit and the acoustic unit can be made by a so-called "cordless" connection.
BRIEF DESCRIPTION OF THE DRAWINGS
For a better understanding of the present invention, reference is made of a detailed description to be read in conjunction with the accompanying drawings, in which:
FIG. 1 is a perspective view for showing a typical cordless type cassette tape player;
FIG. 2 is a schematic block diagram for representing the signal processing arrangement of the cassette tape player shown in FIG. 1;
FIG. 3 is a schematic block diagram for indicating the signal processing arrangement of the receiver shown in FIG. 1;
FIG. 4 is a schematic block diagram for showing the signal processing circuit of a diversity reception type receiver;
FIG. 5 is a schematic block diagram for representing the signal processing circuit of another diversity reception type receiver;
FIG. 6 is a schematic block diagram showing circuit arrangement of a headphone/signal receiving circuit according to an embodiment of the present invention;
FIG. 7 is a perspective view for representing a headphone apparatus according to the embodiment of the present invention;
FIG. 8 graphically represents directivity of an antenna employed in the signal receiving circuit of FIG. 6; and
FIG. 9 schematically shows one example of tuning circuits employed in the signal receiving circuit of FIG. 6.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to drawings, a cordless headphone apparatus according to a preferred embodiment of the present invention will be described.
FIG. 6 schematically shows a circuit arrangement of a headphone/signal receiving circuit 70 of a cordless headphone apparatus according to an embodiment of the present invention. In this drawing, a tuning coil L1 is connected in parallel to a tuning capacitor C1, so that a first tuning circuit 91 is constituted. Also, another tuning coil L2 is connected in parallel to another tuning capacitor C2, so that a second tuning circuit 92 is constituted. At this time, the coil L1 is positioned close to the coil L2 to thereby establish transformer coupling (mutual inductive coupling).
Also, a first antenna 93 and a second antenna 94 are employed, the first tuning circuit 91 is connected to both the first antenna 93 and the ground, and also the second tuning circuit 92 is connected to both the second antenna 94 and the ground. Furthermore, a center tap of the coil L2 is connected to an input terminal of an amplifier 62.
Then, a signal line from this amplifier 62 to amplifiers 68R and 68L is arranged in a similar manner as previously explained in FIG. 3, so that a signal receiving circuit 60 is arranged. Audio signals R and L outputted from the amplifiers 68R and 68L are supplied to a right-channel acoustic unit 70R and a left-channel acoustic unit 70L.
In this case, a headphone 70 is constructed of as a head mount type, as illustrated in FIG. 7. That is, the right-channel/left-channel acoustic units 70R/70L are stored inside housings 71R/71L, respectively. Also, these housings 71R and 71L are coupled to each other by way of a band 72, so that the entire headphone 70 may be put on a head of a user to cover his head. The signal receiving circuit 60 is stored inside the housing 71R.
When the first antenna 93 and the second antenna 94 have directivities, the directivity directions (namely, directions of directivity axes) may be directed perpendicular to each other. For instance, as represented in FIG. 8, when the first and second antennas 93 and 94 have hyperbolic directivity, these first and second antennas 93 and 94 are arranged in such a manner that the directivity (characteristic curve 93A) of the first antenna 93 is positioned perpendicular to the directivity (characteristic curve 94A) of the second antenna 94. For example, the first antenna 93 is made of a coated wire to construct a lead antenna. This lead antenna 93 is provided, for example, from the housing 71R through a band 72 which connects/holds this housing 71R to the housing 71L. It should be noted that since the frequencies fR and fL of the FM signals SR and SL are approximately 240 MHz and the 1/4-wavelengths thereof are approximately 31 cm, when the lead antenna 93 is positioned along the band 72, a tip portion of this lead antenna 93 conducted from the housing 71R may reach the housing 71L.
Also, the second antenna 94 may be made of a helical antenna. Then, since the frequencies fR and fL of the FM signals SR and SL are the above-explained values, the dimension of this helical antenna 94 is selected to be 3 mm (diameter)×40 mm (length), and is stored inside the housing 71R. A portion of this helical antenna 94 is projected outside the housing 71 R, if required. In this case, the first antenna 93 is the lead antenna, and may be regarded as a single upright rod antenna which has a directivity characteristic approximated to the hyperbolic directivity characteristic shown in FIG. 8. Then, the helical antenna 94 is provided within the housing 71R in such a manner that the directivity direction (characteristic curve 94A) of this antenna 94 is positioned perpendicular to that of the lead antenna 93.
Furthermore, although not shown in the drawing, the power supply of the signal receiving circuit 60 may be constituted by, for example, two sets of cells (Japanese unit size No. 3). The respective cells are provided in the housing 71R and 71L in order to establish weight balance of the headphone 70. A wiring line for connecting the housing 71R with the housing 71L is provided along the band 72 and inside this band 72.
With employment of such a structure, the FM signals SR and SL produced from the cassette tape player 1 are received by the first antenna 93 and also by the second antenna 94. These received FM signals SR and SL are supplied via the amplifier 62 to the circuit at the post stage. As a consequence, as previously explained, the audio signals R and L are obtained from the amplifiers 68R and 68L, and then these audio signals R/L are supplied to the acoustic units 70R/70L, so that the user can hear the stereophonic-reproduced sounds.
In this case, since the signal receiving circuit 60 is assembled inside the housing 71R of the headphone 70, no connection cord is required between the signal receiving circuit 60 and the headphone 70.
At this time, since the coil L1 is transformer-coupled with the coil L2, there are phase differences of 90 degrees between the FM signals SR/SL received by the first antenna 93 and the FM signals SR/SL received by the second antenna 94 among the FM signals SR/SL supplied to the amplifier 62. As a results, the FM signals SR and SL received by the antennas 93 and 94 function as circular polarized waves, in appearance. The overall directivities of the first and second antennas 93 and 94 represent omnidirectional (non-directional) directivities, as indicated by a characteristic curve 90 in FIG. 8.
As a consequence, even when there is a changing directional relationship between the cassette tape player 1 and the antennas 93, 94 (headphone 70), the FM signals SR and SL can be continuously received under normal conditions, and therefore the audio signals R/L can be obtained under stable conditions.
As previously explained, in accordance with this headphone 70, since the receiver is connected with the headphone in a so-called "cordless manner", more easy manipulation of this headphone apparatus can be realized, as compared with the conventional headphone apparatus which requires a wire connecting with the receiver 6 as indicated in FIG. 1.
Moreover, in this case, since the first and second antennas 93 and 94 equivalently have omnidirectional directivity characteristics, the reproduced sounds are not adversely influenced by the directional relationship between the cassette tape player 1 and the antennas 93 and 94, the reproduced sounds with higher quality can be continuously obtained.
Also, in order that the omnidirectional directivity characteristics can be achieved, only two sets of first/second tuning circuits 91/92 and two sets of first/second antennas 93/94 are employed. One set of these circuit elements was originally required in this cordless headphone apparatus. Therefore, increasing of the cost is low. In particular, this cost increasing is very low, as compared with that of the diversity reception type headphone apparatuses shown in FIG. 4 and FIG. 5. Furthermore, there is no specific problem in view of the dimension and the weight of the cordless headphone apparatus according to this embodiment mode. Also, the S/N ratio and the clarity of the audio signals R/L are not lowered, which are conversely lowered in the diversity reception type headphone apparatus of FIG. 5.
FIG. 9 indicates an example of the tuning circuits 91 and 92. In this example, the tuning coils L1 and L2 of the tuning circuits 91 and 92 are constructed of a printed circuit board. In other words, a printed circuit pattern 911 is formed in a rectangular helical shape, and lands 912 and 913 are formed on both ends of this printed circuit pattern 911 on an insulating board 910, so that the tuning coil L1 is fabricated.
Then, a capacitor C1 is soldered between the land 912 and the land 913 to thereby constitute the tuning circuit 91, and further the land 911 is connected to the antenna 93 whereas the land 912 is connected via a through hole to a ground pattern formed on a reverse surface of the insulating substrate 910.
Furthermore, another printed circuit pattern 921 is formed in a rectangular helical shape and positioned close to the printed circuit pattern 911, and lands 922 and 923 are formed on both ends of this printed circuit pattern 921 on the insulating substrate 910, so that the tuning coil L2 is fabricated. Then, a capacitor C2 is soldered between the land 922 and the land 923 to thereby constitute the tuning circuit 92.
Then, the land 922 is connected to the antenna 94 whereas the land 922 is connected via a through hole to the ground pattern formed on the reverse surface of the insulating board 910. Furthermore, a center tap 924 of the pattern 921 is connected via a through hole and a pattern formed on the reverse surface of the insulating board 910 to an input terminal of an amplifier 62. Although not shown in this drawing, the remaining circuit of the signal receiving circuit 60 is mounted on the insulating board 910.
As a consequence, the coils L1 and L2 can be formed in a simple manner and in low cost, and the stable coils with less fluctuations can be made.
It should be understood that the total turn numbers of the above-described coils L1 and L2 may be increased and the antennas 93 and 94 may be omitted in the above-described embodiment. Accordingly, these coils L1 and L2 may be alternatively operated as loop antennas. The above-explained embodiment is directed to such a case that the signal source of the audio signals R and L is the headphone type stereophonic cassette tape player 1. Alternatively, cordless microphones and other cordless type audio appliances with using CD, MD, DAT and DCC as recording media may be employed.
As previously described in detail, according to the present invention, the headphone apparatus can be made in the completely cordless mode with respect to the audio appliance such as the cassette tape player, and therefore, this headphone apparatus can be operated very easily, as compared with the conventional headphone apparatus which requires the exclusively used receiver as shown in FIG. 1. Moreover, in this case, the reproduced sounds are not adversely influenced by the directional relationship between this headphone apparatus and the audio appliance, but the reproduced sounds with the high quality can always be obtained.
Also, only two sets of the tuning circuits and two sets of the antennas are merely employed. In addition, one set of these circuit elements are originally required by the known cordless headphone apparatus. Therefore, increasing of the cost is low. In particular, this cost increasing is very low, as compared with that of other diversity reception type headphone apparatuses. Furthermore, there is no specific problem in view of the dimension and the weight of the cordless headphone apparatus according to this embodiment mode. Also, the S/N ratio and the clarity of the audio signals R/L are not lowered. | A headphone apparatus includes a plurality of antennas for receiving an FM signal produced by FM-modulating a carrier signal with an audio signal, a plurality of tuning circuits for receiving reception signals of the plurality of antennas, a mixer circuit for causing tuning coils of the tuning circuits to be transformer-coupled to each other and for frequency-converting an output signal of one tuning circuit into an intermediate frequency signal, an FM demodulating circuit for FM-demodulating the intermediate frequency signal to produce the audio signal, and an acoustic unit for converting this audio signal into a sound. The directivity axes of the antennas are arranged perpendicularly thereby improving the reception of this headphone apparatus. | 7 |
FIELD OF THE INVENTION
This invention relates generally to the treatment of yarn in package form and, more particularly, to a new apparatus and method for maximizing treating equipment utilization and minimizing treating liquor utilization during treatment of yarn in package form.
BACKGROUND OF THE INVENTION
The treatment of yarn in package form may involve washing, bleaching, dyeing, rinsing or other liquid treatment. The yarn is typically wound on dye tubes as yarn packages and placed on a series of spindles or other core members within a treatment chamber. The yarn treating liquid is circulated into the treatment chamber and through the packages of yarn at elevated temperatures and pressures. The heated liquid under pressure penetrates the package and the individual strands of yarn or fibers fully or to a predetermined depth for special effects. The treating liquid is typically forced from the spindle or core member into the inside of the tube outwardly through the yarn, and in some systems the treating liquid is forced from outside the package inward through the package into the core member.
A problem with previous package dyeing systems is that it has not been practically feasible to vary the amount of treatment liquor for optimum usage with loads of yarn varying from a standard capacity of the system. This use of oversized equipment for small loads is both expensive and environmentally unsound because of the need to fill the kiers with the same amount of liquor as for full sized loads.
In other types of textile dyeing systems, for example dye becks for treating lengths rather than packages of textile material, where relatively large dye becks are standard in the art and are designed to handle several hundred yards of material bunched in rope form, conversion systems, such as disclosed in U.S. Pat. No. 3,635,053, have been developed for changing the capacities of such large dye becks by employing a number of relatively small dye becks constructed and designed to be fitted into the standard large dye beck in a side-by-side relation so that separate dyeing operations can be carried out in each of the smaller dye becks simultaneously. However, a satisfactory practical method and apparatus for selectively varying the capacities in package dyeing systems to adjust to loads varying from a standard load are not known.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a method and an apparatus for treating textile yarn in package form.
This and other objects of the present invention are accomplished with an apparatus for treating textile yarn in package form having a kier for supporting yarn packages for treatment therein, a pump connected to the kier for pumping treating liquor to the kier to treat yarn packages supported therein, an expansion tank connected to the kier for receiving treating liquor from the kier which is connected to the pump for passage of treating liquor from the expansion tank to the pump for recirculation to the kier. Additionally, a device for supporting yarn packages in the expansion tank is included for use of the expansion tank as a kier and a device for alternatively connecting the pump to the kier for pumping treating liquor to the kier or to the expansion tank for pumping treating liquor thereto for use of the expansion tank as a kier to treat yarn packages supported therein. Additionally, valving is provided to selectively connect the kier between the pump and the expansion tank for use of the kier as an expansion tank when the expansion tank is being used as a kier.
Preferably, the expansion tank is formed with a treating capacity different from that of the capacity of the kier, usually with the expansion tank having a smaller treating capacity than the kier. At least two heat exchangers of differing capacities as well as a device for selectively connecting one or more heat exchanger between the pump and the alternatively connecting device for selectively connecting the heat exchangers to the kier or to the expansion tank is preferably included. The selectively connecting device may comprise a reverse valve and the pump may comprise a variable speed pump.
The kier may comprise at least two separable sections having cylindrical portions with annular ends as well as a device releasably connecting the sections together at their annular ends in a pressure seal, and at least one cylindrical module insertable between the annular ends of the sections to expand the volume of the kier and a device for releasably connecting the module to the annular ends of the sections in a pressure seal.
In one form of the invention, there is a plurality of kiers for supporting yarn packages for treatment therein, with at least two heat exchangers, a pump for pumping treating liquor through the heat exchangers and the plurality of kiers to treat yarn packages supported in the kiers, as well as an expansion tank connected to the kiers for receiving treating liquor from the kiers and connected to the pump for passage of treating liquor from the expansion tank to the pump for recirculation to the kier. A device for connecting one or more selected ones of the heat exchangers between the pump and one or more selected ones of the kiers is provided. At least one of the kiers may be of a different capacity than at least another of the kiers and at least one of the heat exchangers may be of a different capacity than another of the heat exchangers. Once again, the connecting means may comprise a reverse valve and the pump may comprise a variable speed pump. With this arrangement a selected capacity operation can effectively be accommodated efficiently.
A feature of the present invention is the forming of the kier in at least two separable sections having cylindrical portions with annular ends, means releasably connecting the sections together at their annular ends in a pressure seal. At least one cylindrical module is insertable between the annular ends of the sections to selectively expand the volume of the treatment chamber. A device releasably connects the module to the annular ends of the sections in a pressure seal.
Another feature of the present invention is forming the kier with a cylindrical central portion having an upper annular rim and a lower annular rim, a removable circular lid portion secured in a pressure seal to the upper rim of the central portion, the lid portion having a relatively flat underside in proximity to the supported yarn packages. Also included is a circular lower portion formed in a pressure seal to the lower rim of the central portion, the lower portion having an inner upper facing side formed complementary to the base of the carrier supporting yarn packages in the kier, whereby the volume of liquor needed to fill the kier during package treatment is minimized. For reinforcement of the lid and the lower portion, they are formed with radially extending exterior reinforcing ribs.
The method for treating textile yarn in package form of the present invention comprises the steps of pumping a treating liquor through a heat exchanger to at least one kier and selectively pumping the treating liquor through another heat exchanger to an expansion tank for use of the expansion tank as a kier.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic illustration of a package dyeing machine embodying a first embodiment of the present invention;
FIG. 2 is a schematic illustration of a package dyeing machine embodying a second embodiment of the present invention operating in a first mode;
FIG. 3 is a view similar to FIG. 2 illustrating a variation of the second embodiment of the present invention;
FIG. 4 is a vertical sectional view of a kier of a package dyeing machine of the present invention;
FIGS. 5 and 6 are top and bottom plan views of the kier of FIG. 4, respectively;
FIG. 7 is an elevational view of a kier of a package dyeing machine modified to have a transverse intermediate seam according to one form of the present invention; and
FIG. 8 is an elevational view of the kier of FIG. 6 with an intermediate module inserted therein.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to FIG. 1, a first embodiment of the present invention is shown in the form of a package dyeing machine 10 having a pump 12 which is connected to a kier 20 and an expansion tank 22 via heat exchangers 14 and 16. The heat exchangers may be of a similar size but are preferably of differing sizes in order to increase efficiency depending on the treatment load. The pump pumps treating liquor through the yarn packages. Kier 20 carries the yarn packages mounted on a conventional carrier 26 when a full capacity load of yarn packages are to be treated or a smaller number of yarn packages may be located on a carrier in the expansion tank 22 for treatment. Two return lines 15 from kier 20 and expansion tank 22 to the pump 12 through a reservoir 17 are included in the assembly of FIG. 1. When the expansion tank 22 is used as a kier only one return line is necessary to handle the return flow. However, when the larger capacity kier 20 is used as the treatment chamber, two return lines are preferred to handle the flow.
The yarn packages to be treated are supported within the kier 20 or expansion tank 22 on spindles of a carrier that include a treating liquid distributing manifold 26A and 26B, respectively, with a plurality of spindles 28A and 28B, respectively, rising therefrom towards the top of the kier or expansion tank.
In FIG. 1, the expansion tank 22 and the kier 20 are connected to each other, to the pump 12 and to the heat exchangers 14 and 16 via a conventional series of valves 18A-N. Through the opening and closing of the valves 18 in the configuration of FIG. 1, either the kier 20 or the expansion tank 22 can be selectively operated for treating textile yarn during a package treatment cycle. For example, if the number of packages to be treated is sufficient to use the kier 20, both heat exchangers 16 and 14 are selected for use and the expansion tank 22 operates as an expansion tank. Alternatively, in the mode specifically shown in FIG. 1, where a relatively small number of packages are to be treated, only the smaller heat exchanger 14 is connected for operation. Thus, in the mode specifically shown in FIG. 1, expansion tank 22 is used as the kier and kier 20 is used as the expansion tank.
In order to operate only the smaller heat exchanger 14 valve 18A is closed between heat exchanger 16 and pump 12 while valve 18N between the pump 12 and the small heat exchanger 14 is opened. This connects the pump solely to the smaller heat exchanger 14. Appropriate ones of valves 18B, 18C, 18F, 18M, 18H, and 18I are then opened and 18E, 18K, 18J and 18L closed to allow for treatment of the small quantity of yarn packages 24 in the expansion tank 22 and operation of the kier 20 as an expansion tank rather than as a kier. Thus, if a small load of textile yarn in package form is to be treated, greater efficiency can be obtained through use of only the small heat exchanger 14. Additionally, less dye is used by use of the smaller expansion tank as a kier.
When the kier 20 bears the yarn packages 24 to be treated, the additional amount of treating liquor required may at times result in the need for both heat exchangers 14 and 16 to be used rather than using only the large heat exchanger 16. It is preferable that the expansion tank 22 and the kier 20 as well as the heat exchangers are of differing sizes and selectively usable as shown in FIG. 1 to maximize the versatility and efficiency of the system.
The assembly may be operated in a conventional manner with the kier 20 and expansion tank 22 performing their conventional function. Then, when a small load is to be treated the functions can be reversed. In this operation, the assembly 10 is first pressurized, then the expansion tank 22 is filled with the dye liquor and the whole system is filled with dye liquor. Once the system is heated to operating temperature, the heat causes the liquor to expand and this expansion flows over into the kier 20, which is operating as the expansion tank.
A reverse valve, such as the reverse valve 30 in the embodiment of FIG. 2, may be employed reversibly to permit operation either to circulate the dye liquor through the manifolds 26A and 26B and the spindles 28A and 28B into the interior of the yarn packages and then through the packages to the exterior of the packages and drained down to the pump 12, or, alternatively, to circulate the dye liquor into the kier outside the yarn packages, through the yarn packages, into the spindles and manifold and then to the return lines to the pump.
The valves 18L and 18M in the valving connecting the kier 20 to the expansion tank 22 are to permit draining of wash water after the dyeing operation and while the system is being cleaned.
One of the advantages of using two heat exchangers of different capacities is that after the system is heated to operating temperature using the large capacity heat exchanger the system can be switched over to the small capacity heat exchanger to maintain the operating temperature to obvious advantage.
Referring now to FIG. 2 another embodiment of the present invention is shown. In this embodiment the invention has six kiers 20A through 20F and an expansion tank 22. Once again the pump is connected to the kiers via heat exchangers 14 and 16. The heat exchangers are preferably connected to kiers 20A through 20F via reverse valve 30 of the type previously discussed. In the embodiment shown in FIG. 2, only one kier 20F or any number of the kiers 20A-20F which are of the same capacity may be employed during a package treatment cycle. Thus, the pump 12 and heat exchangers may service only one kier or up to six or more kiers. If a relatively small load is being treated, less than all the kiers will be used and only the smaller heat exchanger 14 need be utilized. Alternatively, if a larger load is being treated, kiers 20A through 20F may be employed, along with either both or only the larger heat exchanger 16, by opening and closing the appropriate valves 19A, 19B, 19C, 19D, 19E and 19F to allow the reverse valve 30 to feed the treating liquor to kiers 20A through 20F. For example, the valving can be operated to connect both heat exchangers to all six kiers, or the large heat exchanger 16 may be connected to five kiers, such as 20A through 20E or 20F, or the large heat exchanger 16 may be connected to the four kiers 20A through 20D, or the small heat exchanger 14 may be connected to either or both kiers 20E and 20F.
In yet another mode of operation seen in FIG. 3, which is the same arrangement as FIG. 2 except that the kiers 20 are not all the same size, some of the kiers 20A through 20D, 20G and 20H may employ the undersized 20G and/or oversized 20H type kiers to suit the quantity of packages being treated. Thus, efficient use of treating liquor and energy is provided by the ability to alternate use of a particular number and size of kiers and by the utilization of particular appropriately sized heat exchangers. The sizes of kiers 20G and 20H may be varied by the insertion of modules between the connecting flanges 60 thereof as further described with respect to FIGS. 7 and 8.
Referring now to FIGS. 4, 5 and 6, another embodiment of the present invention is shown. In this embodiment, a kier or expansion tank 32 is shown with a cylindrical central portion 34 having an upper rim 36 and a lower rim 38. Within the kier a carrier 41 for supporting yarn packages 44 in spool or tube form is situated and conventionally held in place by a ram 43 of a pneumatic piston/cylinder mechanism 45 mounted to the lid 50 and acting on the central standard 47 of the carrier 41. The device includes a carrier manifold 40 that has a series of perforated spindles 42 upon which tubes of yarn packages 44 are placed.
A removable circular lid portion 46 is secured to the upper rim 36 of the central portion 34. When in operation the lid 46 should be secured to the upper rim in a fluid tight relation by a locking band 55. The lid portion 46 has a top side 48 and a bottom side 50 with the bottom side being relatively flat and facing towards the central portion 34 to reduce the fill volume as compared to conventional disk shaped lids.
The kier or expansion tank also has a circular lower portion 52 secured to the lower rim 38 of the central portion 34 with the bottom of the lower portion 52 having an inner facing surface 54 and an outer facing surface 56. The inner facing surface 54 is formed to complement the underside of the carrier manifold 40. Thus, since the bottom surface 50 of the lid portion 46 and the inner facing surface 54 of the lower portion 52 are formed to complement the carrier of yarn packages, less treating liquor is needed to fill the pressure system than in a conventional system and the volume of liquor needed to fill the kier or expansion tank during package treatment is therefore minimized as is the energy needed to heat the liquor. Preferably, the lid 46 and lower 52 portions of the kier or expansion tank 32 bear radial reinforcing ribs 58 formed on the outer facing surfaces 56 of the portions, respectively, to compensate for the non-spherical shapes of the portions in resisting the operating pressure.
Referring now to FIG. 7 yet another aspect of the present invention is shown. Here, a kier or expansion tank 32 having a cylindrical central portion 34 is shown with respect to a work floor 62. The kier or expansion tank 32 also has a lid portion 47 and a lower portion 53. The central portion 34 is connected to the lid 47 and lower 53 portions by conventional flange and locking band connections 60. The flange connections 60 allow for the separation and insertion of central portions 34 as intermediate modules to expand the capacity of the kier 32 as seen in FIG. 7.
Referring now to FIG. 8, an additional cylindrical module 64 is shown in its inserted position. The kier 32 is shown with respect to the work floor 62. Thus, in FIG. 8 the kier or expansion tank 32 can be easily expanded to accommodate larger size loads by insertion of intermediate modules 64. On the other hand, for smaller size loads the module can be removed and the kier used as shown in FIG. 7 for smaller loads. Of course, a series of modules 64 may be inserted for increased capacity.
It will therefore be readily understood by those persons skilled in the art that the present invention is susceptible of a broad utility and application. Many embodiments and adaptations of the present invention other than those herein described, as well as many variations, modifications and equivalent arrangements will be apparent from or reasonably suggested by the present invention and the foregoing description thereof, without departing from the substance or scope of the present invention. Accordingly, while the present invention has been described herein in detail in relation to its preferred embodiment, it is to be understood that this disclosure is only illustrative and exemplary of the present invention and is made merely for purposes of providing a full and enabling disclosure of the invention. The foregoing disclosure is not intended or to be construed to limit the present invention or otherwise to exclude any such other embodiment, adaptations, variations, modifications and equivalent arrangements, the present invention being limited only by the claims appended hereto and the equivalents thereof. | An apparatus for treating textile yarn in package form is disclosed having a kier for supporting yarn packages for treatment therein, a pump connected to the kier for pumping treating liquor to the kier to treat yarn packages supported therein, an expansion tank connected to the kier for receiving treating liquor from the kier and connected to the pump for passage of treating liquor from the expansion tank to the pump for recirculation to the kier, a device for supporting yarn packages in the expansion tank, valving operable for alternatively using the expansion tank as a kier and the kier as an expansion tank. The kiers and expansion tank are of differing capacities to accommodate varying load sizes at minimum liquor ratios. The heat exchangers are also of differing capacities for more efficient operation of the system. | 3 |
FIELD OF THE INVENTION
This invention relates to types of bicyclic nucleator compounds that provide highly versatile nucleation benefits for different thermoplastics. Such nucleator compounds provide very high peak crystallization temperatures and short crystallization cycle time for certain thermoplastic formulations with or without the presence of other calcium stearate and/or peroxide components within the same type of formulation. Furthermore, such inventive nucleator compounds exhibit very little, if any, fugitivity from such thermoplastic formulations thereby providing excellent processing characteristics as well as excellent nucleation capabilities for a variety of different thermoplastic resins, independent of the presence of different, potentially necessary, additives (such as calcium stearate). Thermoplastic compositions as well as thermoplastic additive packages comprising such inventive nucleator compounds are also contemplated within this invention.
BACKGROUND OF THE PRIOR ART
All U.S. patents cited below are herein entirely incorporated by reference.
As used herein, the term “thermoplastic” is intended to mean a polymeric material that will melt upon exposure to sufficient heat but will retain its solidified state, but not prior shape without use of a mold or like article, upon sufficient cooling. Specifically, as well, such a term is intended solely to encompass polymers meeting such a broad definition that also exhibit either crystalline or semi-crystalline morphology upon cooling after melt-formation. Particular types of polymers contemplated within such a definition include, without limitation, polyolefins (such as polyethylene, polypropylene, polybutylene, and any combination thereof), polyamides (such as nylon), polyurethanes, polyesters (such as polyethylene terephthalate), and the like (as well as any combinations thereof).
Thermoplastics have been utilized in a variety of end-use applications, including storage containers, medical devices, food packages, plastic tubes and pipes, shelving units, and the like. Such base compositions, however, must exhibit certain physical characteristics in order to permit widespread use. Specifically within polyolefins, for example, uniformity in arrangement of crystals upon crystallization is a necessity to provide an effective, durable, and versatile polyolefin article. In order to achieve such desirable physical properties, it has been known that certain compounds and compositions provide nucleation sites for polyolefin crystal growth during molding or fabrication. Generally, compositions containing such nucleating compounds crystallize at a much faster rate than unnucleated polyolefin. Such crystallization at higher temperatures results in reduced fabrication cycle times and a variety of improvements in physical properties, such as, as one example, stiffness.
Such compounds and compositions that provide faster and or higher polymer crystallization temperatures are thus popularly known as nucleators. Such compounds are, as their name suggests, utilized to provide nucleation sites for crystal growth during cooling of a thermoplastic molten formulation. Generally, the presence of such nucleation sites results in a larger number of smaller crystals. As a result of the smaller crystals formed therein, clarification of the target thermoplastic may also be achieved, although excellent clarity is not always a result. The more uniform, and preferably smaller, the crystal size, the less light is scattered. In such a manner, the clarity of the thermoplastic article itself can be improved. Thus, thermoplastic nucleator compounds are very important to the thermoplastic industry in order to provide enhanced clarity, physical properties and/or faster processing.
As an example of one type of nucleator, dibenzylidene sorbitol derivative compounds are typical nucleator compounds, particularly for polypropylene end-products. Compounds such as 1,3-O-2,4-bis(3,4-dimethylbenzylidene) sorbitol, available from Milliken Chemical under the trade name Millad® 3988 (hereinafter referred to as 3,4-DMDBS), provide excellent nucleation characteristics for target polypropylenes and other polyolefins. Other well known compounds include sodium benzoate, sodium 2,2′-methylene-bis-(4,6-di-tert-butylphenyl) phosphate (from Asahi Denka Kogyo K.K., known as and hereinafter referred to as NA-11), aluminum bis[2,2′-methylene-bis-(4,6-di-tert-butylphenyl)phosphate] (also from Asahi Denka Kogyo K.K., which is understood to be known as and hereinafter referred to as NA-21), talc, and the like. Such compounds all impart high polyolefin crystallization temperatures; however, each also exhibits its own drawback for large-scale industrial applications.
Other acetals of sorbitol and xylitol are typical nucleators for polyolefins and other thermoplastics as well. Dibenzylidene sorbitol (DBS) was first disclosed in U.S. Pat. No. 4,016,118 by Hamada, et al. as effective nucleating and clarifying agents for polyolefin. Since then, large numbers of acetals of sorbitol and xylitol have been disclosed, including bis(p-methylbenzylidene) sorbitol (hereinafter referred to as 4-MDBS). Representative references of such other compounds include Mahaffey, Jr., U.S. Pat. No. 4,371,645 [di-acetals of sorbitol having at least one chlorine or bromine substituent].
As noted above, another example of the effective nucleating agents are the metal salts of organic acids. Wijga in U.S. Pat. Nos. 3,207,735, 3,207,736, and 3,207,738, and Wales in U.S. Pat. Nos. 3,207,737 and 3,207,739, suggest that aliphatic, cycloaliphatic, and aromatic carboxylic, dicarboxylic or higher polycarboxylic acids, and corresponding anhydrides and metal salts, are effective nucleating agents for polyolefin. They further state that benzoic acid type compounds, in particular sodium benzoate, are the best nucleating agents for their target polyolefins.
Another class of nucleating agents was suggested by Nakahara, et al. in U.S. Pat. No. 4,463,113, in which cyclic bis-phenol phosphates was disclosed as nucleating and clarifying agents for polyolefin resins, as well as U.S. Pat. No. 5,342,868 to Kimura, et al. Compounds that are based upon these technologies are marketed under the trade names NA-11 and NA-21, discussed above.
Furthermore, a certain class of bicyclic compounds, such as bicyclic dicarboxylic acid and salts, have been taught as polyolefin nucleating agents as well within Patent Cooperation Treaty Application WO 98/29494, 98/29495 and 98/29496, all assigned to Minnesota Mining and Manufacturing. The best working examples of this technology are embodied in disodium bicyclo[2.2.1]heptene dicarboxylate and camphanic acid.
The efficacy of nucleating agents is typically measured by the peak crystallization temperature of the polymer compositions containing such nucleating agents. A high polymer peak crystallization is indicative of high nucleation efficacy, which generally translates into fast processing cycle time and more desirable physical properties, such as stiffness/impact balance, etc., for the fabricated parts. Compounds mentioned above all impart relatively high polyolefin crystallization temperatures; however, each also exhibits its own drawback for large-scale industrial applications.
For example, it is very desirable that the effective nucleating compounds exhibit a very high peak crystallization temperature, for example, above 125° C. within a test homopolymer polypropylene that, when unnucleated exhibits a number of different characteristics such as a density of about 0.9 g/cc, a melt flow of about 12 g/10 min, a Rockwell Hardness (R scale) of about 90, a tensile strength of about 4,931 psi, an elongation at yield of about 10%, a flexural modulus of about 203 ksi, an Izod impact strength of about 0.67 ft-lb/in, and a deflection temperature at 0.46 mPa of about 93° (which provides a homopolymer exhibiting an isotacticity of between about 96 and 99%), wherein said peak crystallization temperature is measured by differential scanning calorimetry in accordance with ASTM Test Method D3417-99 modified to measure at heating and cooling rates of 20° C./minute. Such a polypropylene homopolymer provides an effective test subject for this purpose due to the general uniformity of product available (and thus better uniformity in peak crystallization temperature, etc., results, therein for samples of such a thermoplastic), as well as the widespread use of such a thermoplastic. Of course, it should be well understood by the ordinarily skilled artisan that such a test homopolymer is not the only thermoplastic in which the inventive nucleating agent may be present; it is solely a test formulation in order to determine the highest peak crystallization temperature, etc., for certain inventive nucleating agents under certain conditions. Of the nucleating agents mentioned above, only camphanic acid exhibits such a high polymer peak crystallization temperature within such a test homopolymer propylene formulation. However, as shown in the comparative examples within this invention, camphanic acid exhibits very poor thermal stability, where it tends to vaporize and accumulate on the surface of plastic processing equipments during processing. This phenomenon is generally referred to as “plate out” within the plastics industry. The “plate out” effect of this additive make it impractical for any commercial use. Thus, the combination of very high polymer peak crystallization temperature (thus highly efficient nucleation) and a low degree of fugitivity (and thus high thermal stability and low plate-out characteristics) within the target polymers (e.g., preferably polyolefins such as polypropylene) is very desirable within the plastics industry, particularly where the peak crystallization temperature is measured above 126° C. within a homopolymer polypropylene measured by differential scanning calorimetry at a rate of 20° C./minute. So far, such a combination has not been provided within this intensively studied area of polymer nucleating agents.
Beyond high polymer crystallization temperature and low fugitivity, there are a number of other performance characteristics important for the practical use of such nucleating agents. For example, one of great interest is the compatibility of such compounds with different additives widely used within typical polyolefin (e.g., polypropylene, polyethylene, and the like) plastic articles. As noted previously, calcium stearate compatibility is particularly important. Unfortunately, most of the nucleator compounds noted above (such as sodium benzoate, NA-11, disodium bicyclo[2.2.1]heptene dicarboxylate) exhibit deleterious nucleating efficacy when present with such compounds within polyolefin articles. It is generally speculated that the calcium ion from the stearate transfers positions with the sodium ions of the nucleating agents, rendering the nucleating agents ineffective for their intended function. As a result, such compounds sometimes exhibit unwanted plate-out characteristics and overall reduced nucleation performance as measured, for example, by a decrease in crystallization temperature during and after polyolefin processing of greater than 2° C. as compared to the peak crystallization temperature of the nucleated polymer with no calcium stearate present therein. In order to avoid combinations of these standard nucleators and calcium salts, other nonionic acid neutralizers, such as dihydrotalcite (DHT4-A), would be necessary for use in conjunction with such nucleators. Such a combination, however, has proven problematic in certain circumstances due to worsened aesthetic characteristics (e.g., higher haze), and certainly higher costs in comparison with standard calcium salts.
Other problems encountered with the standard nucleators noted above include inconsistent nucleation due to dispersion problems, resulting in stiffness and impact variation in the polyolefin article. Substantial uniformity in polyolefin production is highly desirable because it results in relatively uniform finished polyolefin articles. If the resultant article does not contain a well dispersed nucleating agent, the entire article itself may suffer from a lack of rigidity and low impact strength.
Furthermore, storage stability of nucleator compounds and compositions is another potential problem with thermoplastic nucleators and thus is of enormous importance. Since nucleator compounds are generally provided in powder or granular form to the polyolefin manufacturer, and since uniform small particles of nucleating agents are imperative to provide the requisite uniform dispersion and performance, such compounds must remain as small particles through storage. Certain nucleators, such as sodium benzoate, exhibit high degrees of hygroscopicity such that the powders made therefrom hydrate easily resulting in particulate agglomeration. Such agglomerated particles may require further milling or other processing for deagglomeration in order to achieve the desired uniform dispersion within the target thermoplastic. Furthermore, such unwanted agglomeration due to hydration may also cause feeding and/or handling problems for the user.
Some nucleating agents, such as certain DBS derivatives, exhibit certain practical deficiencies such as a tendency to plate-out at high processing temperatures. DBS derivatives, particularly where the aromatic rings are mono-substituted, show much improved thermal stability. However, such compounds also tend to exhibit undesirable migratory properties coupled with problematic organoleptic deficiencies within certain polyolefin articles. As a result, such compounds cannot be widely utilized in some important areas, such as within medical devices (e.g., syringes, and the like) and food packaging.
These noticeable problems have thus created a long-felt need in the plastics industry to provide such compounds that do not exhibit the aforementioned problems and provide excellent peak crystallization temperatures and low fugitivity for the target polyolefins themselves. To date, the best compounds for this purpose remain those noted above. To date, nucleators exhibiting exceptionally high peak crystallization temperatures, low fugitivity, low hygroscopicity, excellent thermal stability, and non-migratory properties within certain target polyolefins, and compatibility with most standard polyolefin additives (such as, most importantly, calcium stearate) have not been available to the plastics industry.
OBJECTS OF THE INVENTION
Therefore, an object of the invention is to provide a polyolefin nucleating agent that provides excellent high peak crystallization temperatures to polypropylene articles and formulations and also exhibits extremely low fugitivity (excellent thermal stability, low plate-out). A further object of the invention is to provide a nucleator compound and compositions thereof that exhibit excellent calcium stearate compatibility within target polyolefin articles and formulations. Also, the inventive compounds must exhibit excellent low hygroscopicity in order to accord an extremely good shelf-stable additive composition. Another objective of this invention is to provide a nucleating compound and composition that exhibits low migration once incorporated within polyolefin articles. Another objective of this invention is to provide a nucleating agent and composition that exhibits little or no foul taste and/or odor within polyolefin articles. Another object of the invention is to provide a nucleator compound that affects the crystallization process within the target polyolefin polymer in such a manner that the resultant lamellar structure is highly unique (extremely thick) in comparison with other nucleated polypropylene articles and formulations such that said polyolefin exhibits very high stiffness properties. Additionally, it is an object of this invention to provide a nucleator compound or composition that may be used in various polyolefin media for use in myriad end-uses.
Accordingly, this invention encompasses a nucleating agent which induces a peak crystallization temperature of at least 125° C. (preferably, at least 125.5; more preferably, at least 126; still more preferably, at least 126.5; and most preferably at least 127; preferably such a temperature is as high as possible, up to the level of a self-nucleated test homopolymer polypropylene resin, such as at about 137-8° C., with a high temperature of about 134° C. most preferred) for a test homopolymer polypropylene formulation, wherein the unnucleated test homopolymer propylene exhibits a density of about 0.9 g/cc, a melt flow of about 12 g/10 min, a Rockwell Hardness (R scale) of about 90, a tensile strength of about 4,931 psi, an elongation at yield of about 10%, a flexural modulus of about 203 ksi, an Izod impact strength of about 0.67 ft-lb/in, and a deflection temperature at 0.46 mPa of about 93°, and wherein said formulation is extruded then molded into plaques having dimensions of about 51 mm×76 mm×1.27 mm, wherein said peak crystallization temperature is measured by differential scanning calorimetry in accordance with a modified ASTM Test Method D3417-99 at heating and cooling rates of 20° C./minute, and wherein said nucleating agent also exhibits no appreciable fugitivity from said test homopolymer polypropylene formulation during compounding of said test homopolymer polypropylene formulation.
Also encompassed within this invention is a nucleating agent which induces a crystallization half time (t ½ ) of at most 2.0 minutes in a test homopolymer polypropylene formulation, wherein the unnucleated test homopolymer propylene exhibits a density of about 0.9 g/cc, a melt flow of about 12 g/10 min, a Rockwell Hardness (R scale) of about 90, a tensile strength of about 4,931 psi, an elongation at yield of about 10%, a flexural modulus of about 203 ksi, an Izod impact strength of about 0.67 ft-lb/in, and a deflection temperature at 0.46 mPa of about 93° C., and wherein said formulation is extruded then molded into plaques having dimensions of about 51 mm×76 mm×1.27 mm, wherein said t ½ is measured by differential scanning calorimetry at a constant crystallization temperature of about 140° C., and wherein said nucleator also exhibits no appreciable fugitivity from said polypropylene formulation.
Additionally, this invention also encompasses a nucleating agent which induces a standard peak crystallization temperature of at least 123.5° C. in a test homopolymer polypropylene formulation, wherein the unnucleated test homopolymer polypropylene exhibits a density of about 0.9 g/cc, a melt flow of about 12 g/10 min, a Rockwell Hardness (R scale) of about 90, a tensile strength of about 4,931 psi, an elongation at yield of about 10%, a flexural modulus of about 203 ksi, an Izod impact strength of about 0.67 ft-lb/in, and a deflection temperature at 0.46 mPa of about 93° C., and wherein said formulation is extruded then molded into plaques having dimensions of about 51 mm×76 mm×1.27 mm, wherein said peak crystallization temperature measured by differential scanning calorimetry in accordance with a modified ASTM Test Method D3417-99 at heating and cooling rates of 20° C./minute and wherein said nucleating agent is present in at most 1500 ppm, wherein said polymer nucleator exhibits no appreciable fugitivity from said polypropylene formulation during compounding of said polypropylene, and wherein said nucleating agent induces said peak crystallization temperature in said polypropylene formulation when no calcium stearate is present, and wherein said nucleating agent induces a comparative peak crystallization temperature of at most 2° C. lower than said standard peak crystallization for the same polypropylene formulation when at least 800 ppm of calcium stearate is present. Furthermore, such a compound exhibits a very low hygroscopicity as well.
Additionally, this invention encompasses a nucleating agent which produces an effective nucleation density of greater than 7×10 9 nuclei/cm 3 at an isothermal crystallization temperature of about 148° C. in a test homopolymer polypropylene formulation comprising said nucleating agent, wherein the unnucleated test homopolymer propylene exhibits a density of about 0.9 g/cc, a melt flow of about 12 g/10 min, a Rockwell Hardness (R scale) of about 90, a tensile strength of about 4,931 psi, an elongation at yield of about 10%, a flexural modulus of about 203 ksi, an Izod impact strength of about 0.67 ft-lb/in, and a deflection temperature at 0.46 mPa of about 93°, and wherein said formulation is extruded then molded into plaques having dimensions of about 51 mm×76 mm×1.27 mm, and wherein said nucleating agent also exhibits no appreciable fugitivity from said test homopolymer polypropylene formulation during compounding of said test homopolymer polypropylene formulation comprising said nucleating agent.
Still further encompassed within this invention is a nucleating agent which exhibits a nucleation effectiveness factor (NEF) of greater than 0.06 in a test homopolymer polypropylene formulation having a density of about 0.9 g/cc, a melt flow of about 12 g/10 min, a Rockwell Hardness (R scale) of about 90, a tensile strength of about 4,931 psi, an elongation at yield of about 10%, a flexural modulus of about 203 ksi, an Izod impact strength of about 0.67 ft-lb/in, and a deflection temperature of 0.46 mPa at about 93° C., wherein said formulation is extruded and then molded into plaques having dimensions of about 51 mm×76 mm×1.27 mm.
It should also be well understood and appreciated by one of ordinary skill within this art that the inventive nucleating agent is defined above as performing to a certain degree within a test polymer formulation, and is not required to be a component within such a test polymer formulation. Thus, although such an inventive nucleating agent must perform to a certain level within a test homopolymer propylene, it may be present within any other type of polymer (such as a thermoplastic), including blends of polymers. The particular polymers within which such an inventive nucleating is effective and useful are listed below in greater detail.
The bicyclic compounds are defined as organic compounds that contain two or more rings wherein at least two of the said rings share at least two nonadjacent atoms.
Some particular, non-limiting examples of such novel nucleator compounds include the metal or organic salts of saturated [2.2.1]bicyclic dicarboxylates, and most preferably of these types of compounds conforming to Formula (I)
wherein M 1 and M 2 are the same or different and are independently selected from the group consisting of metal or organic cations, and R 1 , R 2 , R 3 , R 4 , R 5 , R 6 , R 7 , R 8 , R 9 , and R 10 are individually selected from the group consisting of hydrogen, C 1 -C 9 alkyl, hydroxyl, C 1 -C 9 alkoxy, C 1 -C 9 alkyleneoxy, amine, and C 1 -C 9 alkylamine, halogen, phenyl, alkylphenyl, and geminal or vicinal C 1 -C 9 carbocyclic. Preferably, the metal cations are selected from the group consisting of calcium, strontium, barium, magnesium, aluminum, silver, sodium, lithium, rubidium, potassium, and the like. Within that scope, group I and group II metal ions are generally preferred. Among the group I and II cations, sodium, potassium, calcium and strontium are preferred, wherein sodium and calcium are most preferred. Furthermore, the M 1 and M 2 groups may also be combined to form a single metal cation (such as calcium, strontium, barium, magnesium, aluminum, and the like). Although this invention encompasses all stereochemical configurations of such compounds, the cis configuration is preferred wherein cis-endo is the most preferred embodiment. The preferred embodiment polyolefin articles and additive compositions for polyolefin formulations comprising at least one of such compounds are also encompassed within this invention.
The term “no appreciable fugitivity” as used as one description within this invention is intended to encompass nucleators which exhibit very high heat stabilities (and thus very low plate-out) within test polypropylene formulations. Therefore, a weight loss of nucleator compound during a thermal stability test of at most 5% is encompassed within this term. Such thermal stability testing is described in greater detail below.
DETAILED DESCRIPTION OF THE INVENTION
As noted above, in order to develop a proper polyolefin nucleator compound or composition for industrial applications, a number of important criteria need to be met. The inventive nucleating agents meet all of these important requirements very well. For instance, as discussed in greater detail below, these inventive salts provide excellent high peak crystallization temperatures in a variety of polyolefin formulations, particularly within random copolymer polypropylene (hereinafter RCP) and homopolymer polypropylene (hereinafter HP). As a result, such inventive salts provide excellent mechanical properties for polyolefin articles without the need for extra fillers and rigidifying additives, and desirable processing characteristics such as improved (shorter) cycle time. The salts also show much improved hygroscopicity comparing to prior art and thus granular or powder formulations of such a salt do not agglomerate or clump together. Lastly, such inventive salts do not interact deleteriously with calcium stearate additives.
Such properties are highly unexpected and unpredictable, particularly in view of the closest prior art, the WO 98/29494 reference discloses nucleation and clarification additives for polyolefin articles including unsaturated [2.2.1]dicarboxylate salts; however, there is no exemplification of a saturated dicarboxylate salt of this type. The closest embodiment within that art is identified as disodium bicyclo[2.2.1]heptene dicarboxylate. After intensive investigations, it has been determined that, quite unexpectedly, as discussed below in greater detail, the hydrogenation of such compounds provides vastly improved nucleation efficacy for the inventive compounds and within the inventive polyolefin compositions. It has now been found that the saturation of Diels-Alder reaction products to form dicarboxylate salts, and in particular, without intending to limit the scope of the invention, saturated bicyclic dicarboxylate salts, provide unforeseen benefits for polyolefin nucleation processes.
As indicated in Table 1, below, the peak crystallization temperatures provided target polyolefin articles with these inventive saturated compounds are from about 2.5 to about 5° C. above that for the related unsaturated compounds. Such dramatic improvements are simply unexpected and are unpredictable from any known empirical or theoretical considerations. Furthermore, significant improvements in hygroscopicity of the saturated compounds were also unexpectedly observed. Such unpredictable improvements are of great practical significance as discussed before.
Yet another surprise was the improved compatibility between these inventive saturated compounds and typical acid scavenger salt compounds utilized within polyolefin formulations and articles, such as calcium and lithium stearate. Such compatibility, coupled with the high peak crystallization temperatures available from the inventive compounds, thus provides a highly desirable thermoplastic nucleator compound. Furthermore, the ability to provide extremely high nucleation density measurements (above an order of magnitude than typical nucleating agents at various isothermal crystallization temperatures) is highly desirable and previously unattainable as well.
The inventive salts are thus added within the target polyolefin in an amount from about 50 ppm to about 20,000 ppm by weight in order to provide the aforementioned beneficial characteristics, most preferably from about 200 to about 4000 ppm. Higher levels, e.g., 50% or more by weight, may also be used in a masterbatch formulation. Optional additives within the inventive salt-containing composition, or within the final polyolefin article made therewith, may include plasticizers, antistatic agents, stabilizers, ultraviolet absorbers, and other similar standard polyolefin thermoplastic additives. Other additives may also be present within this composition, most notably antioxidants, antistatic compounds, antimicrobials (preferably silver-based ion-exchange compounds, such as ALPHASAN® antimicrobials available from Milliken & Company), perfumes, chlorine scavengers, and the like. Such additives, and others not listed, are well known to those skilled in the art.
The term polyolefin or polyolefin resin is intended to encompass any materials comprised of at least one polyolefin compound. Preferred examples include isotactic and syndiotactic polypropylene, polyethylene, poly(4-methyl)pentene, polybutylene, and any blends or copolymers thereof, whether high or low density in composition. The polyolefin polymers of the present invention may include aliphatic polyolefins and copolymers made from at least one aliphatic olefin and one or more ethylenically unsaturated co-monomers. Generally, the co-monomers, if present, will be provided in a minor amount, e.g., about 10 percent or less or even about 5 percent or less, based upon the weight of the polyolefin (e.g. random copolymer polypropylene), but copolymers containing up to 25% or more of the co-monomer (e.g., impact copolymers) are also envisaged. Other polymers or rubber (such as EPDM or EPR) may also be compounded with the polyolefin to obtain the aforementioned characteristics. Such co-monomers may serve to assist in clarity improvement of the polyolefin, or they may function to improve other properties of the polymer. Other examples include acrylic acid and vinyl acetate, etc. Examples of olefin polymers whose transparency can be improved conveniently according to the present invention are polymers and copolymers of aliphatic monoolefins containing 2 to about 6 carbon atoms which have an average molecular weight of from about 10,000 to about 2,000,000, preferably from about 30,000 to about 300,000, such as, without limitation, polyethylene, linear low density polyethylene, isotactic polypropylene, syndiotactic polypropylene, crystalline ethylene propylene copolymer, poly(1-butene), polymethylpentene, 1-hexene, 1-octene, and vinyl cyclohexane. The polyolefins of the present invention may be described as basically linear, regular polymers that may optionally contain side chains such as are found, for instance, in conventional low density polyethylene.
Although polyolefins are preferred, the nucleating agents of the present invention are not restricted to polyolefins, and may also give beneficial nucleation properties to polyesters such as polyethylene terephthalate (PET), polybutylene terephthalate (PBT), and polyethylene naphthalate (PEN), as well as polyamides such as Nylon 6, Nylon 6,6, and others. Generally, any thermoplastic composition having some crystalline content may be improved with the nucleating agents of the present invention.
The compositions of the present invention may be obtained by adding the inventive saturated bicyclic dicarboxylic salt (or combination of salts or composition comprising such salts) to the thermoplastic polymer or copolymer and merely mixing the resultant composition by any suitable means. Alternatively, a concentrate containing as much as about 20 percent by weight of the inventive saturated [2.2.1] salt in a polyolefin masterbatch comprising the required acid scavenger may be prepared and be subsequently mixed with the target resin. Furthermore, the inventive compositions (with other additives potentially) may be present in any type of standard thermoplastic (e.g., polyolefin, most preferably) additive form, including, without limitation, powder, prill, agglomerate, liquid suspension, and the like, particularly comprising dispersion aids such as polyolefin (e.g., polyethylene) waxes, stearate esters of glycerin, montan waxes, mineral oil, and the like. Basically, any form may be exhibited by such a combination or composition including such combination made from blending, agglomeration, compaction, and/or extrusion.
The composition may then be processed and fabricated by any number of different techniques, including, without limitation, injection molding, injection blow molding, injection stretch blow molding, injection rotational molding, extrusion, extrusion blow molding, sheet extrusion, film extrusion, cast film extrusion, foam extrusion, thermoforming (such as into films, blown-films, biaxially oriented films), thin wall injection molding, and the like into a fabricated article.
PREFERRED EMBODIMENTS OF THE INVENTION
Examples of particularly preferred fluid dispersions within the scope of the present invention are presented below.
Production of Inventive Salts
EXAMPLE A
Disodium bicyclo[2.2.1]heptane-2,3-dicarboxylate
To a solution of disodium bicyclo[2.2.1]hept-5-ene-2,3-dicarboxylate (10.0 g, from example 3) in water (100 g) was added 0.5 g palladium on activated carbon (5 wt %). The mixture was transferred into a Parr reactor and was subjected to hydrogenation (50 psi, room temperature) for 8 hours. The activated carbon was filtered out. Water is removed in vacuo at 75° C. The resulting product was dried and milled (m.p >300° C.).
EXAMPLE 2
Calcium bicyclo[2.2.1]heptane-2,3-dicarboxylate
To a solution of disodium bicyclo[2.2.1]heptane-2,3-dicarboxylate (22.6 g, 0.1 mol) in water (150 g) was added a solution of calcium chloride dihydrate (14.7 g, 0.1 mol) in water (100 g). The mixture stirred at 60° C. for 2 hours. The resulting white precipitate was filtered. The white powdery product was dried and milled (m.p. >300° C.).
EXAMPLE 3 (COMPARATIVE)
Disodium bicyclo[2.2.1]hept-5-ene-2,3-dicarboxylate
To a suspension of endo-bicyclo[2.2.1]hept-5-ene-2,3-dicarboxylic anhydride (16.4 g, 0.1 mol) in water (100 g) was added sodium hydroxide (8.0 g, 0.2 mol) at room temperature. The mixture was then stirred at 80° C. for 2 hour. A clear, homogeneous solution was obtained. Water was removed in vacuo at 75° C. and the resulting white crystalline product was dried and milled (m.p. >300° C.).
Other lithium, rubidium, potassium, strontium, barium, and magnesium [2.2.1]heptane dicarboxylate salts were also prepared in like manners for testing. Commercial samples of NA-11, NA-21, 3,4-DMDBS, and 4-MDBS were used in this evaluation without further purification and treatment. Camphanic acid (purity higher than 98%) was purchased from Aldrich Chemical company. It was used without further purification and treatment.
Nucleation Efficacy Tests
Thermoplastic compositions (plaques) were produced comprising the additives from the Examples above and sample homopolymer polypropylene (HP) resin plaques, produced dry blended in a Welex mixer at ˜2000 rpm, extruded through a single screw extruder at 400-450° F., and pelletized. Accordingly, one kilogram batches of target polypropylene were produced in accordance with the following table:
HOMOPOLYMER POLYPROPYLENE COMPOSITION
Component
Amount
Polypropylene homopolymer (Himont Profax ® 6301)
1000 g
Irganox ® 1010, Primary Antioxidant (from Ciba)
500 ppm
Irgafos ® 168, Secondary Antioxidant (from Ciba)
1000 ppm
Acid Scavenger
as noted
Nucleating Agent
as noted
The base HP [having a density of about 0.9 g/cc, a melt flow of about 12 g/10 min, a Rockwell Hardness (R scale) of about 90, a tensile strength of about 4,931 psi, an elongation at yield of about 10%, a flexural modulus of about 203 ksi, an Izod impact strength of about 0.67 ft-lb/in, and a deflection temperature at 0.46 mPa of about 93° C., as well as an expected isotacticity of between about 96 and 99% through xylene solubles analysis] and all additives were weighed and then blended in a Welex mixer for 1 minute at about 1600 rpm. All samples were then melt compounded on a Killion single screw extruder at a ramped temperature from about 204° to 232° C. through four heating zones. The melt temperature upon exit of the extruder die was about 246° C. The screw had a diameter of 2.54 cm and a length/diameter ratio of 24:1. Upon melting the molten polymer was filtered through a 60 mesh (250 micron) screen. Plaques of the target polypropylene were then made through extrusion into an Arburg 25 ton injection molder. The molder was set at a temperature anywhere between 190 and 260° C., with a range of 190 to 240° C. preferred, most preferably from about 200 to 230° C. and at an injection speed within the range of between about 1 and about 5 cm 3 /second. The plaques had dimensions of about 51 mm×76 mm×1.27 mm, and the mold had a mirror finish which was transferred to the individual plaques. The mold cooling circulating water was controlled at a temperature of about 25° C.
Testing for nucleating effects and other important criteria were accomplished through the formation of plaques of clarified polypropylene thermoplastic resin. These plaques were formed through the process outlined above with the specific compositions listed above in the above Table.
These plaque formulations are, of course, merely preferred embodiments of the inventive article and method and are not intended to limit the scope of this invention. The resultant plaques were then tested for peak crystallization temperatures (by Differential Scanning Calorimetry). Crystallization is important in order to determine the time needed to form a solid article from the molten polyolefin composition. Generally, a polyolefin such as polypropylene has a crystallization temperature of about 110° C. at a cooling rate of 20° C./min. In order to reduce the amount of time needed to form the final product, as well as to provide the most effective nucleation for the polyolefin, the best nucleator compound added will invariably also provide the highest crystallization temperature for the final polyolefin product. The nucleation composition efficacy, particular polymer peak crystallization temperature (T c ), was evaluated by using a modified differential scanning procedure based upon the test protocol ASTM D3417-99 wherein the heating and cooling rates utilized have been altered to 20° C./minute each. Thus, to measure the peak crystallization temperatures of the samples, the specific polypropylene compositions were heated from 60° C. to 220° C. at a rate of 20° C. per minute to produce molten formulations and held at the peak temperature for 2 minutes. At that time, the temperature was then lowered at a rate of 20° C. per minute until it reached the starting temperature of 60° C. for each individual sample. The important crystallization temperatures were thus measured as the peak maxima during the individual crystallization exotherms for each sample. After allowing the plaques to age for 24 hours at room temperature, haze values were measured according to ASTM Standard Test Method D1003-61 “Standard Test Method for Haze and Luminous Transmittance of Transparent Plastics” using a BYK Gardner Hazegard Plus.
The following Table lists the peak crystallization temperatures and haze results for the sample plaques prepared with the additives noted above (with certain acid scavengers and levels thereof as well as levels of nucleating agent used therein specified for each sample; Samples 5-10, below included 2500 ppm each of the nucelating agent):
TABLE 1
EXPERIMENTAL
Performance of Bicyclic Nucleators in Polypropylene Homopolymer
Sample #
Nucleator Conc. (ppm)
Peak T c (° C.)
Haze (%)
1
Example A (1000 ppm) a
126
34
2
Example A (2500 ppm) a
128
30
3
Example B (1000 ppm) a
125
48
4
Example B (2500 ppm) a
127
45
5
Lithium bicyclo[2.2.1]heptane
123
56
dicarboxylate a
6
Potassium bicyclo[2.2.1]heptane
125
67
dicarboxylate b
7
Rubidium bicyclo[2.2.1]heptane
123
55
dicarboxylate b
8
Magnesium bicyclo[2.2.1]-
117
78
heptane dicarboxylate a
9
Barium bicyclo[2.2.1]heptane
121
71
dicarboxylate a
10
Strontium bicyclo[2.2.l]heptane
124
56
dicarboxylate a
11
(Comparative Control) a
110
68
12
Example C (Comparative)
122
50
(1000 ppm) a
13
Example C (Comparative)
123
46
(2500 ppm) a
14
3,4-DMDBS (2500 ppm) a
123
11
15
NA-11 (1000 ppm) c
124
32
16
NA-21 (2500 ppm) a
123
20
17
Camphanic Acid (2500 ppm) b
127
30
a Including 800 ppm of calcium stearate acid scavenger
b Including 800 ppm of lithium stearate acid scavenger
c Including 400 ppm of DHT-4A acid scavenger
The data show that inventive nucleating agents in Examples A and B, above, exhibit significantly high polymer peak crystallization temperatures and simultaneous low haze measurements.
Another important test for nucleation efficacy is the crystallization half-time (t ½ ). This measurement was conducted on DSC where the specific polypropylene composition was heated from 60° C. to 220° C. at a rate of 20° C. per minute to produce a molten formulation and held at the peak temperature for 2 minutes. At that time, the temperature was then lowered quickly to 140° C., where the sample was held. The exotherm of crystallization was measured with time. The time where exactly one-half of the heat of crystallization is generated was recorded as the crystallization half time. Shorter crystallization half time is indicative of higher nucleation efficacy. In a practical sense, a shorter crystallization half time is an indicator of a shorter cycle time, and thus of significant value.
TABLE 2
EXPERIMENTAL
Crystallization Half Time in Homopolymer
Sample #
Loading
t 1/2
(from Experimental Table 1)
(ppm)
(minutes)
13 (Comparative)
2500
4.50
2
2500
0.98
4
2500
1.40
The data show that the inventive compounds of Examples A and B exhibit significantly shorter crystallization half times.
Thermal Stability (Fugitivity) Test
Thermal stability of is an important criteria for polymer additives. Additives lacking thermal stability would cause plate out and other processing issues. Stability tests are conducted on a Thermogravimetric Analyzer from TA Instruments. Roughly 10 mg of dry sample is added to the stainless steel sample cell. The sample cell is then blanketed with nitrogen. Sample is allowed to equilibrate for 5 minutes at 25° C. The temperature is then raised at 20° C./min ramp rate until it reaches 500° C. Weight loss in percentage versus temperature is recorded for the sample nucleator from within the sample polypropylene as a result of such thermal stability testing. Polypropylene is typically processed between 200-250° C. and a weight loss of the sample nucleator in excess of 5% at 250° C. is generally considered as unsuitable for use since the remaining amounts would be insufficient for proper and necessary nucleation to occur. The weight loss data for camphanic acid and disodium [2.2.1]cycloheptane dicarboxylate is shown below:
TABLE 3
EXPERIMENTAL
Thermal Stability Results
% Weight loss
% weight loss of
Temperature
of Example A
Camphanic acid
200° C.
0.9%
10%
250° C.
1.2%
47%
300° C.
1.4%
89%
The data indicate that although camphanic acid exhibits comparable polymer peak crystallization temperature, it lacks the necessary thermal stability for practical commercial use.
Calcium Stearate Compatibility Test
In this test, the nucleators were tested in formulations with and without calcium stearate. The nucleation efficacy of the nucleators in each formulation was studied by measuring polymer crystallization temperature. The formulations and testing conditions are identical with those discussed above. A drop of 2° C. or more is considered a failure.
TABLE 4
EXPERIMENTAL
Calcium Stearate (CaSt) Compatibility Test
Sample
Nucleator Conc.
CaSt Loading
Peak
Peak T c
#
(ppm)
(ppm)
T c
Change
18
Example A (2500 ppm) d
0
128
—
19
Example A (2500 ppm) e
800
128
˜0
20
Example B (2500 ppm) d
0
127
—
21
Example B (2500 ppm) e
800
127
˜0
22
NA-11 d
0
124
—
23
NA-11 e
800
121
3
24
Example C d
0
123
—
25
Example C e
800
121
2
26
Camphanic Acid f
0
127
—
27
Camphanic Acid e
800
124
3
d Including 400 ppm of DHT-4A acid scavenger
e Having calcium stearate as the only acid scavenger present
f Including 800 ppm of lithium stearate acid scavenger (lithium stearate is a poor acid scavenger and is thus utilized with camphanic acid in order not to scavenge the camphanic acid itself from the formulation)
The data show that the inventive nucleators in Examples A and Example B pass the compatibility test with calcium stearate.
Hygroscopicity Test
These tests were carried out on the milled products to give adequate surface area for moisture uptake. Two grams of each example were spread out on a watch glass and weighed immediately after drying in a vacuum oven. The samples were then placed in a controlled humidity (65%) environment and the weight was taken each day for 7 days. The percent weight gain was defined as the percent moisture uptake. Experimental Table 5 below summarizes the results:
TABLE 5
EXPERIMENTAL
Hygroscopicity Test Data
Sample #
Nucleating Agent
Weight Gain (% w/w)
28
Example A
1%
29
Example B
0%
30
Example C (Comparative)
8%
It is clear from the above data that saturation of Example 3 reduces the hygroscopicity over that of the prior art significantly, and the use of calcium as the metal reduces the moisture uptake to zero.
Nucleation Efficacy in Polyester
The inventive additives were also tested as nucleating agents for polyester. Additives were compounded with a C. W. Brabender Torque Rheometer at 5000 ppm into Shell Cleartuff™ 8006 PET bottle grade resin having an Intrinsic Viscosity of 0.80. All resin was dried to less than 20 ppm water. Samples were taken, pressed, and rapidly cooled into 20-40 mil films. All samples were dried at 150° C. under vacuum for 6 hours prior to analysis. The samples were analyzed under nitrogen on a Perkin Elmer System 7 differential scanning calorimeter using a heating and cooling rate of 20° C./min. The polymer peak crystallization temperature was measured as described before. The data is shown in Experimental Table 6 below:
TABLE 6
EXPERIMENTAL
Polyester Nucleating Results
Sample
Peak Cryst. Temp. (° C.)
Control
155
Example C
184
Example A
194
Thus, the inventive saturated compound exhibited much improved nucleation of polyester over the control with no nucleator compound and the unsaturated nucleator compound.
Retort Extraction Test
Plaques, as prepared above, were subjected an extraction test as outlined in the following procedure:
Seven plaques were cut into nine strips each to give a total surface area of approximately 600 cm 2 . These strips were rinsed with deionized water and allowed to dry. They were then placed into a glass extraction vessel and covered with 200 ml of deionized water. The glass vessels and their contents were autoclaved for 60 minutes at 121° C., and were allowed to cool and settle for 24 hours. After settling, approximately 60 ml of the extraction solution was transferred to a clean beaker, and 10 ml of this solution was filtered through a 0.8-μm filter fitted to a syringe. The filtrate was collected in a 1-cm quartz cuvette. The cuvette and contents were scanned for peak UV absorbances in the wavelength range 220-240 nm and 241-350 nm, after a suitable deionized water blank had been scanned. Such a test provides indications of the effectiveness of the resultant thermoplastic with regards to the extractability of any contents of the plastic itself and thus is a good indicator as to the usefulness of the thermoplastic product for different types of end-uses. The lower the extraction level, the more useful such thermoplastic is for food contact, for example.
TABLE 7
EXPERIMENTAL
Extraction Performance of Bicyclic Nucleators
in Polypropylene Homopolymer
Additive Conc.
Peak Absorbance
Peak Absorbance
Additives
(ppm)
220-240 nm
241-350 nm
Control
—
0.019
0.006
(no nucleator)
Example A
2500
0.012
0.004
4-MDBS
2200
0.336
0.183
The data demonstrate that the inventive product in Example 1 shows extraction levels comparable to thermoplastic samples containing no nucleator at all and thus indicates that such thermoplastic may be useful for various end-uses.
Nucleation Density
One method of evaluating the nucleating efficiency of a nucleating agent in a given resin is to calculate the density of nucleating sites per unit volume of polymer as well as comparing such density measurements at differing isothermal crystallization temperatures. The greater the density of nucleating sites, the better the nucleating agent. The higher the ratio of densities between different isotherms, the more versatile the nucleating agent.
For these purposes, the effective nucleation densities for the inventive and comparative nucleating agents were calculated by combining isothermal crystallization kinetic data measured using differential scanning calorimetry and spherulitic growth rate data measured with optical microscopy. A Perkin Elmer DSC-7 was calibrated with an indium metal standard at a heating rate of 20 C/min. Polymer samples with a thickness of 250+/−50 microns and a weight of 5.0+/−0.5 mg were encased in aluminum pans. The pans were then heated from 60° C. to 220° C. at 20° C./min, held 2 minutes, rapidly cooled to the isothermal crystallization temperature, and then held at the isothermal crystallization temperature until the crystallization was complete.
The relative crystallinity, C, as a function of time, t, was calculated as demonstrated in [1] . Crystallization Kinetic data were modeled using the Avrami Equation: 1−C=exp (−Kt n ), where K and n are constants. The Avrami equation was rewritten in logarithmic form: ln(−ln(1−C))=lnK+n ln t and then linear regression was used to find the best values of K and n for relative crystallinities between 0.05 and 0.5. The linear spherulitic growth rate of polypropylene at a given temperature, G, was calculated using the equation G=1.62×10 10 exp (−0.20 T), where T has units of degrees Celsius and G has units of μm/sec [1] . For example, G(140° C.)=0.0112 μm/sec.
[1] Journal of Polymer Science: Part B: Polymer Physics, 31, 1395 (1993)
The effective nucleation density, N, was calculated according to N=3 K′/4πG 3 , where K′ is an Avrami rate constant for the case of three-dimensional growth at a linear growth rate. K′ was calculated from K using the following relation: K′=ln2/(ln2/K) 3/n [2] . For example, at an isothermal crystallization temperature of 140° C., homopolymer polypropylene nucleated with 0.1% NA-11UF had Avrami rate constants n=3.21 and K=0.0484 min −3.21 . The corresponding value of K′ was 0.0576 min −3 =2.67×10 −7 sec −3 .
[2] Journal of Applied Polymer Science, 57, 187 (1995)
The following Table shows the nucleation density measurements for various nucleating agents at 140 and 148° C. isotherms. An asterisk for NA-21 indicates that the nucleation density was too low to be measured.
TABLE 8
EXPERIMENTAL
Nucleation Density Measurements
Isothermal T c
Nucleation Density
Nucleating Agent
(° C.)
(nuc/cm 3 )
1000 ppm Ex. A g
140
6 E 11
1000 ppm NA-11 h
140
4 E 10
2200 ppm NA-21 g
140
4 E 9
2500 ppm Camphanic Acid i
140
3 E 11
1000 ppm Ex. A g
148
1 E 11
1000 ppm NA-11 h
148
2 E 9
2200 ppm NA-21 g
148
*
2500 ppm Camphanic Acid i
148
1 E 10
g Including 800 ppm of calcium stearate
h Including 400 ppm of DHT-4A
i Including 800 ppm of lithium stearate
Thus, the inventive nucleating agent provided an increase in nucleation density within the test homopolymer polypropylene at least an order of magnitude greater than the closest typical polyolefin nucleating agents. Therefore, such an inventive nucleating agent is defined as one which, at an isothermal T c of about 148° C. of at least 7 E 9 (7×10 9 ) nuc/cm 2 ; preferably at least 1 E 10; still more preferably, at least 5 E 10; and most preferably at least 1 E 11, within the test homopolymer polypropylene formulation as noted above, and which, as noted above, does not exhibit any appreciable fugitivity from the thermoplastic formulation during compounding thereof.
Furthermore, it is desirable to measure the effectiveness of a given nucleating agent over a broad range of temperatures. An excellent manner of quantifying such effectiveness measurements over such broad temperature ranges is to calculate a what we have termed a nucleation effectiveness factor. Such a factor (hereinafter referred to as NEF) is, for a given additive, defined as the ratio of the nucleation density provided by a nucleation agent at 148° to the nucleation density provided by the same nucleation agent at 140° C. [in other words NEF=N(148° C.)/N(140° C.)]. A nucleating agent which exhibits a higher nucleation effectiveness factor supplies a large number of heterogeneous nuclei to the polymer over a broad temperature range, which leads to faster polymer crystallization over such a expanded range of temperatures. As noted below in the accompanying Table, and using the results in Experimental Table 8, above, such NEF measurements are as follows:
TABLE 9
EXPERIMENTAL
NEF Measurements as Delineated from EXPERIMENTAL TABLE 8
Nucleating Agent
NEF
Example A
0.16
NA-11
0.05
Camphanic Acid
0.03
Thus, the inventive nucleating agent is more effective and versatile than the comparative compounds over a broad temperature range. Preferably, such a NEF is thus greater than about 0.06; more preferably, greater than about 0.08; still more preferably greater than about 0.10; and most preferably greater than about 0.12, since the greater the number, the greater the versatility of the nucleating agent.
Having described the invention in detail it is obvious that one skilled in the art will be able to make variations and modifications thereto without departing from the scope of the present invention. Accordingly, the scope of the present invention should be determined only by the claims appended hereto. | Bicyclic nucleator compounds that provide highly versatile nucleation benefits for different polyolefins are provided. Such nucleator compounds provide very high peak crystallization temperatures and significantly reduced crystallization cycle time for certain thermoplastic formulations with or without the presence of other calcium stearate and/or peroxide components within the same type of formulation. Furthermore, such inventive nucleator compounds exhibits very little if any fugitivity from such thermoplastic formulations thereby providing excellent processing characteristics as well as excellent nucleation capabilities for a variety of different thermoplastic resins, independent of the presence of different, potentially necessary, additives (such as calcium stearate). Thermoplastic compositions as well as thermoplastic additive packages comprising such inventive nucleator compounds are also contemplated within this invention. | 2 |
[0001] This application is a continuation in part of U.S. patent application Ser. No. 08/362,995 filed Dec. 23, 1994 which is a continuation in part of U.S. patent application Ser. No. 08/281,620 filed Jul. 28, 1994 from which priority is claimed.
FIELD OF INVENTION
[0002] This invention relates to a retractable screen system for a closure assembly and improvements thereof which allows the secure sliding and subsequent retraction of the screen from a operative position to a retracted position. The invention is preferably embodied in a window assembly but finds application also in large pivoting windows and patio doors.
BACKGROUND OF THE INVENTION
[0003] The reader is referred to Appilcants Co-pending Applications abovementioned for teachings in relation to improvements to closure assemblies, the teachings thereof which are hereby incorporated by reference.
[0004] Screens are generally provided for doors, patio doors, and windows. One particular type of screen utilized for patio doors for example, includes a metal frame having a groove disposed around its edges. The screen is affixed to the frame by using a spline, a long extended piece of flexible material, which is forced into the groove capturing the edges of the screen. The screen is then slid in front of the opening when the patio door is moved to an opened position. The screen therefore permanently blocks the view of the occupant of the dwelling. The same is true for screens provided with double-hung windows, tilt and slide windows, and casement windows. The screen generally is always in position whether the window is opened or closed.
[0005] Various examples therefore have been developed by inventors to address this problem.
[0006] For example, U.S. Pat. No. 5,505,244 to Thumann describes a retractable covering for a door including a housing containing a roll of screen as best seen in FIGS. 2, 5, 6 A and 6 B thereof. The cover may be affixed to a door adjacent the frame thereof as an after-market product.
[0007] Another example of an after-market type of product is found in U.S. Pat. No. 4,821,786 as best seen in relation to FIG. 6 therein, the structure is adapted to be mounted on one side of a door jamb to be releaseably connected to the other. The assembly is quite complicated and complex and may be considered as an add-on structure.
[0008] Similarly, U.S. Pat. No. 3,911,990 provides a screen in combination with a sliding door. The screen is disposed upon a spring-loaded roller installed on the exterior of the framing sections of the opening adjacent to the window frame.
[0009] U.S. Pat. No. 4,757,852 describes a box-like housing carrying a tube for paying out and taking up a mesh screen. The housing is fastened over a window or door and is not part of the framing section of the door.
[0010] U.S. Pat. No. 4,651,797 describes a roll-up screen door included in a narrow housing containing a conventional spring-biased roll onto which flexible screen material is taken up and paid out. The housing is mounted adjacent one side of a vertical curved strip along one side of the door casement opening. The front vertical edge portion of the screen material is anchored within a vertical groove of the anchoring strip as best seen in FIGS. 3 and 5. Again, the housing extends from the framing section and is not part thereof. A more complex arrangement is found in U.S. Pat. No. 4,359,081 and U.S. Pat. No. 4,261,524.
[0011] Referring now to U.S. Pat. No. 1,150,000 to Matthews, there is described a window screen coiled on a roller for installation on a window frame. The roller for the window is illustrated in FIG. 5 including a hook portion for hooking a complementary hook portion on the screen. The other edge of the screen includes a hook portion for engaging with the trim portion 34 .
[0012] U.S. Pat. No. 1,141,996 to Vanasdale describes another type of roller screen which may be attached to the sill or lintel portion of the frame by mounting brackets as best seen in relation to FIGS. 1 through 6.
[0013] None of the above-mentioned references teach or even infer the installation of a screen within the framing sections of a closure assembly such as a jamb. Each of the products may be considered as an after-market product which is installed upon, adjacent to, on or butting up against the framing section of the appropriate closure member. In essence, some of the installations are unsightly with a housing extending from the general plane of the home or window, extending either outwardly away from or inwardly toward the interior being closed by the closure member. It would therefore be advantageous to solve this problem by providing a screen assembly which may be contained within the framing sections of a closure assembly and which retracts into the frame member and which is substantially invisible until such time as needed.
[0014] U.S. Pat. No. 4,825,921 describes a screen assembly having supporting elements secured along the edge of the material as best seen in relation to FIGS. 4 and 7. The structure also includes a spring-biased element which rides in a track. As best seen in FIGS. 9 through 11, the screen is considered to be an add-on, after-market device as well.
[0015] U.S. Pat. No. 3,842,890 to Kramer describes a coilable closure device as best seen in FIGS. 1 and 18 which includes a frame including a side jamb and a storage jamb, 34 and 36 respectively. The coilable closure device does not include a post and includes a multiplicity of sections as best seen in FIGS. 1 and 6 which sections include elements extending up into and down into respective track areas provided with the frame. The material which coils upon itself is particularly plastic sheet including reinforcing ribs which also act as guiding elements for the sheet. However, nowhere within the reference does it teach the use of such a structure for a screen, but merely as a closure to replace a door between adjacent rooms, for example. Nowhere within the reference does it teach the combination of a closure member such as a window or patio door and a screen. This is simply not described. Therefore, one would not be motivated to solve the problem of combinations of closure members and screens by the reading of the Kramer reference.
[0016] Nowhere therefore within the prior art is there taught improvements to screen assemblies, wherein the entire screen assembly is contained within the framing sections found adjacent to a closure member in a closure assembly, for example a window assembly. Further, nowhere within the art is there found a roll-out screen assembly embodied in a cassette which may be readily inserted within the hollow of a framing section sized to receive said cassette or screen assembly. Further, nowhere in the prior art is there manufactured a screen having an abutment on one edge thereof for engaging with a cooperative abutment on the roller of a screen assembly which may be cut to size as desired to repair a roller screen assembly. Further, nowhere within the prior art is there found various improvements to roll-up screen assemblies to simplify their installation, adjustment and replacement.
[0017] Nowhere within the prior art is such a simplified improved screen assembly provided which retracts into the jamb, sill or header of the frame portion of a window assembly in the retracted position and which is preferably guided to its operative position in guides provided with the jamb, sill or header, and which allows for the manufacture of heavier screens in larger sections without continuously covering of the window.
[0018] It is therefore an object of this invention to overcome many of the deficiencies in the prior art stated above which allows for smooth and simple operation of a retractable screen which is capable of both sliding within a guide channel between the retracted and the operative positions and which at the retracted position is fully contained within the jamb, sill or header section of the closure assembly.
[0019] It is a further object of the invention to provide a retractable screen assembly of appropriate size and construction to replace existing retractable screen assemblies for casement, double hung and/or tilt and slide windows as well as patio doors.
[0020] It is further a primary object of this invention to provide a roll-up screen embodied in the frame of a closure assembly which is retractable into the frame itself without requiring an additional housing.
[0021] It is a further object of the invention to provide a roll-up screen assembly in the form of a cassette which may be mounted within the hollow of a framing section, which cassette includes a front facia portion to close the framing section.
[0022] It is yet a further object of this invention to provide a continuous roll of screen manufactured so as to be cut at a predetermined width and include an anchoring element disposed adjacent one edge of the screen so as to allow ease of installation of the original or replacement screen.
[0023] It is yet a further object of the invention to provide a method of manufacturing a screen.
[0024] It is yet a further object of the invention to provide a cassette which may be side mounted into an opening of the framing section and closed by an exterior facia element.
[0025] It is yet a further object of the invention to provide a closure assembly including a roll-up screen contained with one of its framing sections adjacent the closure member.
[0026] It is yet a further object of the invention to provide improvements in mounting brackets, facia elements, and screens.
[0027] Further and other objects of this invention will become apparent to a man skilled in the art when considering the following summary of the invention and the more detailed description of the preferred embodiments illustrated herein.
SUMMARY OF THE INVENTION
[0028] This invention relates to a retractable screen system for a closure assembly and improvements thereof which allows the secure sliding and subsequent retraction of the screen from a operative position to a retracted position. The invention is preferably embodied in a window assembly but finds application also in large pivoting windows and patio doors. The closure member may further comprise a window sash being a casement, double hung, or tilt and slide installation or, a door or a patio door.
[0029] There is therefore provided improvements to screen assemblies, wherein the entire screen assembly is contained within the framing sections found adjacent to a closure member in a closure assembly, for example a window assembly. Further a roll-out screen assembly is embodied in a cassette which may be readily inserted within the hollow of a framing section sized to receive said cassette or screen assembly. The screen has an abutment on one edge thereof for engaging with a cooperative abutment on the roller of a screen assembly which may be cut to size as desired to repair a roller screen assembly which simplifies their installation, adjustment and replacement.
[0030] There is also provided a simplified improved screen assembly which retracts into the jamb, sill or header of the frame portion of a window assembly in the retracted position and which is preferably guided to its operative position in guides provided with the jamb, sill or header, and which allows for the manufacture of heavier screens in larger sections without continuously covering of the window.
[0031] In a tilt and slide, casement or double hung window a retractable screen is provided disposed within the header, sill or jamb of the assembly which screen accumulates on and pays out from a spring biased roll disposed within said header, sill or jamb, the screen being retractable for egress or cleaning purposes, and available as desired by providing a detent on the opposing framing member engageable with a detent provided with the screen when in its operable position.
[0032] According to yet another aspect of the invention there is provided a window assembly comprising a retractable screen disposed within a framing portion of the assembly, the screen accumulating on and paying out from a spring biased roll disposed within said frame portion, the screen being retractable for egress or cleaning purposes, and available as desired by providing a detent on the opposite frame portion engageable with the screen when in its operable position.
[0033] According to yet another aspect of the invention there is provided a closure assembly comprising a retractable screen disposed within a framing portion of the assembly, said framing portion providing a pocket within which the screen is contained in use, said pocket being bound by three sides of said framing portion thereby forming said pocket, said pocket being closed by a separate cover closing said framing portion, preferably said retractable screen being mounted on said cover and being positioned in said pocket when the cover closing the pocket is installed preferably by clipping a detent provided with said cover in a channel provided with one of the sides of said framing portion providing the pocket, the screen accumulating on and paying out from a spring biased roll disposed within said frame portion, the screen being retractable for egress or cleaning purposes, and available as desired by providing a detent on the opposite frame portion engageable with the screen when in its operable position.
[0034] According to yet another aspect of the invention there is provided a continuous screen formed as a continuous web and adapted to be utilized for a retractable screen for windows, doors and the like having a predetermined width of screen determined by the width or length of the closure member frame, said width of said screen having two ends, preferably each of the ends having an anchor or key shaped element fixed thereto adapted to engage a detent on a handle proximate one end of the screen and adapted to engage a detent of a preferably spring biased, preferably hollow, roller utilized for taking up and letting out the screen in a coil upon said roller, alternatively the handle end of the screen alternatively having a tape or continuous strip of adhesive applied thereto so as to engage and be captured by a handle portion of said screen when utilized in a closure assembly, said screen and said anchor or key shaped elements being cut at a predetermined length to fit said roller when assembled and being installed with said closure assembly and preferably within a hollow of one of said frame sections, wherein said screen may be utilized as an original installation or as a replacement screen for an original installation.
[0035] According to yet another aspect of the invention, there is provided a retractable screen assembly for a closure assembly, said closure assembly including a closure member surrounded by framing portions from which the closure member is supported, said closure member including framing sections, one of said framing sections providing a pocket within which said screen assembly is retained in use, said screen assembly comprising a cassette engageable with the interior of a cover utilized for closing the framing portion and pocket of the closure assembly, preferably said pocket being located proximate the sealing end of the closure member, said retractable screen including a handle portion affixed thereto including a first detent, the opposite jamb from said pocket including a latching portion including a second detent which engages the first detent of the handle portion when the screen is in the fully open position, wherein said cassette may be installed within any convenient pocket disposed within the framing portions of a closure assembly and fixed in position once the cover covering the pocket is installed. In a preferred embodiment, brackets are provided having channels which capture preferably T-shaped guides on the interior of said cover which allow for the fixing of the brackets in relation to the specific screen assembly being installed, said screen assembly also including a hollow tube to which said screen is anchored via a detent on the tube and via a detent on one end of said screen, the other end of said screen including another detent for engaging with the detent of a handle portion of said assembly, said tube having inserted within the ends thereof a pin assembly which will not rotate in relation to said tube as a result of rib portions disposed with said assembly engaging rib portions disposed within the hollow of said tube, each of said pin assemblies including a pin for engaging a pin-receiving opening disposed with each of said brackets, wherein said brackets may be fixed with respect to the interior of said cover thereby fixing the entire screen assembly as a cassette, one of said brackets being adjustable in relation to said torque tube in order to allow for adjustment and variations from installation to installation, preferably said handle portion including telescoping guides which capture the ends of said screen and are retained within a hollow within said handle, said guides for riding within a channel disposed with opposite or opposing framing sections to guide the screen across the opening defined by said closure member when desired. In an alternative embodiment, the brackets may include a box-like element which rests at the bottom of a framing section and being locked in position because of the compatible dimension of the bracket with the framing section and adjustable in position in relation to that bottom in order to provide for variations in manufacturing.
[0036] According to yet another aspect of the invention, there is provided a method of assembling a retractable screen cassette comprising:
[0037] (1) providing a tube upon which said screen will coil up in use,
[0038] (2) providing a pin assembly insertable into the open ends of said hollow tube and being prevented from rotating with respect to said tube as ribs disposed with said tube, engaged ribs disposed with said pin assembly,
[0039] (3) providing a torsion spring having ends which are engageable with said pin assembly ends for providing the correct torsion and tensioning of said spring,
[0040] (4) inserting said spring within the hollow tube and inserting said pin assemblies within said hollow tube and fixing the ends of said pin assemblies to the tyne portions of said torsion spring,
[0041] (5) providing brackets from which said pin assemblies will be adjustably inserted, said brackets being locked in place with respect to the assembly, preferably either by engaging with a detent provided with a flexible cover or alternatively by engaging with the bottom of the framing section,
[0042] (6) adjusting said brackets in relation to the distance from one another so as to correctly tension and carry the screen assembly,
[0043] (7) fixing said screen on said screen assembly by anchoring said screen to said tube via a detent, preferably a T-shaped detent or key for engaging with a key slot on the tube or alternatively by using welding or adhesive, and coiling said screen upon said tube,
[0044] (8) fixing said opposite end of said screen to a handle portion either preferably by a T-shaped detent engaging a T-shaped detent with said handle, or by welding or an adhesive,
[0045] (9) coiling said screen upon said tube,
[0046] (10) preferably engaging said cover portion with said brackets,
[0047] (11) inserting said screen assembly within a pocket of said closure assembly in one of the framing portions thereof,
[0048] (12) covering said pocket with a flexible cover.
BRIEF DESCRIPTION OF THE DRAWINGS
[0049] [0049]FIG. 1 is a schematic perspective view of a tilt and slide window, wherein said windows move in a horizontal direction, illustrated in a preferred embodiment of the invention.
[0050] [0050]FIGS. 1A and 1B are partial schematic perspective views of casement style windows embodying the invention and depicting the motion thereof and illustrated in a preferred embodiment of the invention.
[0051] [0051]FIG. 1C is a partial schematic perspective view of straight line windows embodying the invention and depicting the motion thereof and illustrated in a preferred embodiment of the invention.
[0052] [0052]FIG. 1D is a partial cutaway view of the casement style windows of FIG. 1A depicting a rollaway screen thereof and illustrated in a preferred embodiment of the invention.
[0053] [0053]FIG. 2 is a front view of the window of FIG. 1.
[0054] [0054]FIG. 2 a is a top view of the window of FIG. 1.
[0055] [0055]FIG. 2 b is a end view of the window of FIG. 1.
[0056] [0056]FIG. 3 is a double hung window assembly utilizing hardware similar to that of FIG. 1 and illustrated in a preferred embodiment of the invention.
[0057] [0057]FIG. 4 is a perspective illustration of the hardware only for a double hung window of FIG. 3.
[0058] [0058]FIG. 5 is an exploded perspective view of the components of the hardware of FIG. 4 to be installed in a double hung window assembly.
[0059] [0059]FIG. 6 is a carrier design illustrated in a preferred embodiment of the invention which allows for ease of removal of a window from a window assembly and illustrated in an exploded perspective view.
[0060] [0060]FIG. 7 is an assembled view of the components of FIG. 6.
[0061] [0061]FIG. 8 is a tilt and slide window assembly primarily for the hardware therefore and illustrated in an alternative embodiment of the invention.
[0062] [0062]FIG. 9 is a schematic view of the movement of the shoes of FIG. 8 illustrated in alternative of the invention.
[0063] [0063]FIG. 10 is a perspective illustration of a pulley arrangement installed at the comers of the window assembly of FIG. 8 and illustrated in alternative embodiment of the invention.
[0064] [0064]FIG. 11 is a close-up perspective view of a locking mechanism for the shaft assembly 30 illustrated in a preferred embodiment of the invention.
[0065] [0065]FIG. 12 is an end view of the locking mechanism of FIG. 11 illustrated in a preferred embodiment of the invention.
[0066] [0066]FIG. 13 is an end view of a locking block assembly illustrated in a preferred embodiment of the invention.
[0067] [0067]FIG. 13A is an end view of the track profile used in conjunction with the lock block assembly of FIG. 13 and illustrated in a preferred embodiment of the invention.
[0068] [0068]FIG. 13B is a top schematic view of the lock block assembly of FIG. 13 shown engaging the rack portion of the track and illustrated in a preferred embodiment of the invention.
[0069] [0069]FIG. 13C is a side cross-sectional view of the adjusting cap screw used to adjust the track within the sill or header or jamb portions and illustrated in a preferred embodiment of the invention.
[0070] [0070]FIG. 14 is a top view of the carrier for the shaft assembly of FIG. 17 and illustrated in a preferred embodiment of the invention.
[0071] [0071]FIG. 14A is a cross-sectional view through the diameter of the opening 35 b of FIG. 14 illustrated in a preferred embodiment of the invention.
[0072] [0072]FIG. 15 is an top end view of the sash portions for a tilt and slide window assembly from the opening end of the window and illustrated in a preferred embodiment of the invention.
[0073] [0073]FIG. 15A is a close up view of the section of the assembly of FIG. 15 where the sash abuts with the sill and illustrated in a preferred embodiment of the invention.
[0074] [0074]FIG. 16 is a schematic end view of a central locking system best seen in FIG. 17 and illustrated in a preferred embodiment of the invention.
[0075] [0075]FIG. 16A is an end view of the central locking system of FIG. 16.
[0076] [0076]FIG. 16B specifically illustrates the latching plate and latch of the central locking system and illustrated in a preferred embodiment of the invention.
[0077] [0077]FIG. 17 is an exploded perspective view of a window sash for a tilt and slide or casement window illustrated in a preferred embodiment of the invention.
[0078] [0078]FIG. 18 is an exploded perspective view of the header, sill and jamb portions of the window assembly illustrating the track and its positioning in relation to the sill and header and illustrated in a preferred embodiment of the invention.
[0079] [0079]FIG. 19 is an exploded perspective view of a retractable screen assembly illustrated in one embodiment of the invention.
[0080] [0080]FIG. 20 is a similar view to that of FIG. 19 illustrating another A embodiment of the invention.
[0081] [0081]FIG. 21 is a cross-sectional view of a frame portion containing the retractable screen illustrated in a preferred embodiment of the invention.
[0082] [0082]FIG. 22 is a schematic view of a screen manufactured in another embodiment of the invention illustrated in a preferred embodiment of the invention.
[0083] [0083]FIG. 23 is a schematic view of the installation of the screen of FIG. 22 in a retractable screen assembly and illustrated in a preferred embodiment of the invention.
[0084] [0084]FIG. 24 is a cross-sectional view of the hollow tube upon which the screen is rolled up and illustrated in one embodiment of the invention.
[0085] [0085]FIGS. 25A and 25B are side and end views of the pin assembly shown in FIG. 19 and illustrated in a preferred embodiment of the invention.
[0086] [0086]FIGS. 26A and 26B are side and end views of the slide illustrated in FIG. 19 and shown here in a preferred embodiment of the invention.
[0087] [0087]FIGS. 27A and 27B are side and end views of the bushing of FIG. 19 illustrated herein in a preferred embodiment of the invention.
[0088] [0088]FIGS. 28A through 28C are top end and side views of the mounting bracket of FIG. 19 illustrated in a preferred embodiment of the invention.
[0089] [0089]FIGS. 29A through 29C are side, top and end views of the guide portion illustrated in FIG. 19 and shown here in a preferred embodiment of the invention.
[0090] [0090]FIG. 30 is an end view of the screen handle illustrated in FIG. 19 and shown here in a preferred embodiment of the invention.
[0091] [0091]FIGS. 31A and 31B are top and side views of the screen lock illustrated in FIG. 19 and shown here in a preferred embodiment of the invention.
[0092] [0092]FIGS. 32A and 32B are top and side views of the latching plate of FIG. 19 and shown here in a preferred embodiment of the invention.
[0093] [0093]FIG. 33 is an end view of the sealing block shown in FIG. 19 and illustrated here in a preferred embodiment of the invention.
[0094] [0094]FIG. 34 is a side view of the cover portion for the jamb section of FIG. 21 and illustrated in a preferred embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0095] Referring now to FIG. 1, 2 through 2 b there is illustrated a tilt and slide window assembly. Therefore the assembly 5 includes an outer frame portion 10 which is normally hung within an opening established in a building (not shown). Normally nailing flanges are provided for this purpose attached to the outer frame 10 . The frame 10 includes top portions 17 and bottom portions 16 having tracks disposed therein, as best seen in relation to FIG. 2. Within the tracks are contained a pivot assembly which will be hereinafter described. Primarily the pivot assembly includes a pinion 35 and carriers 38 and 37 interconnected by interconnecting portions 32 and 31 making up an interconnecting member 30 . The pinions move as the window 20 is slide in the track portion by the movement of the pinion 35 with respect to the rack 18 or 19 respectively. In this way the pinions 35 being interconnected remain parallel at all times in their motion along the track within which the rack 19 or 18 is disposed. The hardware is shown in normal view while the window assembly is shown in dotted lines, to illustrate the essence of the assembly.
[0096] Referring now to FIG. 2 there is illustrated the window of FIG. 1, wherein a window 20 and 40 is slidable within a track 15 and 17 upon a shoe 39 . The lower shoe 39 also is connected to a secondary show 39 a for carrying the window which includes rollers 39 b , 39 a 1 and 39 b 2 on the bottoms thereof respectively for ease of movement within track 17 . The pinion 35 rests within the shoe 39 as will be described hereinafter. The arrangement of the interconnecting portion 30 will also be described hereinafter. Window 40 therefore has its own interconnected system as can be best seen in relation to FIGS. 2 a and 2 b.
[0097] Referring now to FIG. 2 a there is illustrated the sash elements 20 and 40 and the rack portions 19 and 19 a which accommodate the motion of the pinion 35 along a full length of the track, as best in FIG. 2 b.
[0098] Referring to FIGS. 1, 2 to 2 b clearly the track portion 17 and 15 cooperate with the rack portions 19 and 19 a to provide for the pinion 35 and its motion when the window remain slidable within the track. By interconnecting the two pinion portions and hence the two pivot shoes, by interconnecting means 30 , the shoes remain in a substantially parallel position in relation to one another at all times. This overcomes the problem described in the background of the prior art. By remaining parallel it is almost impossible for the window therefore to come out of the track when the window is pivoted to be cleaned and therefore is no longer necessary to provide braking portions as in previously described inventions of Canadian Thermo Windows, as referred to in the background of the invention.
[0099] Referring to FIGS. 1A and 1B there is illustrated a casement style window having similar components to that found in relation to FIG. 1 with the exception of only one sash being provided being secured on shaft assembly 30 including portions 31 and 32 . A link L is provided secured proximate ends L 1 adjacent the center of the sash 21 proximate the bottom thereof and adjacent the track 18 adjacent the opening end of the window sash 21 . By positioning the sash in this manner a full range of pivoting motion is available. If the link end L 1 is removable than the window sash may be moved totally to the opposite end remote the pivoting end 21 b on shoe 39 . As with the case of the tilt and slide window a shoe 39 containing a pinion is provided. The pinion is connected to the shaft 30 and engages the rack 18 as it moves along the window sill and header in parallel arrangement between the upper and lower pivots maintained in parallel by the shaft 30 . In this manner the casement style window may be pivoted as normal to an open position, and the pivoting end may be moved to the other end of the window frame away from side 21 b to allow ease of cleaning. By supplying the hardware described without a casement sash the casement window may be assembled without the need for expensive pivots and linkages and without a great deal of assembly labour. As best seen in FIG. 1D for the casement style window in particular a rollaway screen S may be provided which is housed in jamb 17 a as illustrated. The screen S pulls across to engage detent D 1 with detent D 2 in jamb 16 a , whereat it may be locked. This allows a user to clean the glass of sash 21 on the inside without removing the screen.
[0100] Referring to FIG. 1C there is illustrated a tilt and slide type window similar to FIG. 1 with the exception that when closed the window sashes will be oriented in a straight parallel line with one another. In order for this to happen the rack provided 18 includes a portion 18 a made from fiber filled plastic or the like and joined at seam 18 c to an aluminum track 18 b . The sash 21 is therefore moveable as previously described on carrier 39 and rollers 39 a as urged by pinion 35 until the pinion reaches the curved portion of the track 18 a wherein the assembly 30 will move along the curve to the terminus of the track 18 t . The sash portion 21 a will then lock in behind the edge of the sash contained in track 18 ′ and be lockable at that position. The sash 21 ′(not shown) resides on assembly 30 ′ in track 18 ′. As pinion 35 ′ moves within the limits of rack 18 ′ the sash 21 cannot adopt a parallel position unless sash 21 ′ is in its fully closed position. Only then can the end 21 a adopt its fully closed position butting up against the sash 21 ′ at the end opposite the carrier assembly 30 and 39 .
[0101] Referring to FIG. 3 there is illustrated a double hung window assembly embodying the preferred embodiment of the hardware making up the invention substantially equal to that which is disclosed in FIG. 1, with the exception that a coil spring 31 a is provided around the connector portion 31 of the interconnecting portion 30 . By providing the interconnecting portion 31 with a spring 31 a it will no longer be necessary in a double hung window assembly to provide a sash balance, as the spring 31 a is pre-loaded to provide the necessary tension, much the same as a spring which is used in a garage door. In this example as a garage door goes up and down the spring is compressed and tensioned depending on the motion of the door and therefore provides for the return motion of the window assembly. Within the window assembly sashes 20 and 40 shown in ghost line are moveable with hardware substantially made up of a pivot or pinion 35 moving on a rack 18 and 19 respectively and being interconnected by the interconnecting portion 30 .
[0102] Referring to FIGS. 4 and 5 there is illustrated the hardware which is installed within the double hung window assembly of FIG. 3. Pinions 35 therefore are provided, which seat within the carriers or shoes 39 . The pinion includes a shaped opening 35 a which is compatible with the bar stock 34 c and 32 a proximate the ends thereof. The pinion therefore will ride on the rack 18 and 19 within shoe 39 . Opposed supplementary portion 37 is provided to oppose the shoe 39 as it rides in the track. Therefore, referring to FIG. 2 b the portion 37 and 38 may be readily seen. A combined ratchet and pawl assembly is provided with portion 37 or at least connected therewith. The pawl assembly 37 c is resilient biased through the opening 37 d of member 37 so as to release the ratchet 34 b of shaft 34 when the window is to be removed from the assembly. Proximate the other end of the hardware there is provided a backing member 38 in a unique shaft extension 33 which includes portions 33 b , 33 d , 33 c and 33 a wherein the shaft end 32 a extends through. A locking nut 33 e is provided to lock the entire hardware together and to allow for ease of separation thereof. An adjustable connector 31 b is provided proximate the other end which allows for adjustment with regard to the length of section 32 of the shaft so as to allow variation in the sizes of the assembly supported. Portions 31 , 31 b , 32 , and 33 makeup the shaft assembly which allows for ease of installation, adjustment, alignment and removal of the sash assembly. Also the hardware therefore described provides for the interconnection of the pivot shoes proximate their sides and provides for parallel motion of the pivot shoes at all times thereby illuminating the need to lock the pivot shoes in the track assembly.
[0103] Referring to FIG. 6 there is a description of a different shoe construction which is useful when a window is removed, since the carrier will be locked in position when the window is removed for maintenance or for cleaning. Therefore the shoe 39 includes a spring b and a recess therefor and a supplementary portion 39 d and a finger a therefore wherein teeth c are provided on supplementary portion 39 d which teeth are biased by spring b against the pinion 35 to thereby lock against pinion 35 and prevent the motion of the carrier when the window is removed. A sloped wall d is provided with the carrier supplementary portion 39 d which is engaged by a separate simple latching and unlatching mechanism which thereby releases the supplementary portion away from the pinion or toward the pinion when the latch is opened. Therefore when the latch engages the supplementary portion d it will drive the supplementary portion 39 d away from the pinion 35 thereby allowing free motion of the pinion in normal circumstances. However when the latch is disengaged the portion 39 d will be free to move as biased by the spring b toward locking the pinion 35 via the teeth c of the supplementary portion 39 d . The alternate shoe of FIG. 6 and 7 has an opening 39 a within which the extension 35 a passes to engage the connecting member 30 as previously described. The rollers 39 b engage with the notches as shown to improve the motion of the carrier in the track.
[0104] Referring now to FIG. 8, 9 and 10 there is illustrated an alternative embodiment of the invention to maintain the carrier pivots 61 , 65 , 60 and 81 in substantially parallel alignment and thereby eliminate the need for braking mechanisms. FIG. 8 is illustrated as a tilt and slide frame in ghost line with the window 70 also shown in ghost line having pivot 75 and 71 . The pivots 75 and 71 engage with openings within the shoe 61 and 65 in the manner which is known. These pivot pins 75 and 71 may be removed from these shoes merely by retracting them from their locked positions. The sash 70 therefore is moved on the carrier 81 , 82 and 83 proximate the bottom thereof in the track portions as shown and within carrier 60 on the top thereof. A similar sash arrangement would be arranged for the other shoes as well but for simplicity sake this is not illustrated. The important aspect is that a cable 91 is connected to the carrier 60 and the carrier assembly 81 , 82 and 83 substantially as shown in FIG. 9, so that when the window moves toward the right hand side of the drawing that both carriers will move an equal amount by the movement of the cable maintaining the pivots 75 and 71 within the shoes 60 and 81 substantially parallel at all times. Similarly, a cable 90 is provided which moves in conjunction with the carrier 63 , 62 and 61 and the shoe 65 , as best seen in FIG. 9, so that as the shoe 65 is moved in a direction D 2 that the carrier 61 , 62 and 63 will also be moved in the direction D 2 . FIG. 9 therefore shows the path of the cable connecting the carrier described above.
[0105] In order to allow for the movement of the cable the unique pulley arrangement is illustrated in FIG. 10 wherein the cable will travel through the respective channels 107 , 108 and 105 a within the wheel 105 , or through 106 , 104 , 105 a within the opposite wheel or pulley 105 . Assembly 101 is therefore provided which is affixed within the window frame via opening 101 a and a fastener, not shown, which assembly allows for the movement of the cable and hence the carriers in a manner as best seen in FIG. 9.
[0106] Referring now to FIGS. 11 and 12 there is provided a locking mechanism for the shaft 30 which may be used with any lousier assembly. A handle assembly H is provided including a stationary portion H 2 fixed to the sash 21 and a moveable spring biased portion H 1 biased to a continual locked position via spring leaf S 2 . The handle portion H 1 includes a pivot H 4 and detent portions H 5 and H 6 . Normally the spring S 2 will cause the handle portion H 1 to remain in engagement at detents H 5 and H 6 with gear portion or serrations 30 Z of the shaft 30 . Therefore the window or door is locked in that position and cannot be pivoted or slid. When a user engages the handle H 1 and presses it towards H 2 the detents H 5 and H 6 release from the gears 30 Z and hence the window or door may be repositioned as desired. At that repositioned location when the user releases the handles the window or door will again become locked.
[0107] Referring now to FIGS. 13, 13 a , 13 b , 13 c and FIG. 18, there is illustrated a track portion 18 and 19 which is to be installed within, as shown in FIG. 18, the sill and header 220 of a frame assembly also including upwardly extending jamb portions 220 a . The track portions 18 and 19 therefore are installed within the profiles as seen in FIGS. 2 b and 18 by the provision of a locking block assembly 200 which includes an adjuster nut 210 which engages the rack portion 18 x of the rack 18 a of the track profile 18 as best seen in FIG. 13 a . The profile therefore includes the rack 18 a , a riding portion for the rollers 18 e which will be explained hereinafter, and a recess 18 d wherein a carrier as best seen in relation to FIG. 14 rides with the exception of the rollers. The track 18 therefore must be locked in position in the sash 220 , and this is affected by the locking block 200 and the moveable nut 210 . As best seen in FIG. 13 c , the track is inserted into the sill profile as shown so that the carrier may ride on the track. The assembly of FIG. 17 for the sash is therefore engaged with the carrier. The block 200 therefore is screwed down through the profile 15 into the wooden frame member not shown via opening 15 c in the profile and 204 in the block 200 . Two fasteners 205 therefore are provided, and as shown in FIG. 13, they are inclined at an angle to the vertical in order to allow for the provision of an adjuster 206 which is accessible through-the opening 207 in the block 200 wherein a cap screw having a head 206 a having an allen key type access slot is provided. The threading 207 b extends down to the end 207 a proximate the nut 210 .
[0108] As best seen in FIG. 13, the lock block 200 and the locking nut 210 have a profile substantially as shown with a triangular shaped cut out provided adjacent the top thereof and wherein abutting portions 201 and 203 are provided to engage with the flanges 15 b and 15 a of the profile 15 of the sill portion 220 . The triangular cut-out portion includes an upwardly vertical face 202 a , and bottom 202 . Similarly the nut has a shoulder 211 provided and a substantially triangular shaped cut out 212 and an upwardly extending face 212 a for engaging with the sill profile 15 similar to that which is illustrated and described in relation to FIG. 13. The rotation therefore of the cap screw 206 results in the movement of the nut 210 in relation to the block 200 which is fastened in position. The adjustment therefore of the screw allows for the thread to engage a threaded opening not shown in the nut 210 so that the rack portions 213 a provide engagement with the rack 18 a of the track portion 18 and will allow for fine adjustment in the positioning of the track 18 and the locking in position of the track. It has been found sufficient that by providing the block and the adjustment of the nut, it will sufficiently position and lock the track in position and allow for the adjustment of the track which will then further allow for the adjustment of the pivots as best seen in FIGS. 1, 1 a , 1 b , 1 c , FIG. 2, FIG. 3 and FIG. 17 so that the parallelism is not lost, and if fine adjustments once installed are required to the window sash to maintain the parallelism of the system, this is very easy to do. Should the system go out of parallel and require fine adjustment to restore the parallelism, a mere rotation of the head 207 is required for both the sill and headers 220 so that the system is squared.
[0109] The notch portion defined by the faces 202 a and 202 have a unique purpose in that the latch portion 251 as well as 250 , as best seen in FIG. 17, will engage with the face 202 a and provide a lock detent for the lock 251 . This adds reinforcement to the lock provided in that should the triangular shaped detent of the block not be provided, then the lock 251 would engage flange 15 a and in time would wear out that flange in that particular locking position. The nut 210 has a similar function so that either the nut or the block can function as the detent for the latch. Specifically in FIG. 18, the screw 206 is shown being engageable from the nut toward the block, and in fact it is accessible in either direction as shown in FIG. 13 and FIG. 18 without changing the advantages of the system. For access purposes, depending on the installation and the type of window, it may be easier to adjust as shown in FIG. 18 as opposed to FIG. 13. Preferably the block is made from fiber-filled nylon. Alternatively, the block may be made from aluminum. The nut may be made from fiber-filled nylon as well.
[0110] Referring to FIGS. 14, 14 a and 18 , there is illustrated a carrier 39 x which includes a pivot portion 35 for engaging with the shaft portion 32 and 34 c of the pivot assembly and for carrying that shaft assembly and the pivoting end of the sash in the track 18 and 19 respectively of FIG. 18. The carrier includes a portion 39 y provided therewith to carry the rollers 39 b therein. This is very similar to the carrier illustrated and described in the previous descriptions and more specifically in relation to FIG. 1 a and 1 b, with the exception that the details of the carrier were not shown at that time in relation to the thrust wheel 35 c provided on the bottom.
[0111] The carrier, as best seen in FIG. 1 a therefore rides on the rollers on the track profile seen in FIG. 13A on the surfaces 18 e for the roller wheels 39 b and in the notch or cut-out recess 18 d for the side portions adjacent the roller 39 b at 39 z . The pinion portion 35 therefore has an opening 35 b for receiving the shaft 32 which extends toward the bottom of the opening 35 d and which opening 35 b as best seen in FIG. 14 is compatible with the shape of the shaft 32 . The outer surface 35 a of the opening 35 b is compatibly shaped with the opening in the carrier so that the opening 35 b may be accessible to the shaft 32 . At the bottom of the pinion portion 35 is a thrust wheel carrying portion 35 e which carries the thrust wheel 35 c . The thrust wheel 35 c therefore rides in between the shoulders 18 c and 18 b on the surface 18 d of the track profile 18 . The thrust wheel is provided to accommodate any wind load which may be placed on the system when the window is opened. Further, in the normal meshing of gears with a rack, there is a thrusting force created as the pinion 35 moves on the rack 18 x . Therefore, the thrusting wheel will engage from time to time the shoulders or the surfaces defined by the shoulders 18 c and 18 b so as to maintain the parallelism and the accuracy of the installation of the window system. A pinion gear 35 a is therefore provided between the thrust wheel 35 c and the pivot receiving opening 35 b which operates substantially as described in relation to FIG. 1A and FIG. 1 in that as the window rotates the pivot rotates causing the gear 35 a to rotate and move on the track. This is particularly advantageous when the pivot assembly is provided on a casement window as best seen in relation to FIG. 1A in that it is desirable to have the window move away from a pocket provided in the window jamb as best seen in relation to FIG. 1D so that the sash profile will not engage the jamb profile but will readily clear the jamb profile as the window is opened. For example, as best seen in FIG. 1D, proximate the top thereof, it may be readily seen that a pocket is provided in the jamb profile so that the pivot assembly 30 is accommodated at that end of the window. However, a flange portion unlabelled engages the sash cover portion so that within the jamb J 1 there is a pocket J 2 provided which improves the seal of the window in that the cover portion SC extends into the pocket J 2 when the sash is closed. However, when the sash is pivoted as in the case with the casement window of FIG. 1C, the pinion gear when pivoted will move the sash and the sash cover SC out of the pocket J 2 away from the jamb J 1 and provide suitable clearance so that the sash cover SC will not engage with the jamb portion J 3 which is a flange and therefore will clear easily the pocket and all its enabling portions. When the casement window is closed, the opposite happens and the sash cover SC will engage the pocket J 2 and be moved in position with the pivoting of the window to the closed position.
[0112] The rollers 39 b therefore provide a smooth motion of the closure system in relation to the track which would not be present if the rollers were not provided since the track is made from aluminum. The rollers are not absolutely essential in every embodiment, however, it is preferred.
[0113] Referring now to FIG. 15, there is illustrated two sashes side by side shown in end view. The sashes are made substantially as constructed in relation to FIG. 17 wherein the sash 220 is defined by a central I-shaped portion 227 having an opening therein and two side abutting portions 225 and 226 . A pocket therefore for receiving the glass G is defined at 222 . Fin seal portions 221 are therefore provided for abutting the glass G which contains the normal known seal portion SX. The window sash profiles also include flange portions 224 proximate the opening opposite the glass G. Within that opening there is provided in use a closed cell caulking foam which is compressible at portion 240 . This portion extends totally along the sash profile within the opening as shown with the exception of the portion adjacent the pivoting assembly. A cover portion therefore is provided at 230 which engages the tab portions 224 proximate each side of the sash profile. This cover portion when inserted is flexed downwardly as the closed cell foam 240 is compressed as best seen in FIG. 15 a so that the flange portions of the cover at 230 a engage with the flange portion of the sash at 224 to provide a compressed seal for the track cover 230 . The track cover is defined as a track cover although it does occupy the sash as a component thereof in that as the sash is closed over the opening defined between the flange portion 16 a and 16 b as best seen in FIG. 15 a , the snap cover portion will extend down into and engage with the flanges 16 a and 16 b , thus covering the track and snapping into position each time the sash is opened and closed. The typical seals BX and BY are provided as is known in the art.
[0114] Alternatively, as best seen in FIG. 1D, the sash covers may include alternative embodiments shown proximate the jamb portions 16 a and 17 a of the window assembly. Alternatively, a cover portion may be provided over the track portion 15 of sill portion 220 and header portion 220 of FIG. 18 that engages with the sash profile in a similar way to that of the track cover of FIG. 15 a with the exception that the track cover only extends over the second half of the track, that is to say the second half not carrying the window. For example as shown in FIG. 2, the wheel portion 39 a may be eliminated and the track cover may extend along the track portion opposite the pivot assembly so that the sash may slide on the track cover and be assisted to be supported by that track cover only in the second half of the track profile thereby eliminating the second carrier of FIG. 2. The track cover therefore in FIG. 2 as an example would extend from the carrier 39 a toward the left side of the page to allow the pivot assembly 35 to move to approximately the position of the present carrier 39 a wherein it would engage the track cover. In the movement of the carrier 35 to that position, the other end of the window would already be supported by the track cover. This installation therefore would eliminate the carrier 39 a.
[0115] Referring now to FIG. 16B, there is provided locking detents 250 and 251 which engage with the locking detent portions 202 and 212 of the lock and nut portions 200 and 210 . These locking portions 250 therefore and 251 are operated by a handle 260 as best seen in FIG. 16A which is rotatable to cause the motion of the rack portion 265 and the detent 250 into and out of the locking abutment provided with the lock block and the lock nut 200 and 210 respectively. In FIGS. 16, 16A and 16 B, the installation is provided for a casement window assembly. In the United States Patent Application described in the Summary of the Invention which was incorporated by reference, there is no provision of a casement-style window lock. Nor was there the provision of a lock block or nut detents 210 and 200 respectively. The handle therefore 260 is rotated by the user which causes the movement of the corresponding pinion gear 261 , the rotation of the pinion gear 261 affects the movement of the rack 265 , and the latch engaging portion 250 a and 251 a carried within the housings 255 and 254 respectively as best seen in relation to FIG. 17. The rotation of the pinion will therefore also cause the motion of the rack portion 266 sufficiently as provided by the opening 266 a of said rack portion to allow for engagement of said rack portion with said rack portion 265 with the bottom portion affecting the latching and unlatching of detent 251 . Intermediate the two latching portions for the casement window is provided a second pinion 267 which is rotated effectively by the movement of the rack portion 266 . Rotation of the pinion 267 causes rotation of the pinion sector 268 which is engaged with the locking detent 269 for the latch plate 270 and the detent 271 thereof. This latch plate is typical for casement windows as is the movement of the lock 269 , i.e. the rotation thereof. However, with the central locking system provided with this invention, it is the one handle operation of both the detents 250 and 251 and the casement window lock 269 which is in combination the essence of the central locking system. Alternatively, the casement window portion may be left out and the essence of the locking system therefore includes the locking block in the track which provides a detent for the locks 250 and 251 respectively.
[0116] As best seen in relation to FIG. 17, there is provided a cover C(x) which hooks into the sash profile similarly to the cover 230 previously described in relation to FIGS. 15 and 15A through which the handle portion 260 extends. Therefore, the latch assembly is contained within the sash profile, and the only portion extending outside of the sash profile is the handle portion. This handle portion is considerably smaller than the normal handle portion provided with a casement window which is typically rotary, and there is a tremendous elimination of components for a casement-type window. In fact, this will be described hereinafter.
[0117] Referring to FIG. 17, there is shown an exploded perspective view of the window assembly which will fit into the track profile similar to FIG. 18, but more specifically which may be designed for a casement window. The sashes 220 are provided with an opening 227 wherein a corner connector 280 is provided which extends into the opening 227 proximate all four corners and eliminates the necessity for welding. Clip portions 281 bite into the vinyl and are tapered in a direction so as to prevent the removal of the corner connectors once inserted within opening 227 . This snap lock feature therefore provides for the installation of the comer connectors and the quick fastening of the sash profile around the glass G. The track covers 230 are therefore provided and snapped into position once the closed cell foam, best seen in FIG. 15 a at 240 , is inserted within the opening of the sash profile. The hardware including the carriers, best seen in FIG. 18, which are then assembled within the opening opposite the glass of the sash proximate each jamb portion in use. The hardware therefore including the top and bottom track engaging portion 39 x and 37 x , the shaft 32 , the connector 31 b x, the other shaft 31 , and the small shaft 34 c are provided proximate the pivoting end of the window assembly within the sash profile enclosed by a cover similar to that of cover CX. The central lock as described in relation to FIGS. 16, 16A and 16 B is therefore inserted within the other opening of the sash profile and assembled and covered by the cover CX. The window sash is now available for installation within the frame assembly of FIG. 18 once the carrier portions 39 x are engaged with the respective shafts 32 and 34 c . The block portions 200 are therefore locked in position once the track is installed in the frame, and the nut portions are adjusted to allow for the parallelism of the carriers 39 x within the tracks to ensure the parallelism of the sash so that it rides well within the track portions. The window is therefore assembled.
[0118] For a casement window, all of the prior art levers and latch mechanisms are substantially eliminated. This means a great deal to window manufacture in that there are a considerable number of screws and fasteners to hold down the prior art lever linkages of the prior art systems. In the present invention, only the latch block fasteners are provided. The rest of the window assembly merely snaps together with a friction fit of the sash profiles, the sash profile covers and the frames. A minimum of assembly labour is therefore required with the installation of this window assembly. In one particular situation where an old style double-hung window is installed within an opening, it may be conveniently removed by an installer and the present invention may be installed in any of its embodiments including a casement window.
[0119] This is heretofore unknown in that a casement window occupies a certain standard space in the industry, and because of the linkage systems and the known systems, it is not possible to provide a larger window. With the present invention, a larger casement window may be provided which is easily installed with the minimum amount of labour and assembly time required. Should the window now be mis-alligned for any reason, it may be easily adjusted by the rotation of the screw 206 provided. A sophisticated user therefore could easily adjust this once instructed over the phone by an installer, or alternatively the installer may return for a quick adjustment at any time. Also, the window assembly is less likely to go out of adjustment because of the great care taken in the development of the precision of the assembly.
[0120] A method therefore of assembling the window may be considered as described in the above-mentioned description wherein, firstly the sash components are assembled by the quick fastening feature of the corner locking portions which are inserted within the opening of the sash profiles provided and provide one-way friction fit. The closed cell caulking is therefore inserted within the top and bottom of the sash assembled and these portions are covered by the track covers by the compression of the closed cell foam and the engagement of the tabs of the track cover with the tabs of the sash profile. The hardware is then installed along the vertical portions of the sash within the openings thereof opposite the glass which is then covered by a sash cover portion provided. The hardware located proximate the pivoting end is therefore installed on the carrier portions and inserted within the track portion within the sill and header, for example of a window assembly. The window is therefore closed in position with the sash covers or track covers located proximate the sill and header snapping into the frame and closing any path for air to enter the window and pass the primary seals provided as best seen in relation to the FIG. 15A. The track covers also provide blockage of light, air and the friction fit of the sash into the track portions. By providing a track cover along the track remote the pivoting end of the window, this track cover may be used as support as well for the window assembly.
[0121] In another embodiment not shown, a double casement window is provided which is provided in a straight-line window, that is to say a frame is provided wherein a central mullion is disposed. A central mullion separates two casement windows, one opening as a mirror image of the other and containing all of the elements described above in relation to the pivot assembly and the central locking system and track system.
[0122] Referring now to FIGS. 1 and 1D, there is illustrated a retractable screen contained within the opening of the jamb within a framing section for a window assembly having a header 17 , a sill 15 , and two side jambs 5 and 10 . The side jambs 5 and 10 are somewhat identical with the exception of the details herein provided. One of said jambs 5 or 10 , or for that matter in alternative embodiments sill 15 and or header 17 may contain a retractable screen stored on a tube. This may be seen in relation to FIG. 21 which is comparable to FIG. 1D. The screen assembly 300 includes a tube 305 having a pair of ridges 305 a contained within the hollow 300 a thereof, said hollow 300 a for receiving a spring 301 being a torsion spring having two ends 301 a and 301 b . Said ends 301 b and 301 a for anchoring into the assembly and for ensuring that the spring stays in constant torsion loading. A pin assembly 310 and 311 are disposed proximate each end of said tube 305 . The pin 310 includes an opening 310 a for receiving the end 301 a of said torsion spring 301 . Likewise, the insert 302 includes an opening 302 a for receipt of the end 301 b of the torsion spring 301 . The insert 302 engages the pin portion 311 . The pin portion 310 engages the bushing portion 312 . The pin portions 310 b and 311 b are inserted within mounting brackets M 1 and M 2 for mounting in the hollow of the jamb section. The rib portions 305 a and 305 b engage with corresponding rib portions provided with the pin section 311 and the bushing 312 to prevent rotation of the pins with respect to the tube unless the tube itself is rotated. With respect to the brackets M 1 and M 2 , spacers Si may be provided to orient and correctly space the screen assembly in the jamb portion or pocket within which the spring assembly retracts. The screen S is manufactured from a flexible material and has disposed proximate the ends thereof screen welding material or adhesive to adhere to the roller 305 and to the joint provided with respect to the handle portion 320 illustrated best in relation to FIG. 30. The other end of the screen is inserted within the alligator-type locking jaw of FIG. 30 between elements 320 a and 320 b to capture the screen portion S 2 therein. The screen portion 320 also includes a seal portion 321 which will be described hereinafter which locks and is retained within a channel 322 provided on one edge of the aluminum handle portion. Openings 325 and 326 are provided with the handle assembly 320 so as to retain the guide portions 330 therein. The guide portions 330 are contained within the openings 325 and 326 of the handle portion 320 so as to guide the screen assembly as it pays out from the jamb in a track portion provided with the header and sill portion of the framing sections. A latch portion and a latching plate 350 are shown with the assembly. The latching plate 350 is affixed to the opposite jamb for engaging with the latching member 340 wherein the detents mate and cooperate to retain the screen in its closed position. A seal 321 is contained within a seal receiving channel 320 a to seal against the opposite jamb and prevent bugs from entering the living space. The guide members 330 include a leg 330 a which are compatibly shaped with the opening 325 within the handle portion 320 . The handle portion 320 is extruded from aluminum to form all of the details thereof. The bracket portions M 1 and M 2 are mounted within a pocket P as seen in FIG. 1 containing the roll 305 . A cover plate 350 therefore is provided which snaps into place via the leg portion 350 a being inserted within an opening provided adjacent the jamb pocket. The jamb pocket therefore is defined by three sides 10 a , 10 b and 10 c against which the closure member buts up against and seals. This will be described hereinafter in relation to FIG. 21. The screen assembly, and particularly the brackets of FIG. 19 are therefore installed within the frame pocket P of FIG. 21 as being keyed into said frame pocket and engaged with the rear wall 10 c of the jamb 10 . The roller cassette 300 is then installed within the pocket P being pre-tensioned and wherein the pin portions 311 b and 310 b are inserted within openings O 1 and O 2 within said brackets, and the adjustment is provided via the bottom bracket M 2 including the spacer Si with the supplemental adjustment M 3 to ensure that the roller is properly placed in the system. The tension may be adjusted if required by removing the snap-on cover portion 350 at any time. The handle portion 320 is specifically sized to be received within the opening defined between the cover 350 and the adjacent jamb portion 10 b.
[0123] Referring now to FIG. 20, there is illustrated a similar cassette assembly for a retractable screen to that of FIG. 19 with the exception of the mounting brackets and the particulars of the screen. All other elements are identical or substantially identical. The brackets 360 therefore engage the generally T-shaped guide 350 b of the snap-on cover 350 proximate the generally T-shaped channels 360 b disposed therewith as best seen in relation to FIG. 28 b . Only one of the T-shaped channels or pockets 360 b therefore engage the T-shaped guide 350 b which allows for a certain amount of adjustability in relation to the positioning and pretensioning of the screen assembly 300 . The cover is therefore utilized as a chassis to hold the screen brackets and hence the screen cassette. The edges of the screen S 1 and S 2 are therefore provided with adhesive in the form of a tape system to mount the edge S 1 onto the hollow tube 305 and to mount the edge S 2 into the screen-receiving pocket of the handle portion 320 at 320 a . The glides 330 at the end of the handle portion 320 telescope to accept manufacturing installation variations prior to snapping them into the flexible frame track provided thereby providing a seal for the screen pocket and guide rails.
[0124] Referring now to FIGS. 21, 22 and 23 , the screen embodiments shown in FIGS. 19 and 20 may be utilized with a screen assembly as best seen in relation to FIGS. 22 and 23 which include generally T-shaped key portions S 1 and S 2 which are generally T-shaped and which engage with generally T-shaped openings 305 x and 350 x within the tube 305 and within the handle 350 in one embodiment of the invention thereof. By providing such a keyed relationship between the handle and the screen, screen replacement becomes very easy eliminating the need for adhesives and the general cutting of screen sections. The screen width indicated as Z therefore is a constant for all screens. Therefore, one continuous screen may be manufactured having the keyed portions located and anchored to the ends thereof as one continuous roll of screen having a predetermined size or width Z which may be cut to the desired length as the only variable dimension when making the screen assemblies of FIGS. 19 and 20 and/or replacing the broken screen which might result under normal wear of FIGS. 19 and 20.
[0125] Referring now to FIGS. 1D and 21, the screen assembly 310 included in the jamb does not compromise the typical framing size and standards nor interfere with the window function. Clearly the closure member or window 21 may be swung outwardly away from the jamb and be sealed against the seal 21 a in a closed position. Alternatively, when the window is a tilt and slide, the window 21 may be slid away from the jamb 10 . When the window is in the closed position, there is no need for the screen to be utilized. Therefore, the screen assembly 300 remains hidden within the jamb portion 10 of the window assembly. An esthetically pleasing result therefore is pleasant without the unsightly screen being present and without the unsightly lines of an additional housing added onto the jamb section 10 . The cover portion 350 including the guide 350 b may equally be utilized on the side 10 b of the jamb 10 . That is to say it is not necessary to have the cover 350 close the three-sided jamb sections 10 a , 10 b and 10 c from the front face thereof as shown in FIG. 21. Equally, the side face 10 b and in one embodiment a preferred approach will be utilized for the cover facing 350 wherein the cover therefore is not observable at the front of the jamb 10 but only at the side making a much more esthetically pleasing installation.
[0126] Referring to FIGS. 24, 25A, 25 B, 26 A, 26 B, 27 A and 27 B, there is illustrated the tube of FIG. 24 having a predetermined diameter and having rib portions 305 a provided therewith which engage with the compatible detents provided with the pin assembly at 311 a which prevents the rotation of the pins with respect to the hollow tube 305 . In this way, the torsion spring 301 and its effort can not slip in relation to the pins 311 b and 310 b . Similarly, the pin assembly embodying 302 as rib portions 302 b to prevent rotation thereof with respect to the tube portion 305 when engaged with the pin assembly portion 311 . An opening 302 a is provided to engage the spring end 301 b and help in establishing the loading and the constant torsion of the assembly. Similarly, the pin portion 310 has an opening 310 a for engagement with the end of the spring 301 a prior to insertion within the bushing 312 which also includes rib portions 312 a.
[0127] Referring now to FIG. 28A, there is illustrated the bracket of FIG. 20 which bracket 360 includes a pin-receiving opening and a pair of generally T-shaped openings 360 b for receiving the guide portion 350 b of the flexible cover 350 . Only one of the openings 360 b is utilized depending on whether the bracket is being utilized as a top or as a bottom bracket. Clearly, the bracket has adjustability in that it may slide along the guide 350 b in the flexible cover to the predetermined position to turn by the distance separating the pins 311 b and 310 b in the screen assembly. The brackets then may be fixed in position utilizing glue or the like and may be fastened to the opposite wall 10 c of the jamb 10 of FIG. 21 using conventional methods. It is recommended that the fastening be a removable fastener type allowing for repair of the screen assembly.
[0128] Referring now to FIGS. 29A and 29C, there is illustrated the glide portion 330 shown in FIGS. 19 and 20 which glide portion has a generally T-shaped guide-receiving portion 330 b to retain the channel. The member 330 a therefore is provided to be inserted within the opening 325 of the handle portion 320 to seal the entire assembly. Said foot 330 a can be moved in and out of the opening 325 to allow for adjustment as is required.
[0129] Referring now to FIG. 30 in relation to FIGS. 19 and 20, the handle portion 320 is therefore shown including alligator jaw-like portions 320 a and 320 b as seen in FIG. 20 for capturing the edge S 2 of the screen S when the portion 320 b is crimped and moved toward the edge of portion 320 a capturing the screen therebetween via serrated edges 320 i of the side 320 b of the joint. An opening 325 is provided for receipt of the guide portion 330 . The handle portion 320 i allows a user to remove the screen as required.
[0130] Referring now to FIGS. 31 a , 31 b , 32 a and 32 b , there is illustrating the latching portions of the screen assembly comprising items 340 and 350 . The portion 340 is mounted on the handle portion 320 and is clipped in position via a hook portion 340 b to be retained within a slot 320 i and 340 as best seen in FIG. 19. This latching portion engages the latching plate of FIGS. 32A and 32B which is mounted via mounting openings 350 b of the latching plate 350 . The opposite jamb is utilized to mount the latching plate 350 so that as the screen moves across the opening framed by the frame assembly, the detent or latch portion 340 a engages the latch portion 350 a of the latching plate to retain the screen in its operative position. This can be released of course by disengaging the latching portions 340 a and 350 a respectively wherein the screen may be retracted within the opening in the jamb 10 of the framing section.
[0131] Referring now to FIG. 33, there is illustrated the but seal 321 which is anchored in position within the groove 320 a of the handle portion 320 via legs 321 a . The bug seal 321 therefore buts up against the opposite jamb portion not shown via edge 320 b , that is the same jamb portion to which the latching plate of FIGS. 32A and 32B is mounted.
[0132] Referring now to FIG. 34, there is illustrated the cover portion 350 for the assembly of FIG. 20 which includes an arm or leg portion 350 a which is received within the channel 10 x of FIG. 21 which includes a locking edge at 350 b to retain said arm 350 a within the compatible groove 10 x which also includes a detent at 10 y to correspondingly lock the flange in position. The element 350 c therefore is disposed within the interior side of the cover 350 to be received within the channels or guides shown in FIGS. 28A through 28C at 360 b and thereby retain the mounting brackets for the screen assembly in the position required allowing the adjustment thereof and final fixing in relation thereto.
[0133] Those skilled in the art will also appreciate the fact that a screen assembly having two ends separated by a predetermined distance and being formed as a continuous screen which may be cut as required at a predetermined distance as set out by the length of the tube 305 . The anchor portions S 1 and S 2 are a fixed distance and are manufactured with the screen on a continuous length of screening which may be cut as required including cutting these anchor portions as best seen in relation to FIG. 23. This makes screen replacement very easy.
[0134] The entire assembly therefore 300 is provided as a cassette totally assembled and insertable into the jamb opening defined by the three sides of the jamb 10 at 10 a , 10 b and 10 c . It is only necessary to provide the cassette integral with the cover portion 350 which may be either the front cover which clips in position as shown in FIG. 21 or a side cover, not shown, but easily determined by those skilled in the art from the teachings herein.
[0135] As many changes can be made to the invention without departing from the scope of the invention, it is intended that all material contained herein be interpreted as illustrative of the invention and not in a limiting sense. | This invention relates to a retractable screen system for a closure assembly and improvements thereof which allows the secure sliding and subsequent retraction of the screen from a operative position to a retracted position. The invention is preferably embodied in a window assembly but finds application also in large pivoting windows and patio doors. | 4 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application claims priority from provisional application 61/959,712 filed Aug. 30, 2013.
FIELD OF THE INVENTION
This invention relates generally to push-in wire connectors and, more specifically, to a universal push-in wire connector having a collar for collectively shielding different sizes or types of wires.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
None
REFERENCE TO A MICROFICHE APPENDIX
None
BACKGROUND OF THE INVENTION
Twist on wire connectors having a single port for twistingly engaging two or more wires are known in the art. In one type of twist on wire connector a skirt is placed around the open coil end of the twist on wire connector. The skirt extends outward from the sides of the coil end in the twist on wire connector. In the event the bare ends of the wires, which are twistingly joined in a bundle in the wire connector, are axially uneven or if the twisting of wires causes the bare ends of the bundled wires to be axially displaced with respect to one another, the skirt, which extends outward from the coil provides isolation protection to ensure that any exposed portion of the bundled electrical wires is isolated from objects external to the wire connector. This type of wire connector with a single wire port and bundled wires relies on a frusto conical or cylindrical skirt located around the open end of the wire port of the individual twist-on wire connectors and requires each of the electrical wires to be simultaneously formed into electrical engagement with each other. An example of such a skirt is shown in U.S. Pat. No. 6,478,606.
SUMMARY OF THE INVENTION
A push-in wire connector having a plurality of wire ports with the plurality of wire ports surrounded by a single collar that isolates all the electrical wires from the environment external to the wire connector but not from each other with each of the wire ports, which are spaced from one another containing at least one resilient conductor wherein the spring force of the resilient conductor is sufficient to electrically engage a wire that is axially inserted into a port in the push-in connector. The multiport push-in wire connector allows one to sequentially insert individual wires into the push-in wire connector to sequentially form electrical connections between each of the wires while at the same time the collar collectively provides on-the-go isolation of each of the wires from the environment external to the wire connector.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a perspective view of a push-in wire connector with a multiport collar;
FIG. 2 shows a front view of a push-in wire connector of FIG. 1 ;
FIG. 3 shows a cross sectional view of the push-in wire connector of FIG. 1 taken along lines 3 - 3 ;
FIG. 4 shows a perspective view of a collar for a push-in wire connector;
FIG. 5 shows a left side view of the collar of FIG. 4 ;
FIG. 6 shows front view of the push-in wire connector of FIG. 4 ;
FIG. 7 shows a right side view of the collar of FIG. 4 ;
FIG. 8 shows a back view of the push-in wire connector of FIG. 4 ;
FIG. 9 shows a top view of the push-in wire connector of FIG. 4 ;
FIG. 10 shows a bottom view of the push-in wire connector of FIG. 4 ; and
FIG. 11 is a perspective view of a push-in wire connector 11 in dashed lines with a collar 20 mounted proximate the end of the push-in wire connector.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows a perspective view of a push-in wire connector 10 with a set of wires, 40 , 42 , 44 and 46 therein and for purposes of clarity FIG. 2 shows a front view of push-in wire connector 10 without the wires. Wire connector 10 includes a housing 11 having a first cylindrical wire socket or wire port 12 , a second cylindrical wire socket or wire port 13 , a third cylindrical wire socket or wire port 14 and a fourth cylindrical wire socket or wire port 15 each having an axial cylindrical wire inlet passage for axial insertion of a wire therein. As shown in FIG. 1 push-in wire connector 10 contains a first wire 46 in wire port 12 , a second wire 44 in wire port 13 , a third wire 42 in port 14 and a fourth wire 40 in wire port 15 (see FIG. 2 ) with each of the wires extending through an electrically insulating collar 20 .
In joining ends of wires into an electrical connection in the waterproof push-in wire connector 10 a first end of a wire 46 , which has been stripped of the electrical insulation cover, is axially inserted into first socket 12 and a further wire end 44 , which has also been stripped of the electrical insulation cover is axially inserted into second socket 13 with each of the bare wire ends entering into engagement with a common bus strip 23 , which is visible in ports 12 , 13 , 14 , and 15 ( FIG. 2 ) to form an electrical connection between the ends of the wires. In the example shown in FIG. 3 wire 42 , which has a stripped end 41 has been axially inserted into port 15 for forming electrical contact with the common bus strip 23 . The common bus strip 23 allows each of the individual wires 40 , 42 , 44 and 46 to be electrically joined within the push-in wire connector 10 through axial insertion of the wires into the respective ports of the push-in wire connector.
The push-in wire connector 10 allows one to quickly form an electrical connection of a number of wires of different size to each other through use of multiple ports and a common bus strip 23 since the resilient members in each port of the push-in wire connector flexes to adapt to the size of the electrical wire. That is, by axially inserting a wire into electrical contact the at least one resilient member 21 or 22 in the push-in wire connector in port 15 one forms electrical contact between the electrical wire and the bus strip.
FIG. 3 shows resilient strips 21 and 22 that frictionally engaging a wire end 41 with the edges 22 b and 21 b of the resilient strips biting into the wire 41 to both form an electrical contact and hold the wire 41 within the wire port so that the wire cannot be accidentally pulled out of the connector. Similarly, identical resilient strips within the other ports engage a wire end therein with the edges of the resilient strips biting into the wire to both form an electrical contact and hold the wire within the wire port so that the wires cannot be accidentally pulled out of the connector.
A feature of the push-in wire connectors with a collar is that a protected electrical connection between two or more wires can be obtained without requiring additional steps such as rotating a bundle of wires, squeezing the bundle of wires or forcing jaws or clamps around the bundle of electrical wires. In addition, in order to avoid accidentally electrical contact between the wires in the axial passages and the environment outside the wire connector the invention described herein utilizes a single electrically insulating collar to surround all of the wires but not an individual wire. This feature allows one to easily insert a single wire or at a later time insert additional wires in the push-in wire connector. That is, on-the-go one can insert single wires into the connector. For example, one wire at a time since there is no individual collar around the wire port to hinder the sequential insertion of wires into electrical engagement in the push-in wire connector.
To illustrate the formation of the electrical connection with a collar 20 reference can be made to FIG. 3 which shows a cross sectional view of push-in wire connector 10 taken along plane 3 - 3 of FIG. 1 . Push-in wire connector 10 comprises a one-piece housing 11 , which for example may be made from an electrical insulating material such as a polymer plastic and may include two or more wire passages therein which in the embodiment shown are identical to each other although the size and shape of the wire passages may be of different size or shape without departing from the spirit and scope of the invention. FIG. 3 shows a chamber 13 a therein on one end of housing 11 and a cylindrical wire passage 15 formed by a cylindrical wall 15 a extending into housing 11 . Located in the chamber 13 a and held in position by housing 11 is an electrical conductor comprising an elongated bus strip 23 . Positioned proximate to the bus strip 23 is a first V shaped resilient member comprising a resilient electrical conductor 21 having a wire contact region comprising an edge 21 b for scrapingly engaging an outer surface of an electrical wire and a second V shaped resilient member comprising a resilient electrical conductor 22 having a wire contact region comprising an edge 22 b member into for scrapingly engaging an outer surface of an electrical wire to bring the resilient members into an electrical connection. In the example shown each of resilient conductors 21 and 22 are formed at an acute angle Θ so that the wire engaging edge 21 b and wire engaging edge 22 b of each of the resilient conductors exerts a downward pressure on a wire located on the bus strip 23 with sufficient force so as to maintain an electrical connection between a wire therein and the resilient conductor in the presence of the sealant. While resilient springs are shown other wire securement means may be incorporated into the push-in wire connectors.
FIG. 3 shows that the electrically insulating collar 20 , which is secured to port end of push-in wire connector 10 has an interior surface 20 a with the collar having a length L and a width W with the width W greater than the diameter D of the wire passage 13 . In some cases collar 20 may be made from a rigid electrically insulating material and in other cases collar 20 may be made from a flexible electrically insulating material. In this example the multiport collar 20 is setback in all-lateral directions from the wire ports in the push-in wire connector.
A feature of the invention is that the universal push-in wire connector 10 can form an electrical connection with a protective collar for a plurality of electrical wires that are not bundled together. FIG. 3 shows that housing 11 contains a chamber 13 a with a bus strip 23 located therein. Housing 11 includes a first axial wire passage 12 in communication with the chamber 13 a , a second axial wire passage 13 in communication with the chamber 13 a , a third axial wire passage 14 in communication with chamber 13 a and a fourth axial wire passage 15 with each of the axial wire passages having a port for insertion of an electrical wire therein. In this example, as shown in FIG. 2 , each of the axial wire passage are located in a side by side condition in housing. As each of the wire engaging portions within the connector are the same only axial passage 13 is described herein, however, it is within the scope of the invention to have different wire engaging members in the axial passages.
FIG. 3 shows a first resilient conductor 22 having a wire engaging edge 22 b for electrically engaging of a wire end 41 , which has been axially inserted into the first wire port 13 a . Connector 10 includes a second resilient conductor 21 having a wire engaging edge 21 b for electrically engaging of the wire axially inserted into wire port 13 a with the first resilient conductor and the second resilient conductor located in the chamber 13 a in the housing 11 . In this example a bus strip 23 electrically connects the first resilient conductor 22 to the second resilient conductor 23 so that a wire 41 engages the first resilient conductor 22 and a second electrical wire connector 21 , which brings the first electrical wire 40 , the second electrical wire 42 , the third electrical wire 44 and the fourth electrical wire 46 into electrical communication with each other through the common bus strip 23 and the resilient members located therein.
Located external to the housing 11 is the electrically insulated collar 20 having a first end 20 b secured to end 11 a of housing 11 with electrically insulated collar 20 radially or laterally spaced from a sidewall 12 a wire port 12 , a sidewall 13 a wire port 13 , a sidewall 14 a wire port 14 and a sidewall 15 a wire port 15 , as well as laterally spaced from the wires 40 , 42 , 44 , and 46 . In the example shown the collar 20 simultaneously encompasses the first wire port 12 , the second wire port 13 , the third wire port 14 and the fourth wire port 14 with the collar 20 cantilevered outward from an end 11 a of the housing. In this example the collar provides unfettered access to each of the wire ports 12 , 13 , 14 and 15 while inhibiting electrical contact between a wire in either of the wire ports and an object external to electrical insulated collar.
As shown in FIG. 3 the electrical wire 41 is located within the collar 20 to protect the electrical wire from the environment 35 external to the wire connector, however, the collar 20 is not needed to protect the wires 40 , 42 , 44 and 46 from electrical contact with each other within the collar 20 since wires 40 , 42 , 44 and 46 are connected to the same bus strip 23 .
As can be seen in FIG. 1 the collar 20 does not hinder formation of an electrical connection within housing 11 since there is sufficient space to axially insert the wire end yet at the same time the collar protects each of the electrical wires therein from contact with an object in the environment 35 external to the wire connector 10 .
In the example shown the first resilient conductor 22 may exert a larger downward force than the second resilient conductor 21 through the use of resilient conductors of the same material but of different thickness. Consequently, in some cases the rigidity of the wires may be the such that only one of the resilient conductors is in engagement with the wire. If the ends of the wires have been stripped to the same length a portion of the stripped end of the wire may extend outside the port of the push-in wire connector. In other cases the stripping of the wire ends may not be equal which may cause a portion of the stripped end of the wire to extend outside the wire port of the push-in wire connector.
FIG. 2 shows and end view of the push-in connector with each of the wire ports 12 , 13 , 14 and 15 spaced from each other. For example port 22 is spaced from port 15 and port 13 . Port 22 is also spaced from the bottom of the housing by a distance “b” and the top of the housing by a distance “a”. FIG. 2 show the collar 20 is setback from the wire ports to provide an enlarged wire entry. That is, the single collar 20 extends around the end of housing 11 and encompasses all four wire ports 12 , 13 , 14 , and 15 with the collar laterally setback from the wire ports to provide access to the ports in the push-in wire connector. While the push-in wire connector is shown with insulating and waterproofing material 30 in the connector 10 the collar of the present invention may be used with a push-in wire connector without an insulating and waterproofing material therein.
To illustrate the ornamental design of the push-in collar 20 references should be made to FIG. 4 to FIG. 11 where:
FIG. 4 shows a perspective view of a push-in collar 20 for securing to an end face of a push-in wire connector;
FIG. 5 shows a left side view of the push-in collar 20 of FIG. 4 ;
FIG. 6 shows front view of the push-in collar 20 of FIG. 4 ;
FIG. 7 shows a right side view of the push-in collar 20 of FIG. 4 ;
FIG. 8 shows a back view of the push-in collar 20 of FIG. 4 ;
FIG. 9 shows a top view of the push-in collar 20 of FIG. 4 ;
FIG. 10 shows a bottom view of the push-in collar 20 of FIG. 1 ; and
FIG. 11 shows a perspective of a push-in wire connector 11 in dashed lines with a push-in collar 20 of FIG. 4 mounted proximate the end of the push-in wire connector. | A wire connector having a collar surrounding a set of wire ports in a wire connector with the collar providing a collective shield between an environment external to the collar the collar but not between the set of wires within the collar. | 7 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] The present application claims priority to the U.S. provisional application having Ser. No. 60/741,827 entitled “Data Structures and Methods for Genealogical Research”, filed on Dec. 2, 2005, which is incorporated herein by reference.
BACKGROUND OF INVENTION
[0002] This invention relates to the organization, processing and searching of genealogical data. Particularly, this invention relates to improvements to the storage and retrieval of genealogy information, includes methods of inputting and using information from historical data and/or genetic characteristics derived from DNA testing to expand the search capabilities for genealogists.
[0003] The research into genealogical records is a popular hobby, as well as legal research to find un-named heirs.
[0004] Today's worldwide genealogy data records environment can be summarized in general terms as comprising hundreds of millions of relatively large public record sets in non-lineage-linked format, mostly on paper or microfilm, plus proportionately much smaller collections of lineage-linked names, mostly held by individual persons. The smaller collections are increasingly in digital and computer readable format. These smaller collections of relatives' names are generally derived in part for family non-public records, plus extracts from any number of larger public record sets. There are huge national collections of records, such as the U.S. censuses, that may contain hundreds of millions of names. Other national records include census, social security, military and Emigration, immigration and naturalization records, including Passports. At the state level, there are the usual birth; marriage; death; Tax; Voter registration; Wills and probate records. At the local or county level, one might find Land and homestead records/deeds, burial, and court records. Other useful personal or commercial records might include, without limit: Adoption records; Baptism or christening records; Biographies and biographical profiles (as in Who's Who, etc.); Cemetery records and tombstones; City directories and telephone directories; Daughters of the American Revolution records; Diaries, personal letters and family Bibles; Marriage and divorce records; Medical records; Newspaper columns; Obituaries; Occupational records; Oral history; Photographs; School and alumni association records; and Ship passenger lists.
[0005] However, many genealogical researchers eventually reach a limit of tracing their family history or connections that leave them unsatisfied, wishing to delve further back in their family history, discover living relatives, or determine if they are related to a particular living or deceased individual.
[0006] The success of the researcher meeting their objective is highly dependent on the ancestry/ethnicity of the subjects, as well as their ancestor's geographic dispersion. Success is also dependent on existence, or lack thereof, of extant records that have been passed through multiple generations. For example, an individual whose ancestors were held in peony, i.e. as slaves, will have a very difficult time tracing their ancestry due to a lack of available records.
[0007] A greater problem for the genealogical researcher using computerized databases, or programs that can link to and abstract data from computerized records, is the inconsistency and errors in these records. Another problem that frustrates the researcher in meeting their objective is differences in spelling of names, as might change fashion through generations, or ancestors being called by their nickname or abbreviated name in some records that contemporaneously record information about the same person.
[0008] Although genetic markers in DNA are a successful tool in the scientific research of population genetics, the application of this tool to the genealogist has been limited.
SUMMARY OF INVENTION
[0009] In the present invention, the first object is to extend the capability for computerized genealogical research.
[0010] Another object of the invention is to enable the identification of living kin related through a maternal line.
[0011] Another object of the invention is to enables the identification of living kin related through a paternal line.
[0012] The above and other objects of the invention are met by providing data structure and graphic users interface for accessing and searching such databases that force the consistent entry of data.
[0013] Other aspects of the invention are met by providing a search capability that accounts for the historical variation of geographic regions, territories, districts, counties, provinces, states or political boundaries.
[0014] Other aspects of the invention are met by providing a search capability that accounts for genetic markers of the named person's mitochondrial DNA and the names of matriarchal ancestors and their siblings.
[0015] Other aspects of the invention are met by providing a search capability that accounts for genetic markers of the named person's DNA and the names of paternal ancestors and their siblings.
[0016] Other aspects of the invention are met by providing a search capability that accounts for the name of the person conveyed in a slave or related transaction at least one of a date and a geographic or jurisdictional designation associated with the transaction, including emancipation.
[0017] Other aspects of the invention are met by providing a search capability that accounts for multiple alternative names or spellings of the first or last name of a living person or ancestor.
[0018] The above and other objects, effects, features, and advantages of the present invention will become more apparent from the following description of the embodiments thereof taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF DRAWINGS
[0019] FIG. 1 is an illustration of an exemplary graphic user interface that implements multiple embodiments of the invention.
[0020] FIG. 2 is example of the data fields found and associated in an expanding geographic designation data structure.
[0021] FIG. 3 is a family tree to illustrate the application of a data structure and search algorithm that utilizes mtDNA.
[0022] FIG. 4 is a family tree to illustrate the application of a data structure and search algorithm that utilizes DNA on the Y-chromosome.
DETAILED DESCRIPTION
[0023] In accordance with the present invention, FIG. 1 is a graphic user interface (GUI) 100 for the computer implementation of various embodiments of the invention. The GUI contains imputer fields via drop down menus for entering or searching data, as well as navigation buttons for moving to or displaying related GUI's and radio buttons for entering data. The GUI may be used to search a local computer, a server or a plurality of computers and databases, such as might be available over the internet or other data communication networks.
[0024] A researcher that builds or contributes to the database by abstracting information from paper historical records, newspaper accounts and the like might also use such a GUI. In the most preferred implementation of the invention, the combined elements of each embodiment would be available to the genealogical researcher. Many researchers are in fact building the database by contributing information on the search subject, that the point of backward tracing to find ancestors, as well as information known by the individual of living or recently deceased kin, such a parent or grandparent.
[0025] Referring now to FIG. 1 , a top navigation bar region 105 contains a plurality of buttons that either provide instructions to the users (i.e. HELPS AND TIPS), or switch the mode of operation or function (HOME PAGE, NEW LINE, SEARCH and MEMORIZED SEARCHES). The next set of control buttons are arranged in row 110 , for “FATHER” and “MOTHER” allowing the researcher to enter information about either parent of the subject being described or characterized with the remaining input fields on the pages, that is those arranged in rows labeled 120 , 130 , 140 and 150 . It should be appreciated that the GUI 110 is only exemplary as a different layout or multiple GUI pages could be used to enter the same information.
[0026] Row 120 has a plurality of drop down list boxes for entering data in a name field of the person being identified or described in GUI 100 . Name field have drop-down menus that limit responses to exact spelling, or the opportunity to state that particular information is unknown. A name field in any database described herein may be a field for a first name field, a surname or last name, a middle name and a nickname and/or any combination of the aforementioned. As the same individual might be known by multiple first names, or first names of slightly different spellings a plurality of drop down list boxes are arrayed for example in entering up to four alternative first names. A nickname may be entered as well of, or in place of a more formal first name using drop down list box 125 . At least one drop down list box 126 is also provided for entering a surname 126 . The plural first name drop down lists, that is the first, second, third and fourth name buttons are provided to enter into a data structure for searching a first name field for the subject, a last name field for the subject, and a secondary first name field for the subject. The secondary name field for a subject contains a data record that is a variant of the data record in the primary first name field for the subject. The secondary name fields are structured as drop down lists to force the user to consider and implement known alternative spellings, as well as to enter more conventional spellings, thus preventing the entry of spurious information through keyboard entry errors. This embodiment of the invention improves genealogical searching by enforcing a consistency of data input, yet allows for flexibility in that oral traditions may vary from older extant records. Thus, this database maintains a data structure of alternative names and spellings, as well as nicknames that might be used. When the user selects or starts to spell a name the alternative become available in the drop-down menu fields.
[0027] Another embodiment of the invention to improve genealogical searching is to expand the options for selecting names in the drop down lists described above. Such a method might be available to the individual researcher as well as a system/database administrator. The first step in the method is to generate input fields in a GUI (graphic user interface) to receive a first name not in an existing drop down list box or button, the next step is to type or otherwise enter the letters/characters of the first name, which is then received in the database. The next step in the process is for the computer to check the spelling of first name against a database of primary and secondary first names, then if the proposed name is not found in the existing database, the computer software is operative to generate input fields in the GUI for at least one of expanding the secondary names in the database, adding a first name record to the database and selecting a primary name in the database. If there is an exact match with either the primary or the secondary names then the GUI prompts the user to select this name. If there is not an exact match, the user has the option of adding a new name to the list in the drop-down list. If known, the individual's race is optionally entered in drop down list 160 .
[0028] Row 130 includes a plurality of input interfaces to characterize the date and location of the subject's birth. Row 130 is subdivided into a series of drop down list 138 to optionally enter the birth location as either a country, state, county, or other political subdivision.
[0029] Date input fields allow for the entry of an exact day, via separate drop down list buttons for the day, month and year. Alternatively, when there is less certainly, only the year need be entered. Database field for dates permits an exact date or an approximate date, thus accounting for the possibility of a two-year error arising from the inaccuracy of recording and reporting ten-year census records in the U.S.A. The entry of the year may be selected as either exact (such as might be found on a birth certificate) or approximate (such as might apply to a census record) by clicking on a radio style button such as 133 a for birth year 133 . Likewise, the entry of the year of death may be selected as either exact or proximate by clicking on a radio style button 143 a for characterizing the death year by button 143 . Alternatively, using buttons 134 , a range of birth years may be specified. Using buttons 144 , a range of the year of death may be specified.
[0030] Row 140 includes a plurality of input interfaces to characterize the date and location of the subject's death, if it has occurred. Row 140 is subdivided into a series of drop down lists 148 to optionally enter the death location as either a country, state or county or other political subdivision.
[0031] Row 150 includes a plurality of input interfaces to characterize what may be known about the residence or domicile of the subject during their lifetime. Row 150 is subdivided into a series of drop down lists 170 to optionally enter the location of residence as either or a country, state or county or other political subdivision. Row 150 is further subdivided into a series of input fields 180 to enter the date range of residence for the subject.
[0032] Another embodiment of the invention to improve genealogical searching is a branched geographic database. Geographic designations or indicators include country and any political or judicial subdivisions therewith (i.e. state, commonwealth, county, parish, as well as any chancery, probate or district court).
[0033] The geographic names of regions and places typically changes over time. Historical documents typically reflect the correct name for the place at the time the record or document was created. Thus for example, the same individual if born in a town in the Commonwealth of Virginia that eventually became part of the State of West Virginia might have on their birth certificate the place of birth as Virginia, but West Virginia recorded as the place of birth in the death certificate if they were born and died in the same location. However, a sibling born in the same location while it was still Virginia might have Virginia listed on their death certificate as the place of birth, if they died in another state, their living kin having record the verbal record they relied upon that their parent or grandparent was born in Virginia. Accordingly, it is unlikely that a researcher would realize the first example is the same person, or that the first example and second example are siblings. Accordingly, in a preferred embodiment of the invention when a researcher enters the subjects name, date of birth/death (or date range) along with the location of this life cycle event the search algorithm would take into account that during the subject time period entered in the date search field the geographic description of the life cycle event would have an alternative and equally valid description. The search algorithm would be generated to include this alternative by look up in a data structure having fields for a first geographic designation, a second geographic designation, at least one date and at least one alternative geographic description. After look up from this data structure the actual search for the individual would be based on matching to a data structure representing the individual that includes data fields for at least the first or last name of the subject, the subjects primary geographic designation and the subjects secondary geographic designation derived from the subjects primary geographic designation based on a prior history.
[0034] The relationship of the fields in portions of this database is shown in FIG. 2 as a series of interrelated data fields 200 . The database has a least one record field 210 for a primary geographic name, such as that might be matched with the user's entry in drop down lists 138 , 148 and 170 in the GUI 100 of FIG. 1 . The data structure then has at least one date related field 215 which contains data representing when at least a portion of the geographic region in field 210 was known by a different, that is a secondary name, in field location 230 . Optionally the data structure contains alternative fields such as 220 that might represent a different date when the geographic region in field 210 was known by a tertiary name.
[0035] Another embodiment of the invention to improve genealogical searching utilizing information derived from mitochondrial (mt)DNA. As mtDNA is inherited only through the mother, persons related by a common ancestor in the line of mother-grandmother-great grandmother-great great grandmother etc. will share the same mtDNA.
[0036] With respect to genealogical research, mtDNA and DNA are characterized by many unique regions not associated with protein synthesis, regulation and gene expression but known to uniquely vary between individuals. Each such particular region is called a marker. Each marker may have one or more characteristics values, representing a specific sequence of nucleotides in the genome at a particular location. Individuals have a greater probability of being related if more or all of the known genetic markers have the same value. Once a person has characterized their own mtDNA, they can add to a searchable database using, among other information, the name or identity of each marker and the value of the marker for each named relation they know of in their maternal line. Thus, research to find or identify siblings of ancestors in the subject's maternal line, and possibly living relatives descended maternally from these ancestors, can be accomplished by searching a common database, wherein a large number of individuals have entered parameters of their own mtDNA markers, which would then be attributed to the known ancestors in their maternal line.
[0037] Such a database would contain data fields for the subject's name, a plurality of genetic markers of the named person, a value associated with each genetic marker, the name of a matriarchal ancestor of the subject. In preferred embodiments, the data structure and search algorithm generated therefrom will also include data fields linking multiple named subjects and the relationships. In more preferred embodiments, the data structure and search algorithm generated therefrom will also include data fields for adding the name of female siblings of the maternal line, as descendents of female siblings, be they male or female, would inherit largely the same mtDNA (other than for mutations that are known to occur a very low frequency over tens or hundreds of generations). This principle is illustrated schematically in FIG. 3 as a theoretical abstract of a portion of a database showing the male (F for father) and female (M for Mother) parent at each generation and their offspring that would have the common mtDNA markers. Although the mtDNA passes to both male and female offspring only the female offsprings are shown at each generation level. This is because only the female is capable of passing the mtDNA to the next generation. At the bottom, or living generation, are two research subjects R 1 and R 2 that have a match of mtDNA markers. R 1 has built a multi-generation linked family tree 301 from a variety of records before using mtDNA data, shown by a solid bold line linking parents to children. Family tree 301 extends from the common maternal ancestor, M eve , to R 1 . However, R 2 has built a multi-generation linked family tree 302 that does not extend to M eve , but is one generation removed. Fortunately, R 1 's tree included a maternal ancestor, designated S 1 , who was known to have a sibling S 2 . As S 1 and S 2 have the same mother, M eve , they share the same mtDNA, which is passed on to R 1 and R 2 . Accordingly as the both tree 301 and tree 302 at generation level 303 have a female siblings that are likely to be the same person based on name and preferably at least one of age, place of birth, death or residence, R 2 can then extend the knowledge of her ancestry to reach the generation of M eve , as well as to add branch 301 contributed by R 1 . Thus, finding both a match in mtDNA and at least a common pair female sibling in their maternal lines R 1 and R 2 can discover they are related. In more preferred embodiments such matriarchal ancestor database includes record fields for date and/or lifecycle event such as the birth, death, marriage, religious ceremony, divorce, place of birth, death, and/or marriage, property acquisition or bequest, or mere domicile or place of residence. In the most preferred embodiments, the matriarchal ancestor database includes record fields for the names of male siblings.
[0038] Another embodiment of the invention to improve genealogical searching utilizes information derived from DNA of the Y chromosome of male subjects or the male siblings of subjects. Such a database would contain data fields for the subject's name, a plurality of genetic markers of the named person, a value associated with each genetic marker, the name of a patriarchal ancestor of the subject. In preferred embodiments, the data structure and search algorithm generated therefrom will also include data fields linking multiple named subjects and the relationships. In preferred embodiments, the data structure and search algorithm generated therefrom will also include data fields for adding the name of male siblings of the paternal line, as only male descendents of male siblings would inherit largely the same DNA on the Y-chromosome, other than for mutations that are known to occur a very low frequency over tens or hundreds of generations. This principle is illustrated schematically in FIG. 4 as a theoretical abstract of a portion of a database showing the male (F for father) and female (M for Mother) parent at each generation and their offspring that would have the common Y-chromosome DNA markers. As the Y-chromosome DNA only passes to male offsprings, the female offspring are not shown to simplify the diagram. At the bottom, or living generation, are two research subjects R 1 and R 2 that have a match of Y-chromosome DNA markers of either themselves or a male sibling. R 1 has built a multi-generation linked family tree 401 from a variety of records before using DNA data, shown by a solid bold line linking parents to children. Family tree 401 extends from F adam to R 1 . However, R 2 has built a multi-generation linked family tree 302 that does not extend to F adam , but one generation removed. Fortunately, R 1 's tree included a paternal ancestor, designated S 1 , who was known to have a male sibling S 2 . As S 1 and S 2 have the same Father, F adam , they share the same DNA, which is passed on to both R 1 and R 2 . Accordingly as the both tree 401 and tree 402 at generation level 403 have a pair of male siblings that are likely to be the same person based on name and preferably at least one of age, place of birth, death or residence, R 2 can extend the knowledge of his or her ancestry to now reach the generation of F adam , as well as branch 401 contributed by R 1 . Thus finding both a match in Y-chromosome DNA and at least a common pair male sibling in their paternal lines R 1 and R 2 can discover they are related. In more preferred embodiments such paternal ancestor database includes record fields for date and/or lifecycle event such as the birth, death, marriage, religious ceremony, divorce, place of birth death and/or marriage, or mere domicile or place of residence. In most preferred embodiments, the patriarchal ancestor database includes record fields for the names of female siblings. Such a database would contain data fields for the subjects name, a plurality of genetic markers of the named person, a value associated with each genetic marker, the name of a sibling of an ancestor of the subject.
[0039] Another embodiment of the invention to improve genealogical searching utilizes information historical records that record the conveyance or emancipation of slaves. Such records can be founds in ancient wills, courthouse records of sales, contemporaneous newspaper accounts and the like. Such a database would contain data fields for the conveyor's name, the receiver's name, at least a first or last name of the person conveyed or emancipated, and at least one of a date and a geographic or jurisdictional designation associated with the transaction.
[0040] While the invention has been described in connection with a preferred embodiment, it is not intended to limit the scope of the invention to the particular form set forth, but on the contrary, it is intended to cover such alternatives, modifications, and equivalents as may be within the spirit and scope of the invention as defined by the appended claims. | Improved methods of genealogical research utilize databases with fields that more uniquely identify individuals and relationships for the purpose of tracing and identifying ancestors or living relations. In selected embodiments, the fields represent genetic markers on the mitochondrial DNA and biographic or historical data useful in tracing matriarchal heritage. In other embodiments, the fields represent ownership records or conveyances of property between related or unrelated individuals. In other aspects of the invention methods of searching account for the evolution of geographic and political divisions in searching genealogical database, as well as the alternative spelling of names and nickname. | 6 |
BACKGROUND OF THE INVENTION
This invention relates to multilamp photoflash devices having circuit means for sequentially igniting the flashlamps and, more particularly, to improved means for permitting reliable flashing of an array of photoflash lamps, particularly arrays operated by comparatively long duration, low voltage firing pulses.
Numerous multilamp photoflash arrangements with various types of sequencing circuits have been described in the prior art, particularly in the past few years. Series and parallel-connected lamp arrays have been shown which are sequentially fired by mechanical switching means, simple electrical circuits, switching circuits using the randomly varied resistance characteristics of the lamps, arc gap arrangements, complex digital electronic switchin circuits, light-sensitive switching means and heat-sensitive switching devices which involve melting, fusing or chemical reaction in response to the radiant energy output of an adjacently located flashlamp. The present invention is concerned with an improved radiant-energy-activated switching means useful in a relatively inexpensive photoflash unit of the disposable type. In particular, the present switching means is particularly advantageous in photoflash arrays emloying lamps adapted to be ignited sequentially by successively applied firing pulses from a low voltage source.
A currently marketed eight-lamp photoflash unit employing radiation switches is described in U.S. Pat. Nos. 3,894,226 and 4,017,728 and referred to as a flip flash. A ten lamp version is described in U.S. Pat. Nos. 4,156,269 and 4,164,007. The unit comprises a planar array of high voltage flashlamps mounted on a printed circuit board with an array of respectively associated reflectors disposed therebetween. The circuit board comprises an insulating sheet of plastic having a pattern of conductive circuit traces, including terminal contacts, on one side. The flashlamp leads are electrically connected to the circuit traces, such as by means of eyelets, and the circuitry on the board includes a plurality of solid state switches that chemically change (convert) from a high to low resistance so as to become electrically conducting after exposure to the radiant heat energy from an ignited flashlamp operatively associated therewith. The purpose of the switches is to promote lamp sequencing and one-at-a-time flashing.
One type of solid state switch which operates in this manner is described in U.S. Pat. No. 3,458,270 of Ganser et al, in which the use of silver oxide in a polyvinyl binder is taught as a normally open radiant energy switch. Upon radiant heating, the silver oxide decomposes to give a metallic silver residue which is electrically conductive. Silver carbonate has also been used in lieu of or together with silver oxide. For example, U.S. Pat. No. 3,990,833, Holub et al, describes a mass of a composition comprising silver oxide, a carbon-containing silver salt and a humidity resistant organic polymer binder, the switch mass being deposited on a circuit board so as to interconnect a pair of spaced apart electrical terminals formed by the printed circuitry thereof. A similar type radiation switch exhibiting an even greater humidity resistance at above normal ambient temperatures is described and claimed in U.S. Pat. No. 3,990,832, Smialek et al, which describes the use of a particular stabilizer additive, such as an organic acid, to preclude or reduce the tendancy of the silver source in the switch material from premature conversion to a low electrical resistance when exposed to ambient humidity conditions. U.S. Pat. No. 3,951,582, Holub et al, describes a similar type switch with a colored coating, and U.S. Pat. No. 4,087,233, Shaffer, describes a switch composition comprising silver carbonate, a binder, and an oxidizer such as barium chromate, which is particularly resistant to high relative humidity and above normal ambient temperatures. U.S. Pat. No. 3,969,065, Smialek, describes a solid state switch comprising a mixture of solid copper salt with a humidity resistant organic polymer binder and a finely divided metal reducing agent, and a U.S. Pat. No. 3,969,066, Smialek et al, describes a switch comprising a mixture of finely divided cupric oxide with a humidity resistant organic polymer binder.
The use of a glass bead filler in a solid state switch is described in U.S. Pat. No. 4,080,155 of Sterling for preventing the switch material from being burned off or blown off the circuit board. An improved switch composition which avoids these problems is described in copending application Ser. No. 021,398, filed Mar. 19, 1979, and assigned to the present assignee. The improved burn-off prevention and reduced heat absorption are attained by replacing part of the silver carbonate and/or silver oxide in the switch composition with a proportion of electrically nonconductive inert particulate solids which comprise as much as 25-65% by weight of the total dried composition.
All of the aforementioned switch compositions have been described with respect to use in photoflash arrays employing high voltage type lamps adapted to be ignited sequentially by successively applied high voltage firing pulses from a source such as a camera-shutter-actuated piezoelectric element. Accordingly, none of these prior patents or applications mention a specific switch closure interval, i.e., the time of conversion from a high electrical resistance to a low electrical resistance upon exposure to radiation emitted from an adjacent flashlamp. Consideration of such switch closure, or conversion, time has not been necessary in a high voltage piezo-fired array since the electrical firing pulse duration is less than 10 microseconds, whereas the normally open radiation switch is not activated until 5-10 milliseconds; i.e., the conversion time is 5 to 10 milliseconds. If it is desired to use such normally open radiation switches in a low voltage photoflash array intended for operation with a typical camera actuated, battery powered pulse source, the reliability of proper lamp sequencing can be adversely affected. In a low voltage array, the electrical pulse duration can extend to a period longer than the conversion time of the normally open radiation switch. If the pulse duration is long enough, a second lamp will inadvertently flash, thereby causing the loss of that lamp in the intended useful sequence of lamp operation. Accordingly, it is desirable to have a normally open radiation switch that will activate (be converted) after the camera pulse has ended. By way of specific example, consider a low voltage camera having a pulse duration which varies from 4 to 10 milliseconds. In such an application, a switch conversion time of greater than about 12 milliseconds would be required. For these purposes, switch conversion time is defined as the elapsed time between the start of the firing pulse, and thus the high electrical resistance (open circuit) state of the switch mass, and the time at which the switch resistance reaches a predetermined low resistance state, which functions as a closed circuit in the operating application.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide a photoflash unit having improved switching means for permitting reliable flashing of an array of photoflash lamps.
A principle object of the invention is to provide an improved, normally open radiation-actuated electrical switch for use in devices such as photoflash arrays and in which the switch composition is formulated to provide a predetermined conversion time of about 12 milliseconds or greater.
A further object is to provide an improved solid-state switch composition which more readily facilitates control of switch conversion time.
These and other objects, advantages and features are attained, in accordance with the invention, by appropriate selection of the composition of the switch admixture to provide a predetermined conversion time of about 12 milliseconds or greater. A preferred conversion time is from about 12 to 19 milliseconds. Typically the switch admixture comprises silver carbonate and/or silver oxide, silver-coated glass beads, and a binder. The use of a selected proportion of silver-coated glass beads as a conductivity-enhancing filler in a silver compound switch is described in copending application Ser. No. 148,358 filed concurrently herewith and assigned to the present assignee.
According to one embodiment of the invention, the proportion of binder in the dried composition by weight of the admixture is in the range of 10% to 15%, and the conversion time and resistance of the switch after conversion are directly related to the proportion of binder. In another embodiment, the proportion of silver carbonate in the dried composition by weight of the admixture is in the range of 45% to 0%, and the proportion of silver oxide in the dried composition by weight of the admixture is in the range of 0% to 45%; in this case, the conversion time and resistance of the switch after conversion are directly related to the proportion of silver carbonate replacing silver oxide in the mixture. In yet another embodiment, the switch admixture further includes 11% to 40% of electrically non-conductive inert particulate solids comprising one or more members selected from the group consisting of titanium dioxide, aluminum dioxide, aluminum phosphate, barium sulfate, and silicon dioxide. In this instance, the conversion time and the resistance of the switch after conversion are directly related to the proportion of the inert particulate replacing silver carbonate and/or silver oxide in the mixture; accordingly, this approach is not suitable for applications when the maintenance of a very low post-conversion resistance is critical. In yet another embodiment, the composition of the switch admixture further includes 50% to 60% silver-coated metal beads, and the conversion time of the switch is directly related to the proportion of silver-coated metal beads replacing silver-coated glass beads in the mixture. The resistance of such a switch after conversion, however, is inversely related to the proportion of silver-coated metal beads replacing silver-coated glass beads in the mixture.
BRIEF DESCRIPTION OF THE DRAWINGS
This invention will be more fully described hereinafter in conjunction with the accompanying drawings in which:
FIG. 1 is a front elevation of a multilamp photoflash unit in which the present invention is employed;
FIG. 2 is a front elevation of a circuit board used in the unit of FIG. 1, the circuit board including radiation connect switches in accordance with the invention;
FIG. 3 is an enlarged fragmentary detal view of a proportion of the circuit board of FIG. 2 showing the switching arrangement associated with one of the lamps; and
FIG. 4 is an enlarged fragmentary schematic cross-sectional view taken along 4--4 of FIG. 1.
DESCRIPTION OF PREFERRED EMBODIMENT
FIG. 1 illustrates a multilamp photoflash unit of the general type described in the aforementioned U.S. Pat. No. 4,164,007. This unit is similar in general operation to that described in the aforementioned U.S. Pat. No. 4,017,728, except that the construction has been modified to include additional lamps in a housing having the same outer dimensions. Whereas the unit described in U.S. Pat. No. 4,017,728 included a planar array of eight flashlamps (two groups of four) with associated reflector cavities provided in a single reflector member, the present unit comprises a planar array of ten flashlamps 11-15 and 21-25 mounted on a printed circuit board 43 (see FIG. 2) with an array of respectively associated reflector cavities 11'-15' and 21'-25' disposed therebetween. For low voltage pulse operation, the lamps can be of the filament type. Lamp 24 is omitted in FIG. 1 to show reflector cavity 24', which is typical of all the reflector cavities. The lamps are horizontally disposed and mounted in two parallel columns, with the lamps of one column staggered relative to the lamps of the other column. Each of the lamps has a pair of lead-in wires (not shown) connected to the printed circuitry on board 43 by respective eyelets 11a and 11b, etc., or solder joints. The column of lamps 15, 13, 11, 22 and 24 are positioned with their respective bases interdigitated with the bases of the adjacent column comprising 14, 12, 21, 23 and 25, the bases of one column thereby facing the bases of the adjacent column. The reflector cavities are provided on a pair of strip-like panels 40 and 41 which are conveniently separable for assembly purposes. The array is provided with a plug-in connector tab 16 at the lower end thereof which is adapted to fit into a camera or flash adaptor. A second plug-in connector tab 16' is provided at the top end of the unit, whereby the array is adapted to be attached to the camera socket in either of two orientations, i.e., with either the tab 16 or the tab 16' plugged into the socket. The lamps are arranged in two groups of five disposed on the upper and lower halves, respectively, of the elongated, rectangular-shaped array. Upper group 17 comprises lamps 11-15 and lower group 18 includes lamps 21-25; the reflector cavities 11', etc., are disposed behind the respective lamps so that as each lamp is flashed, light is projected forwardly of the array. The lamps are arranged and connected so that when the array is connected to a camera by the connector tab 16 only the upper group 17 of lamps will be flashed. By this arrangement, only lamps relatively far from the camera lens axis are flashable, thus reducing the undesirable " red-eye" effect.
The construction of the array comprises front and back housing members 36 and 37 (only the outer periphery of the back housing member is visible in FIG. 1), which preferably are made of plastic and are provided with interlocking members (not shown) which can be molded integrally with the housing members and which lock the housing members together in final assembly to form a unitary flash array structure. The front housing member 36 is a rectangular concavity and the back housing member 37 is substantially flat and includes integral extensions 39 and 39' at the ends thereof which partly surround and protect the connector tabs 16 and 16' and also function to facilitate mechanical attachment to the camera socket. Sandwiched between the front and back housing members 36 and 37, in the order named, are the flashlamps 11, etc., the pair of adjacent strip-like reflector panels 40 and 41 (preferably each being aluminum-coated plastic molding) shaped to provide the individual reflector cavities 11' etc., a transparent electrically insulating sheet 42 (shown only in FIG. 4), the printed circuit board 43 provided with integral connector tabs 16 and 16', and an indicia sheet (not shown) which may be provided with information and trademarks, and other indicia such as flash indicators located behind the respective lamps and which change color due to heat and/or light radiation from a flashing lamp, thus indicating at a glance which of the lamps have been flashed and not flashed.
Window means, such as openings 67, are provided in each of the reflector cavities 11', etc., behind the lamp aligned therewith. The circuit board 43 is provided with corresponding openings 30 to facilitate radiation from the flashlamps reaching the flash indicators. The rear housing member 37 is transparent (either of clear material or provided with window openings) to permit viewing of the indicia on the indicia sheet. The front housing member 36 is transparent, at least in front of the lamps 11, etc., to permit light from the flashing lamps to emerge forwardly of the array, and may be tinted to alter the color of the light from the flashlamps.
The height and width of the rectangular array are substantially greater than its thickness, and the height and width of the reflector panels 40, 41, the insulating sheet 42, and the circuit board 43 are substantially the same as the interior height and width of the housing member 36 to facilitate holding the parts in place.
Referring to both FIGS. 1 and 2, the tab 16, which is integral with the circuit board 43, is provided with a pair of electrical terminals 31 and 32, and similarly the tab 16' is provided with a pair of terminals 31' and 32', for contacting terminals of a camera socket for applying firing voltage pulses to the array. The circuit board 43 has a "printed circuit" thereon, as shown in FIG. 2, for causing sequential flashing of the lamps by firing voltage pulses applied to the terminals 31, 32, 31' and 32'. The top and bottom halves of the printed circuitry preferably are reverse mirror images of each other. The lead wires (not shown) of the lamps 11 etc., (FIG. 1) may be attached to the circuit board 43 in various ways such as by means of crimped metal eyelets 11a, 11b, etc., placed through openings in the board or, as preferred for low voltage circuits, by solder joints to conductive pads forming part of the circuit pattern.
The circuit located on the upper half of the circuit board of FIG. 2 and activated by the pair of input terminals 31 and 32 includes five lamps 11-15 arranged in parallel across the input terminals and four normally closed (N/C) radiant-energy-activated disconnect switches 71, 72, 73 and 74 each connected in series with a respective one of the lamps 11-14. Each N/C disconnect switch is responsive to the flashing of the lamp with which it is series-connected to form an open circuit. The circuit also includes four normally open (N/O) radiant-energy-activated connect switches 61 62, 63 and 64 for providing sequential flashing of the lamps 11-15 in response to firing pulses successively applied to the input terminals 31 and 32. Each N/O connect switch is responsive to the flashing of an associated lamp to form a closed circuit condition. One terminal (lead-in wire) of each of the lamps 11-15 is connected in common by means of an electrical "ground" circuit run 50 to input terminal 31. The "ground" circuit run 50 includes the terminals 31 and 31' and makes contact with one of the connector junctions for each of the lamps.
As described in the previously referenced U.S. Pat. No. 4,017,728, Audesse et al, each of the N/C disconnect switches 71-74 comprises a length of electrically conductive, heat shrinkable, polymeric material which is attached to the circuit board at both ends, with its midportion spatially suspended over an aperture 30 to avoid contact with the heat absorbing surfaces of the circuit board. This arrangement maximizes the speed with which the shrinking and separation of the midportion of the switch element occurs upon its bein heated by the radiant output of an ignited flashlamp.
The first lamp to be fired, namely, lamp 11, is connected directly across the input terminals 31 and 32 via the N/C disconnect switch 71. The second through fourth N/O connect switches, namely, 62, 63 and 64 are series connected in that order with lamp 15, which is the fifth and last lamp to be fired, across the input terminals 31 and 32. Further, the third lamp to be fired (lamp 13) is series connected with N/O switch 62, and the fourth lamp to be fired (lamp 14) is connected in series with N/O switch 63.
In order to limit the resistance build-up caused by additional series N/O switches, and any possible circuit discontinuity caused by misplacement of the first N/C switch 71, the first N/O switch to be activated (switch 61) is series-connected with the second lamp to be fired (lamp 12) across the input terminals 31 and 32 but parallel-connected with the above-mentioned series combination of N/O switches 62-64 and lamp 15.
Terminal 32 is part of a conductor run 51 that terminates at three different switches, namely, the N/C disconnect switch 71, the N/O connect switch 61, and the N/O connect switch 62. The other side of switch 71 is connected to lamp 11 via circuit run 52 and eyelet (or solder junction) 11a. Circuit run 53 connects switches 61 and 72, and circuit run 54 connects the other side of switch 72 to lamp 12 via eyelet (or solder junction) 12a. A circuit run 55 interconnects switches 62, 73 and 63 while the other side of switch 73 is connected to lamp 13 via circuit run 56, and eyelet (or solder junction) 13b. Switches 63, 74 and 64 are interconnected by a circuit run 58 and eyelet (or solder junction) 14a. Finally, a circuit run 59 connects the other side of switch 64 to lamp 15 via eyelet (or solder junction) 15b.
For high voltage pulse source applications, the aforementioned circuit runs have typically comprised a silk-screened pattern of silver-containing conductive material. The compositions of the N/O connect switch material according to the present invention and copending application Ser. No. 148,358 however, permit use of a circuit board 43 having circuit runs formed of die-stamped aluminum, thereby providing significant cost advantages. For example, U.S. Pat. No. 3,990,142 describes a die-stamped printed circuit board, and copending applications Ser. Nos. 131,614 and 131,711 both filed Mar. 19, 1980 and assigned to the present assignee, describe die-stamped circuit boards for photoflash devices. If operation from a low voltage pulse source is intended, the circuit runs of FIG. 2 are typically formed of copper, either etched or die-stamped.
The radiant-energy-activated N/O connect switches 61-64 are in contact with and bridge across the circuit runs that are connected to them. More specifically, each N/O switch comprises a mass of material interconnected to a pair of spaced apart electrical terminals in the circuits. FIGS. 3 and 4 illustrate this for switch 61. The material for the connect switch is selected to be of the type initially having an open circuit or high resistance, the resistance thereof becoming converted to a lower value when the material receives radiation in the form of heat and/or light from a respective adjacent lamp, upon the lamp being flashed. For this purpose, each of the connect switches is respectively positioned behind and near to an associated flashlamp 11-14. To facilitate radiation transfer from the flashlamp to its corresponding N/O connect switch, each of the reflectors includes a window means, such as an opening 67, in alignment with the respective radiation connect switch. Each of these connect switches has a composition according to the invention, as will be described hereinafter, and upon receiving heat and/or light radiation from the adjacent lamp when it is flashed, converts from an open circuit (high resistance) to a closed circuit (lower resistance) between its switch terminals on the circuit board.
As described in U.S. Pat. No. 4,130,857, Brower, the high resistance material employed in providing the N/O connect switches 61-64 is also disposed on and about each of the ends of the N/O disconnect switches. For example, as illustrated in FIG. 3, the disconnect switch 71 is attached to circuit board 43 so as to extend laterally across aperture 30 with respect to the lamp. Conductive trace 53 extends to provide one electrical terminal for a connect switch 61 while a trace 51 provides the other connect switch terminal. In addition, trace 51 is carried over one end of strip 71, and trace 52 contacts the other end of strip 71. In this instance, patches 78 and 79 of high resistance material cover each end of the conductive strip 71 to shield the circuit run carry-over regions from abrasion during the manufacturing process and further secure the strip to the circuit board. In addition to this mechanical protection, the high resistance patches 78 and 79 provide insulation to prevent shorting or spark-over between the strip ends and the nearby circuit traces 53 and 50 (also see FIG. 2). In this position, the patches 78 and 79 are masked by the reflector during flashing. Although there are other methods of insulating the disconnect switch ends, such as by a coat of insulating resin, use of connect switch paste eliminates a production process by combining the switch-depositing step and the insulating step.
As has been explained, the lower portion of the circuit board contains a substantially reverse mirror image of the same circuitry shown in the upper part of the circuit board, and therefore will not be described in detail. It will be noted that the circuit runs from the plugged in terminals 31 and 32 at the lower part of the circuit board extend upwardly so as to activate the circuitry in the upper half of the circuit board. Similarly when the unit is turned around and tab 16' is plugged into a socket, the circuit board terminals 31' and 32' will be connected to activate the lamps which then will be in the upper half of the circuit board, and hence in the upper half of the flash unit. This accomplishes the desirable characteristic whereby only the group of lamps relatively farthest away from the lens axis will be flashed, thereby reducing the possibility of the phenomenon known as "red-eye".
The circuit on the circuit board 43 functions as follows. Assuming that none of the five lamps in the upper half of the unit have been flashed, upon occurrence of the first firing pulse applied across terminals 31 and 32, this pulse will be directly applied to the lead-in wires of the first connected flashlamp 11, whereupon the lamp 11 flashes and becomes an open circuit between its lead-in wires. Heat and/or light radiation from the flashing first lamp 11 is operative via its respective reflector aperture to activate the N/C disconnect switch 71 and the N/O connect switch 61. As a result, the normally closed disconnect switch 71 is operative in response to the radiation from the lamp to rapidly provide a reliable open circuit to high voltages and thus electrically remove lamp 11 from the circuit, whereby the subsequent lamps 12-15 are unaffected by short circuiting or residual conductivity in lamp 11. The radiation causes the normally open connect switch 61 to become a closed circuit (or a low value of resistance), thereby connecting the circuit board terminal 32 electrically to the second lamp 12 via the normally closed disconnect switch 72. By the time this occurs, the firing pulse should have diminished to a value insufficient to cause the second lamp 12 to flash. Accordingly, to assure reliable operation in this respect, the composition of the normally open connect switch mass is selected to provide a predetermined minimum conversion time, as shall be described hereinafter.
When the next firing pulse occurs, it is applied to the lead-in wires of the second lamp 12 via the now closed connect switch 61 and disconnect switch 72, whereupon the second lamp 12 flashes, thereby causing disconnect switch 72 to rapidly provide an open circuit and causing connect switch 62 to assume a low resistance. Once switch 62 has been activated the resistance of the N/O connect switch 61 is bypassed along with any potential discontinuity caused by the N/C disconnect switch 71. When the next firing pulse occurs, it is applied via now closed connect switch 62 and disconnect switch 73 to the third lamp 13, thereby firing that lamp, whereupon the radiation from lamp 13 activates disconnect switch 73 to rapidly provide an open circuit and causes connect switch 63 to become essentially a closed circuit across its terminals. The next firing pulse applied, via now closed connect switch 63 and disconnect switch 74 to the lead-in wires of the fourth flashlamps 14, thereupon causing the lamp to flash. The radiation from lamp 14 activates the disconnect switch 74 to rapidly provide an open circuit and causes connect switch 64 to become essentially a closed circuit across its terminals. Thus, the next firing pulse will be applied, via now closed connect switch 64 to the lead-in wires of the fifth flashlamp 15, thereupon causing the lamp to flash. Since this lamp is the last lamp in the active circuit, it does not matter whether its lead-in wires are an open or closed circuit after flashing. When the flash unit is turned around and the other connector tab 16' attached to the camera socket, the group 18 of the lamps that then becomes uppermost and farthest away from the lens axis will be in the active circuit and will be flashed in the same manner as has been described. In a low voltage embodiment, the lamps 11, etc., are of the filament type and the firing pulses are provided from a camera-actuated battery supply of a few volts, e.g., 3 to 45 volts having a pulse duration of up to ten milliseconds.
In accordance with the present invention, each of the solid-state radiation connect switches 61-64 is a dried mass of material having a selected composition comprising an admixture of silver-carbonate and/or silver oxide, silver-coated glass beads and a binder, such as polystyrene resin. The coated glass beads can be selected to have a silver content of from about 4% to 12% as a dried weight proportion of the beads. Such glass beads are commercially available, e.g., from Potters Industries Incorporated, Hasbrouck, N.J., in the form of spheres, spheroids, or oblong spheroids having an average diameter of 6-125 microns and preferably 10-50 microns average diameter. The composition may further include fillers and stabilizers. For example, a proportion of barium chromate may be included to enhance environmental stability as described in U.S. Pat. No. 4,087,233. Further, for high voltage circuit applications, the switch composition may include a high proportion of non-conductive inert particulate solids by use of a filler, such as titanium dioxide, as described in copending application Ser. No. 021,398 filed Mar. 19, 1979 and assigned to the present assignee. Other inert fillers that can be used are aluminum oxide, aluminum phosphate, barium sulfate, and silicon dioxide. In accordance with yet another aspect of the invention, the switch composition may further include a selected proportion of silver-coated metal beads. Such metal beads are commercially available, e.g., from Boronite, Bloomfield, N.J.; we prefer substrate metals of copper or nickel coated with about 6% silver and having a bead size of 200 mesh or finer.
As described hereinbefore, the firing pulse duration from a camera-actuated low voltage (e.g., 3 to 45 volts) battery source, according to one application embodiment, varies from 4 to 10 milliseconds. We have found that for reliable operation of a photoflash array from such a low voltage pulse source, the conversion time for the normally open radiation switch should be greater than about 12 milliseconds, and preferably lie in the range from 12 to 19 milliseconds. As previously stated, conversion time may be defined as the elapsed time between the start of a firing pulse, when the switch mass has a sufficiently high electrical resistance to present an open circuit, and the time at which the switch resistance reaches a sufficiently low value to present a closed circuit, e.g, about 0.5 ohms or less in a low voltage operated circuit.
According to the present invention, the desired switch conversion time can be predetermined by appropriate selection of the constituents and proportions of the switch composition.
For example, an increase in the percentage of binder increases the conversion time and increases the final resistance of the switch. Although a range of 12% to 14% binder is optimum, the binder can be varied from 10% to 15%, according to the requirements of timing and resistance of the flash system. A specific example of the aforementioned effects is illustrated in Table 1 below, wherein the binder employed is polystyrene resin.
TABLE I______________________________________ Post Conversion% % Ag-Coated % Binder Timing ResistanceAg.sub.2 CO.sub.3 beads Dry Wgt. msec. Ohm______________________________________50 40 10 9.8 0.0750 35* 15 15.7 0.15______________________________________ *Note that a change in the percentage of silvercoated glass beads did not significantly change the timing characteristics of the switch, in a test designed to check that possibility.
Replacing silver oxide with silver carbonate slows the switch conversion time and increases the switch resistance. A mixture of the two silver compounds results in timing and resistance characteristics somewhere between the two extremes. The change in timing in this instance is believed to result from the silver carbonate having to breakdown into silver oxide and then into metallic silver, rather than breaking down directly into metallic silver as does the silver oxide. The change in resistance results from the higher percentage of metallic silver per given weight of silver oxide, as compared to the percent of metallic silver in silver carbonate. A specific example of the aforementioned effects is illustrated in Table 2 below.
TABLE 2______________________________________ Post Conversion % % Ag-Coated % Timing Resistance% Ag.sub.2 CO.sub.3 Ag.sub.2 O Beads Binder msec. Ohm______________________________________45.0 0.0 40 15.0 16.9 0.6422.5 22.5 40 15.0 16.2 0.530.0 45.0 40 15.0 12.2 0.29______________________________________
The addition of an inert filler slows the switch conversion time and increases switch resistance. Hence, this can be used only where the need for a very low post conversion resistance is not critical. As a specific example, titanium dioxide was used as a filler and the results are illustrated in Table 3 below.
TABLE 3______________________________________ % Post Conversion% Ag-Coated % % Timing ResistanceAg.sub.2 CO.sub.3 Beads TiO.sub.2 Binder msec. Ohm______________________________________50.0 40.0 0.0 10.0 9.8 0.0740.0 40.0 10.0 10.0 10.9 0.1030.0 40.0 20.0 10.0 16.3 0.45______________________________________
Replacing the silver-coated glass beads with silver-coated metal beads was discovered to slow the switch conversion time but to decrease switch resistance. The increase in switch conversion time can be attributed to the heat-sinking effect of the metal beads as compared to the glass beads. The decrease in resistance results from the metal being a conductor, while the glass beads are an insulator without the silver coating. Note that Table 4 below shows a higher percentage of silver-coated metal beads when measured by weight, but the silver-coated metal beads and the silver-coated glass beads are of equal volume. This factor also affects the weight percentage of binder, which is indicated as much lower in the metal bead composition even though approximately equivalent in volume to the binder employed in the glass bead composition (50-40-10). In this particular instance, the silver coated metal beads are 200 mesh or finer copper beads covered with 6% silver (Boronite #53-15).
TABLE 4______________________________________ % Post Ag-Coated % Conversion% Glass % Ag-Coated Bin- Timing ResistanceAg.sub.2 CO.sub.3 Beads Metal Beads der msec. Ohm______________________________________50.0 40.0 0.0 10.0 9.8 0.0734.0 0.0 59.0 6.8 12.2 0.02______________________________________
In each of the above cases, the switch mixture was made into a paste by ball milling in a suitable solvent such as butyl cellosolve acetate. The solids content may be adjusted to suit the method of switch application. For silk screening over circuit boards, we prefer to adjust the solids content to about 74%. This mixture is deposited as a mass of material across respective conductor run terminations, as represented by patches 61-64. For example, FIGS. 3 and 4 illustrate switch 61 wherein such a mixture is deposited as a mass bridging conductor runs 53 and 51. Switches 61-64 having this patch composition consistently provided with desired conversion times and post-conversion resistance values across the respective conductor run terminations.
Although only polystyrene resin was mentioned herinbefore for use as a binder material, other useful binders include cellulose esters, cellulose ethers, polyalkylacrylates, polyalkylemethacrylates, styrene copolymers, vinyl polymers, and polycarbonate.
Accordingly, although the invention has been described with respect to specific embodiments it will be appreciated that modifications and changes may be made by those skilled in the art without departing from the true spirit and scope of the invention. For example, the described radiation switches are not limited to use in a planar photoflash array of the type illustrated but are equally suitable for use in photoflash units having linear arrays of lamps, whether of vertical or horizontal arrangement, powered by a connector having two or more terminals. | A photoflash unit having a plurality of flashlamps mounted on a printed circuit board containing circuitry for sequentially igniting the flashlamps in response to successive firing pulses applied thereto. The circuitry includes a plurality of solid-state switches capable of being activated by radiant energy generated during flashing of lamps located adjacent to respective switches. Initially, each of the switches has a resistance sufficiently high to provide an open circuit to the applied firing pulses, and after being activated by radiation, the switch undergoes chemical conversion to a conductive state over a finite time interval. The switches are prepared from compositions comprising admixtures of silver carbonate and/or silver oxide, silver-coated glass beads and a binder; the admixtures may also include electrically non-conductive particulate solids, such as titanium dioxide, and/or silver-coated metal beads. The constituents and proportions of the switch compositions are selected to provide a predetermined conversion time of twelve milliseconds or greater, thereby permitting reliable functioning with comparatively long duration, low voltage firing pulses. | 7 |
BACKGROUND
This invention pertains to a jet regulator with a jet regulator housing in whose interior a jet regulation device is provided that has passage openings running approximately across the passageway cross section, the openings being offset with respect to one another in the circumferential direction about the jet regulator housing or in the direction of flow of the jet regulator, wherein the jet regulation device has at least one insertable component containing the passage openings.
There is a prior art jet regulator containing at least one metal sieve on the outlet side, wherein a number of perforated plates are installed ahead of this metal sieve solely to reduce the flow (see U.S. Pat. No. 4,119,276). Metal sieves of this type, such as those provided in U.S. Pat. No. 4,119,276 among others, tend to scale up, however.
A prior art jet regulator is known from DE 196 42 055 C2, which is used in the outlet mouthpiece of a sanitary outlet valve to produce a soft bubbling and non-splashing water jet. The prior art jet regulator has a perforated plate that divides the incoming water jet into a number of individual jets which are then recombined into a homogeneous overall jet in a jet regulation device, if necessary after mixing with air.
In this case, the shell-like jet regulator housing of the prior art jet regulator is made up of at least two shell sections designed as peripheral segments. The jet regulating device has pins that run perpendicular to the direction of flow which project on the inside of at least one of the peripheral segments that are manufactured as plastic injection molded parts.
In DE-U-297 18 728 a prior art jet regulator is described as having a jet regulator housing in whose interior a jet regulation device is provided. The jet regulation device has passage openings extending across the cross section of the flow, with the openings being offset with respect to one another in the circumferential direction about the jet regulator housing or in the direction of flow of the jet regulator. Thereby, the jet regulation device of the prior art jet regulator has an insertable component that contains the passage openings, said component consisting of at least two shell parts forming cylinder sectors. These shell parts can be assembled into a cylindrical shell. Pin sections are provided in each of these shell parts that form pairs of impingers that are aligned with one another when the shell parts are assembled.
The design of the prior art insertable component according to DE-U297 18 728, which contains shell parts and forms cylinder sectors, also limits the design possibilities, and thus also the areas of application of the prior art jet regulator, as well as requiring expensive injection-molding tools.
Therefore, the objective arises of creating a jet regulator of the type mentioned above that can be manufactured with little effort using simple common manufacturing techniques, with the jet regulation device thereof not tending to scale up.
The solution to this objective according to the invention with regard to the jet regulator of the type mentioned above is provided in particular in that a number of insertable components are provided that can be inserted one after the other in the direction of flow into the jet regulator housing, that the insertable components have a peripheral external support ring and ribs are connected to it on the inside and extend from one end to the other across the flow cross section, and that the approximately parallel ribs of the insertable components that are separated from one another define unidirectionally oriented passage openings.
The jet regulator according to the invention has a jet regulation device that is made up of essentially a number of insertable components that can be inserted into the jet regulator housing in the direction of flow one after another. Each of these insertable components has a number of unidirectional passage openings that run approximately across the passageway cross section. The passage openings of adjacent insertable components are arranged offset with respect to one another either in a circumferential direction about the jet regulator housing or in the direction of flow of the jet regulator.
If the passage openings are arranged offset with respect to one another in the circumferential direction, the adjacent insertable components form a mesh structure without requiring a conventional metal sieve, which can lead to undesired scaling of the jet regulator. If on the other hand, the passage openings are arranged offset with respect to one another in the direction of flow, the passage openings of the adjacent insertable components, which are oriented approximately in the same direction, form a cascade-like structure. Even though complex meshed or cascade-like structures, which can dramatically slow down the flow velocity and form a soft bubbling water jet, can be created with the help of the insertable components provided according to the invention, each insertable component is in and of itself of a comparatively simple design and can be produced with little effort using simple conventional manufacturing techniques.
In this way, an especially simple and preferred embodiment of the invention provides that the insertable components are located offset with respect to one another rotationally to form a mesh structure.
In order to prevent the ribs that define the passage openings from bending, it is advantageous if the insertable components have at least one support rib that extends perpendicular to the ribs that run approximately parallel, in particular that is diametric, said support rib being preferably connected to the ribs.
In order to be able to position the passage openings of the adjacent insertable components as much perpendicular with respect to one another as possible into a mesh structure, or as unidirectionally as possible into a cascade-like structure, a further development of the invention that should also be protectable provides that positioning projections and recesses are provided on the jet regulator housing on the one hand and on the insertable components on the other hand in order to install the insertable components in the correct positions, and that to this end projections are provided preferably on the exterior of the insertable components and notched insertion guides are provided on the interior of the housing that are open toward the inlet side.
In this way, the correct sequence of the individual insertable components, which can also be designed uniquely, is ensured when the jet regulator according to the invention is assembled, provided that the positioning projections and recesses provided at the jet regulator housing and on the insertable components are designed differently and are fitted to effect the correct positioning of each insertable component accordingly.
So that the individual jets fed to the jet regulation device of the jet regulator according to the invention can be reshaped therein into a homogeneous overall jet, it helps if the width of the ribs of the insertable components is less than their height in the direction of flow. The water jet is well directed and evenly distributed between the ribs, which are higher than they are wide.
The insertable components of the jet regulator according to the invention can be manufactured in an especially simple manner as injection molded parts. So that the overfill that remains in the plane of separation of the injection molding tool does not result in any undesired noise buildup, it is advantageous if the ribs of the insertable components have a section at the inlet side with a larger cross section and an adjacent section at the discharge side with a comparatively smaller cross section. In this way, the plane of separation between the two halves of the mold of the injection molding tool can be located precisely in the plane of separation between the section of the ribs at the inlet side and the section at the discharge side.
The individual jets are divided especially well and noiselessly in the jet regulation device of the jet regulator according to the invention if the inlet section of the ribs at the inlet side of the first insertable component is designed similar to a saddle roof, and if a round section at the discharge side follows this directly via a quick return of the cross section, preferably with an approximately rectangular cross section.
An elevated braking effect can be imposed on the water stream without having to fear an undesired backup if the inlet section of the ribs of an insertable component that is placed after the first insertable component at the inlet side has a rounded side facing the inlet, and if a round section at the discharge side follows this directly, preferably via a quick return of the cross section, preferably with an approximately rectangular cross section.
The ribs of the adjacent insertable components can be held at a minimal distance from one another as necessary without a problem if the height of the support ring of the insertable component oriented in the direction of flow is larger than the height of the ribs and of the support rib, if present, and if the ribs and the support rib are located within the peripheral contour of the support ring.
It is especially advantageous if at least two insertable components are provided one after the other in the direction of flow, preferably directly adjacent to one another.
In order to be able to divide the water stream that flows to the jet regulator according to the invention into individual jets, a preferred embodiment of the invention provides that a jet splitting device is installed before the jet regulation device that has at least one perforated plate that can be latched removably to the jet regulator housing.
The individual components of the jet regulator according to the invention are held securely and fast in their position if the perforated plate pushes against an insertable component at its discharge side and if, to this end, the perforated plate has at its discharge side guide stems that extend preferably up to the first insertable component and push against it.
Good jet formation in the jet regulator according to the invention is facilitated even more if a flow rectifier is installed after the jet regulation device at the discharge side, said rectifier having circular segmented or honeycomb shaped outlet openings whose opening widths are smaller than their height in the direction of flow.
In order to secure the jet regulator according to the invention against willful destruction of the insertable components located in the interior of the jet regulator housing and to be able to simultaneously use the flow rectifier as a vandalism security device, it is advantageous if the flow rectifier is connected in one piece to the jet regulator housing and is located at its discharge end.
The insertable components of the jet regulator according to the invention can be manufactured in a simple manner using simple conventional manufacturing methods. Thus, a further development according to the invention provides that the insertable components are manufactured with a support ring, ribs and if necessary support rib and projections as a one-piece metal part via forging or cold forming. Such insertable components designed as metal parts exhibit excellent mechanical stability and temperature resistance in comparison to plastic parts. Moreover, insertable components made of stainless steel, for example, can be recommended for areas of used where high hygienic requirements exist.
Metallic insertable parts can also be manufactured in small numbers especially economically if the insertable components are manufactured from a metal sheet using a stamping and/or shaping process. Insertable components that are manufactured from a metal sheet via a stamping and/or shaping process and therefore allow a high profitability.
In order to be able to slow down effectively the individual jets issuing from a perforated plate or similar jet splitting device it can be helpful if at least one of the insertable components that is designed as a stamped and/or shaped part has ribs that have an external contour that widens in the flow direction. The ribs can have a curved or roof-shaped external contour. Curved ribs can be designed for example circular arc shaped or elliptical.
In order to be able to successively slow down the speed of the individual jets from insertable component to insertable component, it can be helpful if the tilt angle of the rib profile of the curved or roof-shaped ribs provided on the insertable components in the direction of flow successively decreases. This allows the ribs provided on the upper insertable component or the upper insertable components to have a steeper angle in the tilt of their rib profile in comparison to the ribs on the subsequent insertable components.
It is advantageous if the metal sheet is made of brass or preferably stainless steel. Thereby, the projections on the support ring of the insertable components provided to position the insertable components can be formed out of an un-deformed section of the metal sheet.
According to another aspect of the invention, the insertable components are designed with a support ring, ribs and if necessary a support rib and projections in one piece as an injection molded part, in particular as a plastic injection molded part.
BRIEF DESCRIPTION OF THE DRAWINGS
Other features of the invention can be found in the following description of an exemplary embodiment of the invention in connection with the claims as well as the drawing. The individual features can be implemented in and of themselves or together to form an embodiment according to the invention.
Shown are:
FIG. 1 is a longitudinal view of a jet regulator having a jet regulation device made of a number of insertable components that can be inserted into the jet regulator housing,
FIG. 2 is a plan view of the jet regulator from FIG. 1 showing the discharge side,
FIGS. 3 a - 3 c are views of the jet regulation device designed as a perforated plate, wherein this perforated plate is shown in plan views from the discharge side and from the inlet side ( FIGS. 3 a and 3 c ) and in a longitudinal section ( FIG. 3 b ),
FIGS. 4 a and 4 b are views of the insertable component of the jet regulation device of the jet regulator from FIGS. 1 and 2 after the perforated plate, wherein this insertable component is shown in a longitudinal section ( FIG. 4 a ) and in a plan view ( FIG. 4 b ),
FIGS. 5 a and 5 b are views of the next insertable component of the jet regulator of FIGS. 1 and 2 , also shown in a longitudinal section ( FIG. 5 a ) and in a plan view ( FIG. 5 b ),
FIGS. 6 a - 6 e are views of an insertable component manufactured from a metal sheet via a stamping and shaping process in a plan view of the inlet end ( FIG. 6 a ) as well as in a longitudinal section ( FIG. 6 b ) and a cross section ( FIG. 6 c ), wherein an enlarged detail view of the inlet end and the cross section is shown in FIGS. 6 d and 6 e , respectively,
FIG. 7 is a partial view of a metallic insertable component in the area of a rib that is bent into a roof shape, and
FIG. 8 is a partial view of a metallic insertable component in the area of a rib that is bent into a circular arc shape.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIG. 1 , a jet regulator is shown that can be used to produce a homogeneous soft bubbling and non-splashing water jet to the outlet mouthpiece of a sanitary outlet valve, which is not shown here further.
The jet regulator 1 has a shell-like jet regulator housing 2 in whose interior a jet regulation device is provided in the form of a perforated plate 3 perforated in the direction of flow Pf 1 , followed by a jet regulation device 4 and at the discharge side a flow rectifier 5 . In order to keep dirt particles out of the interior of the housing of the jet regulator 1 and in order to be able to ensure its free flowing operation, an intake filter 6 is placed upstream of the jet regulator 1 in the flow direction.
The perforated plate 3 , the plane of which is oriented perpendicular to the direction of flow Pf 1 , has a number of flow-through holes 7 separated from one another, each of which has at the inlet side a conical round inlet opening 8 (see FIGS. 3 b , 3 c ).
The fluid stream that flows into the jet regulator 1 is divided into a number of individual jets in the jet splitting device, which is designed as a perforated plate 3 . These individual jets are then formed into a homogeneous and soft bubbling overall jet in the jet regulation device 4 that follows.
The jet regulation device 4 has in addition to this two insertable components 9 , 10 directly adjacent to one another, each of which has unidirectional passage openings 11 that extend across the cross section of the passageway. The passage openings 11 of the two adjacent insertable components 9 , 10 are offset with respect to one another in the direction of flow Pf 1 , thus forming a cascade-like structure.
It would also be possible to arrange the insertable components 9 , 10 offset with respect to one another in the circumferential direction such that instead a mesh structure results. In this way, the passage openings 11 of each insertable component 9 , 10 are unidirectional, i.e. they run parallel to one another,—but taken together the two insertable components 9 , 10 form a sieve or grating structure. By means of this sieve or grating or—as in this case—cascade-like structure, the water jet is slowed down to be able to exit as a soft bubbling overall jet.
The insertable components 9 , 10 each have an external support ring 12 and ribs 13 that are connected to its interior, running approximately parallel and at a distance from one another, between which slotted passage openings 11 are formed. As can be seen in a comparison of FIGS. 1 , 4 a and 5 a , the section 14 of the ribs 13 at the inlet side has a larger cross section and section 15 at the discharge side after it has a smaller cross section in comparison. Thereby, the plane that separates the inlet side and the outlet side of the ribs 13 of the insertable components 9 , 10 , which are designed as plastic injection molded parts, at the same time constitutes the plane of separation of the injection molding tool used. This eliminates excess injection molding flashing from occurring at the inlet side injection mold that could otherwise result in undesired, noise-generating turbulence.
The section 14 of the ribs at the inlet side of the first insertable component 9 shown in FIG. 4 in more detail is designed similar to a gable roof. Section 15 at the discharge side follows this directly via a quick return of the cross section, and has an approximately rectangular cross section and is rounded at the discharge side. As shown in FIG. 4 b . a support rib 25 can be provided that is diametric and extends perpendicular to the ribs 13 . As can be seen in FIG. 1 , the flow-through holes 7 are placed in the perforated plate 3 so that their centerlines are approximately axially aligned with the centerline of a rib 13 located after it at the discharge side.
In FIG. 5 , the insertable component 10 that is placed after the first insertable component 9 inserted from the inlet side is shown in more detail. The ribs 13 of this insertable component 10 have a section 14 at the inlet side that has a rounded inlet side. Section 15 at the discharge side follows this directly via a quick return of the cross section, and has an approximately rectangular cross section and is also rounded at the discharge side. The position of this next set of ribs increases the resistance to the flow of water without resulting in an undesired backup.
As can be seen in FIG. 1 , the insertable components can be inserted removably into the jet regulator housing 2 at the inlet side of the housing together as far as an insertion backstop 16 . To this end, the external perimeter of the support ring 12 of the insertable components 9 , 10 is made to fit the unobstructed inner diameter of the jet regulator housing 2 . After inserting the insertable components 9 , 10 into the jet regulator housing 2 , the perforated plate 3 is then inserted into the jet regulator housing 2 and removably attached there.
In order to secure the correct positional arrangement of the insertable components 9 , 10 with respect to one another and the perforated plate 3 , positioning projections and recesses are provided on the jet regulator housing 2 on the one hand and on the insertable components 9 , 10 or perforated plate 3 on the other hand. To this end, the insertable components 9 , 10 and the perforated plate 3 have guide projections 17 and 18 that fit notched insertion guides 19 in the inner diameter of the housing that are open in the direction of the inlet.
Whereas the guide projections 17 on the insertable components 9 , 10 project radially outward and are located on opposite sides, the guide projections 18 provided on the perforated plate 3 project in the direction of flow Pf 1 . The guide projections 18 provided at the perforated plate 3 can if necessary be dimensioned long enough that the perforated plate 3 pushes against the insertable component 9 that follows it by means of these guide projections 18 and additionally secures it in place.
It can also be seen from FIGS. 1 , 4 , and 5 , that the height of the support ring 12 of the insertable components 9 , 10 oriented in the direction of flow Pf 1 is larger than the height of the ribs 11 and that the ribs 11 remain within the peripheral contour of the support ring 12 so that the flow envelops the ribs 11 from all sides.
In order to evenly distribute the individual jets that are again divided into a soft bubbling overall jet in the jet regulation device 4 , a flow rectifier 5 is installed after the jet regulation device 4 at the discharge side, with the rectifier having honeycomb-shaped or—as here—circularly segmented outlet openings 21 .
The width of these outlet openings 21 is smaller than their height measured in the direction of flow Pf 1 . Since the flow rectifierer 5 is connected in one piece to the jet regulator housing 2 and is located at its discharge end, this flow rectifier 5 also serves simultaneously as a safety against vandalism.
The jet regulator 1 can be designed as a ventilated or unventilated jet regulator. The sanitary component, which in this case is designed as a ventilated jet regulator, has ventilation openings 20 at the peripheral cover of its jet regulator housing, with the openings feeding into the area between the perforated plate 3 and the jet regulation device 4 .
It can be seen from FIG. 1 that the through holes 21 of the flow rectifier 5 are separated by guide walls 22 that extend approximately in the direction of flow Pf 1 . These guide walls 22 have a wall thickness that is a fraction of the unobstructed hole diameter of a through hole 21 that is surrounded by the guide walls 22 . In order to facilitate the good functioning of the flow rectifier 5 , it has been shown to be advantageous if the ratio h:D between the height h of the guide walls 22 and the overall diameter D of the flow straightener 5 is less than 1 and in particular less than 1:2.
In FIG. 6 , an insertable component 23 is shown in various views and corresponds in its functioning to insertable components 9 , 10 in FIGS. 4 and 5 . However, whereas the insertable components 9 , 10 shown in FIGS. 4 and 5 are designed as plastic injection molded parts, the insertable component 23 according to FIG. 6 is manufactured in one piece from a metal sheet in a stamping and shaping process. Insertable component 23 according to FIG. 6 also has ribs 13 that lie alongside the passage openings 11 running approximately across the passageway cross section and oriented unidirectionally. The ribs 13 are held in an external support ring 12 and can be inserted with it into a jet regulator housing. Located at the support ring 12 are guide projections 17 that are formed from an undeformed section of the metal sheet and that serve as positioning projections.
As can be seen from FIG. 6 c and the detail representation in FIG. 6 e , the profile of the unidirectional ribs 13 is roof-shaped.
The sheet thickness of the metal sheet used to manufacture the insertable component 23 is in accordance with the requirements of strength and formability of the material. Suitable materials include brass or preferably stainless steel. A brass sheet can subsequently be surface treated in order to ensure an improved corrosion protection.
The height of ribs 13 depends for one thing on the intervening material that is left over between the adjacent ribs 13 in the un-deformed condition of the flat metal sheet as maximum rib height, but can also be reduced if strips of material are stamped out of the flat metal sheet before the shaping process is performed to create the rib profile.
The insertable component 23 manufactured from a metal sheet exhibits relatively low manufacturing costs and higher mechanical stability and temperature resistance. Moreover, the use of an insertable component 23 made of a stainless steel can be recommenced for those areas of application where especially high hygienic requirements exist.
The height of the peripheral support ring 12 , which is likewise manufactured by shaping from the flat metal sheet, is larger or the same as the rib height. The height of the support ring 12 determines the axial separation between two adjacent insertable components 23 , wherein it can prove to be advantageous to configure the axial separations according to the side angle of the rib profile.
The number of unidirectional ribs 13 is dependent on the requirements of water jet braking and can be varied. A positioning of the insertion point of the metallic insertable component 23 required is accomplished by means of the projection 17 that is produced by not forming the flat metal sheet in this area into a peripheral circular arc.
Comparing FIGS. 7 and 8 makes it clear that the profiling of the unidirectional ribs 13 can be selected both roof-shaped as well as curved. In this way, the angle of the rib profile can be designed differently, depending on how dramatically the water jet that arrives from above is to be slowed down. If the velocity of the individual jets coming from the jet splitting device is to be slowed down successively from insertable component to insertable component, it is also possible to provide the rib profile of the ribs 13 provided at an upper insertable component 23 with a steeper angle in comparison with the ribs 13 of an insertable component 23 placed after it at the discharge side.
As the examples in FIGS. 4 through 8 show, the jet regulator 1 shown here can also be manufactured with little effort using simple, conventional manufacturing techniques, wherein its jet regulation device 4 and its flow rectifier 5 do not tend to scale up. | The invention relates to a jet regulator ( 1 ), comprising a jet regulator housing ( 2 ), within the interior of which a jet regulation device ( 4 ) is provided. According to the invention, such a jet regulator ( 1 ) can be produced at low cost, by means of simple conventional production techniques with simultaneous anti-scaling effect on the jet regulation device ( 4 ), whereby the jet regulation device ( 4 ) comprises several insertable components ( 9, 10 ), which may be inserted in series in the jet regulator housing ( 2 ) in the direction of flow (Pf 1 ). The insertable components ( 9, 10 ) comprise passage openings ( 11 ), which are unidirectionally defined and extend across the cross-section of the passage, and the passage openings ( 11 ) of adjacent insertable components ( 9, 10 ) are arranged offset to each other in the circumferential direction of the jet regulator housing ( 2 ), or in the direction of flow (Pf 1 ) of the jet regulator ( 1 ). | 4 |
This application is a continuation of application PCT/EP00/02278, filed Mar. 15, 2000, now abandoned. The invention relates to a safety device having at least one back seat airbag for a motor vehicle.
BACKGROUND OF THE INVENTION
Safety devices for a motor vehicle, having airbag apparatus, are generally known in various embodiments. In particular, airbag apparatus with one or more airbags in the front, side and bead impact areas of front occupants and rear occupants are known. These airbags, in the event of a vehicle impact, are inflatable as a function of impact delay and impact direction, by means of an individually associated, activable gas generator, to cushion and attenuate an impact on an occupant.
U.S. Pat. No. 5,738,368 discloses a safety device having a back seat airbag for a motor vehicle, comprising at least one back seat for a rear occupant and a front seat assembly arranged in front of the back seat and consisting of a seat part and a backrest. The at least one back seat airbag is inflatable by means of at least one gas generator activable in event of a sensed vehicle impact. The at least one back seat airbag collapsed in neutral position and the at least one gas generator are arranged and fixed in the rear of a front seat backseat and adjustable together with the latter. The back seat airbag is so fashioned, and an airbag exit opening is so directed upon the back seat occupant that the fired back seat airbag is expandable towards the chest and head of the back seat occupant.
Concretely for this purpose, in a rearward region of the front seat backrest, an opening is provided into which a supporting plate is fitted, firmly connected to lateral backrest frame parts by way of a lateral attachment flange. On this supporting plate, the gas generator is arranged and held together with the airbag. The backrest frame parts are swingably articulated to the seat structure to make possible an adjustment of the inclination of the backrest. The swing articulations are designed and dimensioned so strong that forces can be absorbed and transmitted by them. In addition, a swinging flap is provided, swingably articulated to the supporting plate and, in neutral position with safety device not activated, closing the openings in the front seat backrest and accordingly covering the supporting plate, including gas generator and airbag. In event of activation of the safety device, the swinging flap is swung by the inflating airbag into an open position, so that the airbag can unfold towards the head and chest in front of the back seat occupant. The swinging flap is at the same time held in a certain swing position by retaining bands. A disadvantage of this construction is that seat comfort is considerably reduced by the arrangement of numerous hard parts in the backrest, because under load they will press through the backrest of the front seat. Besides, such a construction is evidently elaborate and hence expensive, so that in practical use, such a device is less adapted to the purpose upon the whole.
U.S. Pat. No. 5,324,071 discloses a safety device for a motor vehicle in which an airbag module comprising a gas generator is fixed, not to the vehicle seat but, independently of the vehicle seat, to a framework fixed to the floor. This framework is fixed to the floor by way of a slide rail stationary relative to the floor, the seat being adjustable relative to the framework and hence relative to the airbag module fixed to the framework. The airbag module is here configured as a bead-supporting airbag module, and can be accommodated in a receptacle at the back of the headrest in certain adjusted positions of the vehicle seat only. What this is supposed to accomplish is that the distance of the headrest airbag from the back seat occupant region behind it is always the same.
U.S. Pat. No. 5,782,529 discloses a safety device on a vehicle seat in which an inflatable airbag is integrated into the backrest, and upon activation of the safety device, it inflates inside the backrest and therefore can furnish an impact protection for the user of the seat in question. Part of this airbag may also be so constructed inside the backrest that it provides protection for the knee region of a rear occupant seated behind. A gas generator is here merely represented schematically in the seat portion. No inflatable back seat airbag inflatable towards the head and chest of a rear occupant sitting behind the front seat is provided.
French Patent 2,131,475 A discloses a vehicle seat around which a supporting framework is arranged for attachment of parts such as for example safety devices. Such a construction, especially in crash situations, constitutes a considerable potential hazard to the vehicle occupants, in particular those seated behind the vehicle seat in question, and is therefore impracticable. Besides, such a framework is unattractive.
Japanese Patent Publication 04 166,455 discloses a construction of a safety device for a motor vehicle, in which an airbag module is arranged in an upper rear portion of a front seat backrest. By way of a control means, the inclination of the front seat backrest can be adjusted relative to the back seat occupant seated on the corresponding back seat.
Thus a problem underlying all of these arrangements consists in mounting the airbags, and particularly the gas generators, at locations in the vehicle where the requisite space is available, without poor appearance, and providing a favorable position of an airbag deployment opening from the point of safety engineering, together with a practicable airbag framework.
The object of the invention is to propose a suitable installation for a rear seat airbag device this is simple and inexpensive to produce.
SUMMARY OF THE INVENTION
In accordance with the invention, a rear seat airbag device includes an airbag arranged in an airbag housing which is mounted to the rear portion of a front seat. The housing has an airbag deployment opening directed to deploy the airbag toward the head and chest of a rear seat occupant.
Advantageously, the gas generator of the airbag apparatus may be connected to the seat underframe in an especially stable manner, without need to provide costly measures for this purpose. This means that the seat underframe may thus be employed in an advantageous twofold function for stable attachment of the at least one gas generator and at the same time of an airbag housing module as a whole. This contributes considerably to the functional dependability of the safety device over all. A rigid fixation by way of a carrier, or a direct fixation of the gas generator to the seat underframe in the rear area of the front seat part is further favorable in that the structural space there available is otherwise unused. In addition, seat comfort is not impaired by such an arrangement, since the rear area of the front seat regularly lies beneath the under side of the backrest and therefore is in any event not loaded by a front seat occupant.
With the back seat airbag arrangement in the rear area of the front seat, directly in front of a back seat occupant, a rapid and direct deployment of the back seat airbag in a region of potential impact on a back seat occupant can be achieved.
In one embodiment, the airbag module consists of a back seat airbag and the at least one gas generator is arranged in the rear area of the front seat, preferably in or on the underframe, and integrated with an airbag deployment opening directed obliquely to the rear and upward. The back seat airbag may include a flat and narrow lower portion that deploys in a first stage along the front seat backrest upward without colliding with the feet or knees of a back seat occupant. Then in a second phase, a voluminous upper portion of the back seat airbag unfolds in front of the back seat occupant in the chest and head direction. Thus, the filled back seat airbag has a flat and narrow configuration in the lower region and a voluminous configuration in the upper region. Such an embodiment, with good protective function, may be economically installed. The airbag deployment opening may alternatively be formed in the case of a crash only, in that the expanding airbag rips along a seam of a cover closing the airbag deployment opening and integrated in the front seat part, thus clearing the airbag deployment opening.
In another embodiment, a gas generator is integrated in the rear area of the front seat part, preferably in the seat underframe. The housing includes a cover behind the front seat backrest and resting in contact therewith, wherein the cover is capable of being forced away from the rear surface of the front seat backrest to form a passage. Between the rear surface of the front seat backrest and the cover is located a back seat airbag area in the uninflated condition, connected to the gas generator and partly unfolded. In the case of an activation of the back seat airbag due to a crash, the airbag forces the covering by pressure build-up in a first phase to form a cushion which also acts as passage. Through this passage, the upper portion of the back seat airbag is then deployed out in front of the back seat occupant in chest and head direction.
Preferably, the cover extends as a plate-like part from the front seat underframe upward about to a middle portion of the front seat backrest. Thus the cover in combination with the airbag part filled in the passage may advantageously configure a knee cushion as knee airbag for the remaining protective function of the back seat airbag.
In a preferred embodiment, the cover is swingably articulated to the front seat underframe and spring-loaded towards the rear surface of the front seat backrest. By such a swingable and spring-loaded arrangement, the cover advantageously moves in contact with the front seat backrest at its various adjustments of inclination. An accompanying motion of the cover is possible with a swingable mounting of the cover even if the cover is connected to the front seat backrest. Such a connection may for example be made by at least one tear strip, as a weak point intended to fail upon elevation of pressure in the back seat airbag to form the passage, in which case the cover is held by catch strips at a predetermined distance from the front seat backrest. Alternatively, the cover may be articulated to the front seat backrest only.
In another alternative embodiment, a stirrup is arranged behind the front seat backrest as carrier for the back seat airbag and the gas generator. The stirrup is of inverted U-shaped configuration, with the ends of the side legs of the stirrup being connected to the front seat underframe and/or to a seat rail. The cross-bar of the stirrup thus lies behind the front seat backrest surface, and higher than the front seat part. In the cross-bar of the stirrup, the back seat airbag is accommodated in its uninflated position. The airbag deployment opening is preferably arranged directed obliquely upward and rearward, so that upon activation of the back seat airbag due to a crash, it will be fillable in front of the back seat occupant to be protected in chest and head direction. The gas generator may be arranged in the cross-bar or in the seat underframe, in which case it will be connected to the airbag sack by way of a gas line.
In a preferred modification of this embodiment, the cross-bar of the stirrup is padded at least in the areas facing the knees of a back seat occupant, thus having the function of a knee cushion.
In this embodiment also, the stirrup may be swingably articulated to the front seat underframe, possibly with spring prestress, so that the stirrup will be carried along in various settings of the front seat backrest. Possibly also, the stirrup may be fixedly connected to the seat frame or the seat rails, and the backrest be adjusted within a limited region in front of the stirrup. This has the advantage that the stirrup will additionally reinforce the front seat, for example in a rear-end collision.
The function of the proposed airbag apparatus may be impaired if the front seat backrest is swung very far back in inclination, for example into a reclining position. To prevent such an impairment, it is proposed further that while the vehicle is being operated, an adjustment of the inclination of the front seat backrest be permitted only within a fixed comfort range, without extreme displacements to the rear. A swing of the front seat backrest into a reclining position may be released only when the vehicle is stationary. When starting a vehicle, with a front passenger seat backrest swung into reclining position, an acoustic or visual warning may be given, or the front seat backrest may be automatically erected from the reclining position by means of a mechanical drive. The swing of the front seat backrest may also be limited only in the event that there is an occupant sitting in the back seat. The back seat airbag may likewise, be arranged to deploy only if the corresponding rear seat is occupied.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a schematic representation of a first embodiment of an airbag device for a motor vehicle, in which an airbag module is arranged in a rear area of a front seat.
FIG. 2 shows a schematic representation of a second embodiment of an airbag device for a motor vehicle, having a back seat airbag capable of being unfolded by way of a passage.
FIG. 3 shows a schematic representation of a third embodiment of an airbag device for a motor vehicle, having a stirrup as carrier for the back seat airbag and the gas generator.
DESCRIPTION OF THE INVENTION
FIG. 1 shows a rear seat airbag device 9 mounted on front seat assembly 1 . Front seat assembly 1 , shown in a normal sitting position in FIG. 1, comprises a front seat part 2 having a swingable front seat backrest 3 with headrest 4 . The front seat assembly 1 is arranged in front of a back seat for back seat occupants.
In the rear area of the front seat part 2 , outside of the sitting area of the front seat occupant, an airbag module 5 is integrated in the seat underframe. The airbag module 5 comprises a back seat airbag 6 in collapsed deflated condition and an associated gas generator 7 . An airbag deployment opening 8 is directed obliquely rearward and upward.
As shown dotted in FIG. 1, the back seat airbag 6 is so constructed that in the event of a crash, in a first phase, a lower portion 30 will unfold in an area behind and along the front seat backrest 3 upward. In a second phase, an upper portion 31 will deploy in chest and head direction in front of the back seat occupant. The back seat airbag 6 in filled condition is thus flat and narrow in the lower region 30 and voluminous in the upper region 31 .
FIG. 2 schematically shows a second embodiment of a rear seat airbag device 10 for a motor vehicle, on a front seat assembly 11 . In this airbag device 10 , a gas generator 12 is integrated in the rear area of a front seat 13 in the seat underframe 37 , which is shown in the partially cut-away view.
Behind a backrest 14 of the front seat assembly 11 , a cover 15 is arranged, extending upward as a plate-like part of the front seat underframe, as far as the middle of the front seat backrest height. The cover 15 is swingably articulated to the front seat underframe, and in the deflated position indicated by solid lines in FIG. 2, the cover 15 follows the contour of the rear surface 16 of the front seat backrest.
Between the rear surface 16 of the front seat backrest and the cover 15 , in the uninflated condition, indicated by solid lines in FIG. 2, lies a partly deployed portion 17 of a back seat airbag 18 connected to the gas generator 12 .
Upon activation of the back seat airbag 18 due to a crash, in a first phase it controllably pushes the cover 15 rearward to a deployed position 15 a , forming a passage and a flat knee cushion as knee airbag 32 , as indicated by dotted lines in the representation of FIG. 2 . In a second phase, the upper portion 33 of back seat airbag 18 unfolds in chest and head direction in front of a back seat occupant, as likewise indicated by dotted lines in FIG. 2 .
FIG. 3 schematically shows a third embodiment of a rear seat airbag device 19 . In the case of this airbag device 19 , behind a backrest 20 of a front seat assembly 21 , a stirrup 22 is mounted as carrier for a back seat airbag 23 and a gas generator 24 connected to the back seat airbag 23 .
The stirrup 22 is of inverted U-shaped configuration, and connected by the ends of the lateral legs 25 , 26 of the stirrup to a front seat underframe. The stirrup 22 is swingably or fixedly articulated to the front seat underframe.
The stirrup 22 further comprises a stirrup cross-bar 27 extending more or less at the middle height of the front seat backrest 20 in the area of its rear surface 28 .
As may be seen further in the schematic representation of FIG. 3, the cross-bar 27 of the stirrup is finished to function as a knee cushion with a pad 29 facing the knees of a back seat occupant. The stirrup 22 and the cross-bar 27 are so arranged as to form an airbag deployment opening 30 directed obliquely upward and rearward.
Upon activation of the back seat airbag 23 due to a crash, it is unfolded in chest and head direction in front of a back seat occupant, as indicated by dotted lines 34 in the representation of FIG. 3 .
To prevent the functioning of the safety devices 9 , 10 and 19 represented in FIGS. 1 to 3 from being impaired by a front seat backrest 3 , 14 and 20 in a reclined position, visual or acoustic warnings may be provided. Alternatively, inclination adjustment of the front seat backrest 3 , 14 , 20 may be limited to a fixed comfort range only when the vehicle is in operation or when the rear seat is unoccupied. Full reclining maybe permitted only when the vehicle is not being operated or when the rear seat is vacant.
While there have been described what are believed to be the preferred embodiments of the invention, those skilled in the art will recognize that other and further changes can be made thereto without departing from the spirit of the invention, and it is intended to claim all such changes and modifications as fall within the true scope of the invention. | A rear seat airbag device is arranged with an airbag housing mounted to a rear portion of a front seat of a vehicle. The housing has an airbag deployment opening which deploys the airbag upwardly and toward the head and chest portion of a rear seat occupant. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a divisional of application Ser. No. 14/102,624, filed Dec. 11, 2013, currently pending;
Which was a divisional of application Ser. No. 13/757,361, filed Feb. 1, 2013, now U.S. Pat. No. 8,635,504, issued Jan. 21, 2014;
Which was a divisional of application Ser. No. 13/468,173, filed May 10, 2012, now U.S. Pat. No. 8,392,773, issued Mar. 5, 2013;
Which was a divisional of application Ser. No. 12/966,136, filed Dec. 13, 2010, now U.S. Pat. No. 8,230,280, issued Jul. 24, 2012;
Which was a divisional of application Ser. No. 12/782,129, filed May 18, 2010, now U.S. Pat. No. 7,873,889, issued Jan. 18, 2011;
Which was a divisional of application Ser. No. 12/351,510, filed Jan. 9, 2009 now U.S. Pat. No. 7,747,918, issued Jun. 29, 2010;
which is a divisional of application Ser. No. 11/857,688, filed Sep. 19, 2007, now U.S. Pat. No. 7,493,535, issued Feb. 17, 2009;
which is a divisional of application Ser. No. 11/015,816, filed Dec. 17, 2004, now U.S. Pat. No. 7,284,170, issued Oct. 16, 2007;
which claims priority from Provisional Application No. 60/534,298, filed Jan. 5, 2004.
This application is related to U.S. patent application Ser. No. 10/983,256, filed Nov. 4, 2004, now U.S. Pat. No. 7,284,170, issued Oct. 16, 2007, which is incorporated herein by reference.
BACKGROUND
Field
This disclosure relates in general to circuit designs, and in particular to an improvement in the design of IEEE 1149.1 Tap interfaces of ICs and core circuits for improved communication of test, debug, emulation, programming, and general purpose I/O operations.
Today's ICs may contain many embedded 1149.1 Tap architectures (Tap domains). Some of these TAP domains are associated with intellectual property (IP) core circuits within the IC, and serve as access interfaces to test, debug, emulation, and programming circuitry within the IP cores. Other TAP domains may exist in the IC which are not associated with cores but rather to circuitry in the IC external of the cores. Further, the IC itself will typically contain a TAP domain dedicated for operating the boundary scan register associated with the input and output terminals of the ICs, according to IEEE std 1149.1.
FIG. 1 illustrates a simple example of an IEEE 1149.1 Tap domain 102 . The Tap domain includes a Tap controller 104 , an instruction register (IR) 106 , at least two data registers (DR) 108 , and multiplexer circuitry 110 . The Tap domain interface consists of a TDI input, a TCK input, a TMS input, a TRST input, and a TDO output. In response to TCK and TMS control inputs to Tap controller 104 , the Tap controller outputs control to capture data into and shift data through either the IR 106 from TDI to TDO or a selected DR 108 from TDI to TDO. The data shifted into IR 106 is updated and output on bus 114 to other circuits, and the data shifted into a DR 108 is updated and output on bus 112 to other circuits. DR 108 may also capture data from other circuits on bus 112 and IR 106 may capture data from other circuits on bus 114 . In response to a TRST input to the Tap controller 104 , the TAP controller, IR and DR are reset to known states. The structure and operation of IEEE 1149.1 Tap domain architectures like that of FIG. 1 are well known.
FIG. 2 illustrates the state diagram of the Tap controller 104 . All IEEE 1149.1 standard Tap controllers operate according to this state diagram. State transitions occur in response to TMS input and are clocked by the TCK input. The IEEE 1149.1 Tap state diagram is well known.
FIG. 3 illustrates an example system where a number of Tap domain 102 interfaces of ICs 306 - 312 or embedded cores 306 - 312 within ICs are connected together serially, via their TDI and TDO terminals, to form a scan path 302 from TDI 304 to TDO 306 . Each Tap domain 102 of the ICs/cores 306 - 312 are also commonly connected to TCK 314 , TMS 316 , and TRST 318 inputs. The scan path's TDI 304 , TDO 306 , TCK 314 , TMS 316 , and TRST 318 signals are coupled to a controller, which can serve as a test, debug, emulation, in-system-programming, and/or other application controller. While only four Tap domains 102 of ICs/cores 306 - 312 are shown, any number of IC/core Tap domains may exist in scan path 302 , as indicated by dotted line 322 . The scan path 302 arrangement of IC/core Tap domains is well known in the industry.
As seen in FIG. 3 , if data is to be input to Tap domain 102 of IC/core 312 from controller 320 it must serially pass through all leading Tap domains of ICs/cores 306 - 310 . Further, if data is to be output from Tap domain 102 IC/core 306 to controller 320 it must pass through all trailing Tap domains of ICs/cores 308 - 312 . Thus a data input and output latency exists between Tap domains of ICs/cores in scan path 302 and controller 320 . As will be seen later, the present disclosure provides a way to eliminate this data input and output latency by making use of the direct TMS 316 and/or TCK 314 connections between the Tap Domains of ICs/cores 306 - 312 and controller 320 . Having a direct connection for data input and output between the controller 320 and the Tap domains 102 , via the TMS and/or TCK connections, provides improved data communication throughput during test, debug, emulation, in-circuit-programming, and/or other type of operations. Further, using the direct TCK and/or TMS connections for data input and output between controller 320 and Tap domains 102 only involves the controller and the targeted Tap domain. Non-targeted Tap domains are not aware of or affected by the direct TMS and/or TCK communication.
SUMMARY
The present disclosure provides a method and apparatus of communicating data between; (1) an IC in a scan path and a controller of the scan path using the standard direct TMS and/or TCK connections that exists between the IC and controller, (2) a first IC of a scan path and a second IC of the scan path using the direct TMS and/or TCK connections between the ICs, (3) a first core circuit of a scan path in an IC and second core circuit of the scan path of the IC using the direct TMS and/or TCK connections between the cores. The TMS and/or TCK data I/O communication occurs while the Tap controller of the Tap domains of the IC/core are in a non-active state. Thus the TMS and/or TCK I/O communication does not disturb or modify the state of Tap domains of the IC/core in a scan path. The TMS and/or TCK I/O communication is achieved by adding circuitry to the IC/core and coupling the circuitry to the TMS and/or TCK terminals of the IC's/core's Tap domain. When enabled by control output from the IC's/core's Tap domain, the added circuitry becomes operable to input data from the Tap domain's TMS and/or TCK terminal or output data onto the Tap domain's TMS and/or TCK terminal. Conventional controllers 320 coupled to the TMS and TCK signals are improved, according to the present disclosure, such that they can input data from a Tap domain's TMS and/or TCK terminal and output data to a Tap domain's TMS and/or TCK terminal.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a conventional IEEE 1149.1 Tap domain architecture.
FIG. 2 illustrates the state diagram of a conventional IEEE 1149.1 Tap controller.
FIG. 3 illustrates a conventional arrangement of ICs or cores within ICs with their Tap domains connected in a scan path and the scan path coupled to a controller.
FIG. 4 illustrates the scan path and controller arrangement of FIG. 3 adapted for TMS I/O communication according to the present disclosure.
FIG. 5 illustrates TMS I/O communication circuitry coupled to a Tap domain according to the present disclosure.
FIG. 6 illustrates the TMS I/O Circuit of FIG. 5 according to the present disclosure.
FIG. 7 illustrates circuitry and timing for receiving Manchester encoded TMS input data according to the present disclosure.
FIG. 8A illustrates a Manchester decoder state machine for receiving encoded TMS data according to the present disclosure.
FIG. 8B illustrates a state diagram of the operation of the Manchester decoder state machine of FIG. 8A .
FIG. 9 illustrates circuitry and timing for transmitting Manchester encoded TMS output data according to the present disclosure.
FIG. 10A illustrates a Manchester encoder state machine for transmitting encoded TMS data according to the present disclosure.
FIG. 10B illustrates a state diagram of the operation of the Manchester encoder state machine of FIG. 10A .
FIG. 11 illustrates how TMS I/O communication can occur while a Tap controller is in the Run Test/Idle state according to the present disclosure.
FIG. 12 illustrates how TMS I/O communication may occur while a Tap controller is in other states according to the present disclosure.
FIG. 13 illustrates TMS I/O communication occurring between and IC and a controller.
FIG. 14 illustrates TMS I/O communication occurring between two ICs.
FIG. 15 illustrates TMS I/O communication occurring between two core circuits within an IC.
FIG. 16 illustrates the scan path and controller arrangement of FIG. 3 adapted for TCK I/O communication according to the present disclosure.
FIG. 17 illustrates TCK I/O communication circuitry coupled to a Tap domain according to the present disclosure.
FIG. 18 illustrates the TCK I/O Circuit of FIG. 17 according to the present disclosure.
FIG. 19 illustrates circuitry and timing for receiving Manchester encoded TCK input data according to the present disclosure.
FIG. 20A illustrates a Manchester decoder state machine for receiving encoded TCK data according to the present disclosure.
FIG. 20B illustrates a state diagram of the operation of the Manchester decoder state machine of FIG. 20A .
FIG. 21 illustrates circuitry and timing for transmitting Manchester encoded TCK output data according to the present disclosure.
FIG. 22A illustrates a Manchester encoder state machine for transmitting encoded TCK data according to the present disclosure.
FIG. 22B illustrates a state diagram of the operation of the Manchester encoder state machine of FIG. 22A .
FIG. 23 illustrates how TCK I/O communication can occur while a Tap controller is in the Run Test/Idle state according to the present disclosure.
FIG. 24 illustrates how TCK I/O communication may occur while a Tap controller is in other states according to the present disclosure.
FIG. 25 illustrates TCK I/O communication occurring between and IC and a controller.
FIG. 26 illustrates TCK I/O communication occurring between two ICs.
FIG. 27 illustrates TCK I/O communication occurring between two core circuits within an IC.
DETAILED DESCRIPTION
FIG. 4 illustrates a scan path system 402 of ICs/cores that include Tap domains plus additional TMS I/O circuitry. The combination of the Tap domain and TMS I/O circuitry is referred to as TAPIO 416 . FIG. 4 is similar to FIG. 3 in regard to the way the TDI, TDO, TCK, TMS, and TRST signals are coupled between the TAPIOs 416 and controller 420 . Controller 420 is different from controller 320 in that it has been improved according to the present disclosure to include the capability of communicating data to and from the TAPIOs 416 via the TMS connection. Controller 420 maintains the conventional ability of controller 320 to communicate the Tap domains of the TAPIOs 416 using the standard IEEE 1149.1 serial protocol. As seen, the TMS connection between controller 420 and TAPIOs 416 is shown as a bidirectional signal path, as opposed to the unidirectional signal path of the TMS connection in FIG. 3 . When a TAPIO 416 is selected for sending data to the controller 420 according to the present disclosure, the TMS connection will become an output from the TAPIO and an input to the controller. When a TAPIO 416 is selected for receiving data from the controller 420 according to the present disclosure, the TMS connection will become an output from the controller and an input to the TAPIO. As can be seen in FIG. 4 , data is transferred directly between a selected TAPIO 416 and controller 420 . Therefore the data latency problem mentioned in regard with FIG. 3 does not exist in FIG. 4 .
Additionally, according to the present disclosure, one TAPIO of an IC/core in the scan path may communicate to another TAPIO of an IC/core in the scan path via the common bidirectional TMS connection. To achieve this mode of operation, the controller 420 selects one TAPIO to transmit and another TAPIO to receive. The controller then disables its TMS output driver so that the transmitting TAPIO can output on its TMS terminal to send data to the TMS terminal of the receiving TAPIO. Again, the data is directly transferred between the TAPIOs without the aforementioned latency problem.
FIG. 5 illustrates the TAPIO circuit 416 in more detail. As seen the TAPIO 416 consists of a Tap domain 502 , a TMS communication circuit 514 , or communications interface, And gates 506 - 508 , and a Clock Source circuit 528 . The Clock Source 528 can be a clock producing circuit within the IC or it can come from a pin of the IC. Tap domain 502 is similar to Tap domain 102 with the exception that it includes And gate 504 for detecting when the Tap controller 104 , which includes a state machine, is in the Run Test/Idle (RTI) state 202 of FIG. 2 . The Tap controller 104 is a four bit state machine defining the 16 unique states shown in FIG. 2 . Each of the 16 Tap states is defined by a unique one of the four bit state machine codes. While not shown, the four inputs of the And gate 504 are inverted or not inverted to allow the And gate to detect, with a logic high output, when the Tap controller is in the Run Test/Idle state. For example, if the Run Test/Idle state has a four bit code of 0101, then the “0” inputs to And gate 504 will be inverted such that the And gate will receive all “1's” at its inputs so that it outputs a logic one when the Tap controller is in the Run Test/Idle state. This will be the case throughout the remainder of this specification for all And gates that are described for use in detecting Tap controller states. Also while And gates are shown being used to detect Tap controller states, other gating circuits may be used as well.
Further, Tap domain 502 differs from Tap domain 102 in that it includes an Enable TMS Output signal 510 and an Enable TMS Input signal 512 . The Enable TMS Output signal is set whenever the TMS communication circuit 514 is to perform a data output or protocol operation on TMS. The Enable TMS Input signal is set whenever the TMS communication circuit 514 is to perform a data input or protocol operation on TMS. As seen, the Enable TMS Input or Enable TMS Output signals can come, by design choice, from either the IR 106 via bus 114 or from a DR 108 via bus 112 .
When Enable TMS Output is set high and when the Tap controller 104 is in the Run Test/Idle (RTI) state 202 , the output of And gate 506 will go high to enable the TMS communications circuit 514 to perform a TMS output or protocol operation. When Enable TMS Input is set high and when the Tap controller 104 is in the Run Test/Idle (RTI) state, the output of And gate 508 will go high to enable the TMS communications circuit 514 to perform a TMS input or protocol operation. During either TMS communication operation, the Tap controller 104 remains in the Run Test/Idle state 202 .
TMS communication circuit 514 consists of a Frame Counter 516 , And gate 520 , TMS I/O Circuit 526 , Data Source 522 , and Data Destination 524 . The Frame Counter 516 is a data register 108 that can be scanned via TDI and TDO by the Tap controller 104 to load a count of the number of data frames that are to be sent from the Data Source 522 during a TMS output operation. A data frame in this disclosure is defined by a fixed number of transmitted data bits. After being scanned, and when enabled by the output of And gate 506 , the Frame Counter operates as a counter to count the number of data frames output on TMS. After all data frames have been sent out on TMS, the count complete (CC) output from the Frame Counter will go low to halt the TMS output operation of TMS I/O Circuit 526 , via And gate 520 . And gate 520 is gated on and off by the Enable TMS Output signal being high and low respectively. When gated off, the CC output from the Frame Counter cannot inadvertently, say during an 1149.1 protocol operation that passes through the Run Test/Idle state, enable the TMS I/O Circuit 526 . The Frame Counter receives IR & Tap Control input via bus 530 for scanning in the count, control input 518 from the TMS I/O Circuit 526 for knowing when to count a frame, and a clock input from the Clock Source circuit 528 .
When enabled for inputting data from TMS in one communications protocol, the TMS I/O Circuit 526 receives the TMS data and transfers it to the Data Destination circuitry 524 . Data Destination circuitry 524 may be any circuitry within an IC including but not limited to; (1) an address bus, (2) a data bus, (3) a Ram memory, (4) a Cache memory, (5) a register file, (6) a FIFO, (7) a register, (8) a processor, (9) a peripheral circuit, or (10) a bus coupled to circuitry external to the IC.
When enabled for outputting data on TMS in another communications protocol, the TMS I/O Circuit 526 receives data from the Data Source circuitry 522 and outputs the data on TMS. Data Source circuitry 522 may be any circuitry within an IC including but not limited to; (1) an address bus, (2) a data bus, (3) a Ram memory, (4) a Rom memory, (5) a Cache memory, (6) a register file, (7) a FIFO, (8) a register, (9) a processor, (10) a peripheral circuit, or (11) a bus coupled to circuitry external to the IC.
FIG. 6 illustrates TMS I/O Circuit 526 in more detail. TMS I/O Circuit consists of a Data & Clock Decoder 604 , Input Register 602 , Data & Clock Encoder 614 , and Output Register 612 . As will be described in more detail later, the TMS communication is based on Manchester data communication whereby the clock and data signals are combined and transmitted together on TMS.
The function of the Data & Clock Decoder 604 is to receive a frame of Manchester encoded data on TMS terminal 316 , extract the data 606 and clock (CK) 608 components from the encoded data, and input the data 606 serially to Input Register 602 in response to the extract CK signal 608 . Enable (EN) signal 628 enables Input Register 602 to receive the data 606 . Input Register 602 , once filled with a complete serial data frame, outputs the data frame in parallel to Data Destination 524 via data bus 622 . CK signal 608 and Data In Ready control signal 606 controls the Data Destination to receive the parallel data from bus 622 . This process of receiving Manchester encoded serial data frames from TMS terminal 316 , decoding the serial data frames into parallel data patterns, and inputting the parallel data patterns to Data Destination 524 is repeated until the TMS input communication operation is completed.
The function of the Data & Clock Encoder 614 is to control the Output Register 612 , via Enable (EN) 626 , CK 618 and Data Output Ready 616 signals, to receive parallel data patterns from the Data Source 522 via bus 624 and output the data serially, via Data signal 620 , to the Data & Clock Encoder 614 . The Data & Clock Encoder 614 encodes the serial input data 620 with a clock from Clock Source 528 to produce a frame of serial Manchester encoded data to be output on TMS terminal 316 . This process of receiving a parallel data pattern from the Data Source 522 , converting the parallel data pattern into a frame of serial Manchester encoded data, and outputting the frame of serial Manchester encoded data onto TMS terminal 316 is repeated until all the parallel data patterns from Data Source 522 have been serially transmitted from TMS terminal 316 . As seen in FIG. 6 , the Data Out Ready signal 616 , which controls the input of parallel data patterns from the Data Source to the Output Register is also input to Frame Counter 516 to control the frame count. The count value in the Frame Counter 516 controls the number of parallel data patterns that are output as encoded serial frames from TMS 316 . The Frame Counter 516 decrements once per each Data Out Ready signal. As seen in FIG. 5 , when the frame count in Frame Counter 516 expires, the Frame Counter halts the TMS serial output operation by setting the count complete (CC) signal low.
FIG. 7 illustrates a timing example of the Data & Clock Decoder circuit 604 receiving Manchester encoded data on TMS terminal 316 . Manchester encoding, is well known and operates by sending an encoded signal as a pair of opposite bits. In the timing diagram, each pair of opposite bits are shown within boxes 708 . Each box represents a Manchester encoded signal. In one example of Manchester encoding, an encoded logic one is represented by a logic zero bit followed by a logic one bit, and an encoded logic zero is represented by a logic one bit followed by a logic zero bit. An alternate Manchester encoding reverses the polarity of the bit pair for an encoded logic one and encoded logic zero.
As seen the Manchester Decoder circuit 702 in circuit 604 , when enabled by Input Enable, becomes operable to receive a first control segment or Start signals 704 , four logic ones in this example, from TMS 316 . More than two consecutive logic ones is an illegal Manchester bit encode, therefore more than two logic ones can be used as an indication to initialize the Manchester Decoder for receiving serial frames of encoded TMS data. While two Start signals, each comprising two logic ones, are shown in this example, more Start signals may be used if desired. After recognizing the Start signals, the Manchester Decoder receives frames 1 -N of Manchester encoded serial data from TMS 316 . The Manchester Decoder extracts the Data and CK components from each Manchester encoded bit in the frame and shifts the extracted Data into the Serial Input Parallel Output (SIPO) Register 602 . The Enable output from the Manchester Decoder enables the SIPO Register 602 to receive data. After each frame is decoded and shifted into SIPO Register 602 , the Manchester Decoder outputs the Data In Ready signal to Data Destination 524 . In response to the Data In Ready signal the Data Destination receives (stores and/or processes) the parallel output of Register 602 . This process continues until the Manchester Decoder receives Stop signals 706 , four logic zeros in this example, from TMS 316 . More than two consecutive logic zeros is an illegal Manchester bit encode, therefore more than two logic zeros can be used as an indication to cause the Manchester Decoder to stop receiving serial frames of encoded TMS data. While two Stop signals, each comprising two logic zeroes, are shown in this example, more Stop signals may be used if desired.
FIG. 8A illustrates a more detail example of Manchester Decoder circuit 702 . The Manchester Decoder 702 consists of a Manchester Decoder State Machine 802 and a Bit Counter 806 . The state machine 802 receives the TMS signal from TMS terminal 316 , a clock signal from Clock Source 528 , the Input Enable signal from And gate 508 , and a count complete (CC) signal from Bit Counter 804 . The state machine outputs a Data signal to SIPO Register 602 , a clock (CK) signal to SIPO Register 602 and Data Destination 524 , an Enable signal to SIPO Register 602 , the Data In Ready signal to Data Destination 524 , count control to Bit Counter 804 .
FIG. 8B illustrates the operation of state machine 802 . When the Input Enable signal is set high, the state machine begins sampling the TMS input for Start signals 704 . The frequency of the Clock Source is set sufficiently high to allow over-sampling of the TMS input signal. After Start signals are detected, the state machine begins sampling the TMS input to decode the Manchester encoded bit pairs 708 . Each time a bit pair is decoded, the appropriate Data value is clocked into SIPO Register 602 by the CK signal and the Bit Counter is clocked by counter control outputs. During the decode operation, the state machine monitors the CC input from the counter 804 . When a CC signal is detected, indicating that the number of bits received is equal to a full frame of bits, the state machine sets the Data In Ready signal high to enable the Data Destination to receive the full frame of bits from the parallel output from SIPO Register 602 . This process continues until the state machine receives the Stop signals 706 on the TMS signal, indicating the end of the transmission of Manchester encoded data frames. The state machine transitions to the Stop state and waits for the Input Enable signal to be set low by the Tap controller 104 exiting the Run Test/Idle state. A subsequent JTAG scan operation to either the DR 108 or the IR 106 register (i.e. the register from which it came) can set the Enable TMS input signal 512 low. When Input Enable goes low, the state machine 802 transitions back to the Input Enable state.
FIG. 9 illustrates a timing example of the Data & Clock Encoder circuit 614 outputting Manchester encoded data on TMS terminal 316 . In the timing diagram, each Start 704 , Data 708 , and Stop 706 bit signals are again illustrated as they were in FIG. 7 . As seen the Manchester Encoder circuit 902 in circuit 614 , when enabled by Output Enable, becomes operable to transmit Start signals 704 , four logic ones in this example, onto TMS 316 . Since the TMS terminal of an IC or Core is normally driven by a controller 420 , the controller must disable its drive of the TMS terminal to allow the TMS terminal of the IC or Core to become an output to drive the TMS of the controller during TMS output modes of operation. The disabling of the TMS controller output is indicated a “Z” in the timing diagram.
As seen, a 3-state buffer 904 inside the Manchester Encoder 902 becomes enabled during TMS output operation to drive the TMS terminal of the IC or core. After transmitting the Start signals, the Manchester Encoder loads parallel data into the Parallel Input Serial Output (PISO) Register 612 from the Data Source 522 and starts shifting the PISO Register 612 . Each bit shifted from the PISO Register to the Manchester Encoder is appropriately encoded as a Manchester bit pair signal 708 and transmitted out of the IC or core via the TMS terminal 316 . As seen the transmission of the Manchester bit pairs begins following the last transmitted Start signal. The Manchester Encoder combines the data and clock components together such that a Manchester Decoder 702 in the receiving controller 420 or other IC/core can extract the components back into separate data and clock signals. The Enable output from the Manchester Encoder enables the PISO Register 612 to load and shift out data. The serial data shifted out from one parallel load of the PISO Register forms one serial bit frame. After each frame is shifted out of the PISO Register 612 , the Manchester Encoder outputs the Data Out Ready signal to PISO Register 612 and Data Source 522 . In response to the Data Out Ready signal the PISO Register 612 inputs parallel data from Data Source 522 to began the next serial output frame that is encoded and output on TMS 316 . This process continues until the Output Enable input to the Manchester Encoder goes low, at which time the Manchester Encoder outputs Stop signals 706 , four logic zeros in this example, onto TMS 316 and disables the output buffer 904 , ending the TMS output operation.
FIG. 10A illustrates a more detail example of Manchester Encoder circuit 902 . The Manchester Encoder 902 consists of a Manchester Encoder State Machine 1002 , Bit Counter 1004 , TMS buffer 904 , and Clock Divider (CD) 906 . The state machine 1002 receives the Data output signal from PISO Register 612 , a clock signal from Clock Source 528 via Clock Divider 906 , the Output Enable signal from And gate 520 , and a count complete (CC) signal from Bit Counter 1004 . The state machine outputs a clock (CK) signal to PISO Register 612 and Data Source 522 , an Enable signal to PISO Register 612 , a Data Out Ready signal to PISO Register 612 and Data Source 522 , count control to Bit Counter 1004 , and encoded data to TMS 316 via buffer 904 .
FIG. 10B illustrates the operation of state machine 1002 . When the Output Enable signal is set high, the state machine enables the output buffer 904 and outputs Start signals 704 onto TMS 316 . Also the first parallel data pattern from Data Source 522 is loaded into PISO Register 612 . After sending the Start Bits, the state machine begins encoding the serial output data shifted from PISO Register 612 into Manchester encoded outputs on TMS 316 . The frequency of the CK output from the state machine 1002 is sufficiently less than the frequency of the clock output from the Clock Divider 906 to allow each data bit shifted out of PISO Register 612 to be encoded into the appropriate Manchester bit pair signal 708 . Each time an encoded bit pair is output on TMS 316 , the Bit Counter counts in response to control inputs from state machine 1002 . During the encoding operation, the state machine monitors the CC input from the Bit Counter 1004 . When a CC signal is detected, indicating that the last bit of the current bit frame is being shifted out of PISO Register 612 , the Data Out Ready signal is set to cause the next parallel data pattern from Data Source 522 to be loaded into PISO Register 612 to allow starting the next frame of data bit outputs from the Register 612 . Each data bit of each new frame of data loaded and shifted out of PISO Register 612 is encoded into Manchester bit pairs and output on TMS 316 . This process continues until the state machine 1002 detects the Output Enable signal going low, as a result of the count in Frame Counter 516 expiring and setting its frame count complete CC signal low, which in turn sets the Output Enable signal low via And gate 520 . When Output Enable is detected low, the state machine 1002 outputs the Stop signals 706 to indicate to controller 420 or other IC/core that the transmission of Manchester encoded data frames has come to an end. The state machine then disables output buffer 904 from driving the TMS terminal 316 and transitions to the Output Enable state of the diagram. When the TMS output operation is ended, the controller 420 enables its TMS output, transitions the Tap 104 from the Run Test/Idle state to set the Enable TMS Output signal low by a JTAG scan operation to either the DR 108 or the IR 106 register from whence it came.
Preferably the Clock Sources 528 in the transmitting and receiving devices (i.e. controller 420 , IC, or core) are of the same frequency. This would ensure that, by the use of Clock Divider 906 of Manchester Encoder 902 , the data encoded and output from a transmitting device's Manchester Encoder 902 will be at a bit rate easily over-sampled and decoded by the non-divided Clock Source 528 driving the Manchester Decoder 702 in a receiving device. A test that TMS data transmitted from Encoder 902 at the divided Clock Source rate is properly received by Decoder 702 at the full Clock Source rate can be achieved by simply enabling both circuits in the same device to operate simultaneously to transmit and receive data over their common TMS connection, then check that the data received in the Data Destination circuit 524 is correct.
As seen in the TMS Manchester communication timing diagrams of FIGS. 7 and 9 , the format of a TMS output operation is the same as the format a TMS input operation. Both formats include a header of at least two Start signals 704 followed by frames of Manchester data signals 708 followed by a trailer of at least two Stop signals 706 . This allows simple and standardized data communication between a TMS transmitting device (i.e. controller 420 , IC, or core) and a TMS receiving device (i.e. controller 420 , IC, or core). Other more complex formats may also be implemented as the need arises, such as formats that include frames for addressing and commanding operations to support more sophisticated communication needs.
FIG. 11 illustrates how a TMS I/O operation is initiated by the Tap controller transitioning into the Run Test/Idle state 202 . Prior to transitioning into the Run Test/Idle state, a scan operation will have been performed to set the Enable TMS Output 510 or Enable TMS Input 512 signal high, depending upon whether an TMS input or TMS output is desired. Also if it is a TMS output operation, the Frame Counter 516 is loaded with the frame count value. Once this setup procedure is accomplished, the Tap controller 104 is transitioned into the Run Test/Idle state as shown in FIG. 11 . Once in the Run Test/Idle state, the TCK clock is halted at a low logic level. The RTI signal is set which enables And Gates 506 and 508 to pass the Enable TMS Input or Output signals 510 and 512 to TMS communication circuit 514 . The selected TMS input or TMS output operation begins at time 1102 and is executed during time 1104 as shown in FIG. 11 while the Tap is in the Run Test/Idle state with the TCK halted. When the TMS input or TMS output operation is competed at time 1106 , the TMS and TCK signal may once again be operated by the controller 420 to transition the Tap controller 104 through its states. As can be seen, with the Tap controller in the Run Test/Idle state and with the TCK halted, TMS input and TMS output operations are completely transparent to the Tap controller and all IEEE 1149.1 circuitry connected to the Tap controller. While this example halts the TCK at a low logic level, the TCK could be halted at a high logic level as well.
FIG. 12 is provided to illustrate that other Tap controller states, other than Run Test/Idle, may be used to perform TMS input and TMS output operations. For example, the Shift-DR state 1202 , the Pause-DR state 1204 , the Shift-IR state 1206 , and the Pause-IR state 1208 all may be used in addition to the Run Test/Idle state for TMS input and output operation modes. To use these additional Tap controller states as states in which TMS input and output operations may be performed is simply a matter of providing And gates 1210 to decode when the Tap controller is in one of the states, as And gate 504 did for detecting the Run Test/Idle state, and providing an Or gate 1212 for indicating when any of the And gate 1210 outputs are high. The output of the Or gate 1212 would be substituted for the RTI output of And gate 504 in FIG. 5 and input to And gates 506 and 508 . With this substitution made, the TCK could be halted in any one of these states to allow the TMS I/O operation to be started, executed, and stopped, as was shown and described in regard to the Run Test/Idle state of FIG. 11 . While And/Or gating is shown in this example, other gating circuitry types could be used as well to detect the other Tap states.
FIG. 13 illustrates an example of the TMS I/O operation of the present disclosure being performed between an IC 1302 of a scan path 402 and a controller 420 as shown in FIG. 4 . If the controller is performing a TMS output operation, the IC will be performing a TMS input operation to receive the data from the controller via the TMS connection. If the IC is performing a TMS output operation, the controller will be performing a TMS input operation to receive the data from the IC via the TMS connection.
FIG. 14 illustrates an example of the TMS I/O operation of the present disclosure being performed between a first 1402 and second 1404 IC of a scan path 402 . If IC 1402 is performing a TMS output operation, IC 1404 will be performing a TMS input operation to receive the data from IC 1402 via the TMS connection. If IC 1404 is performing a TMS output operation, IC 1402 will be performing a TMS input operation to receive the data from IC 1404 via the TMS connection. During these operations, the TMS output of controller 420 of FIG. 4 will need to be disabled to allow the TMS terminal of the outputting IC to drive the TMS connection between the ICs.
FIG. 15 illustrates an example of the TMS I/O operation of the present disclosure being performed between a first 1502 and second 1504 core circuit within an IC of scan path 402 . If core 1502 is performing a TMS output operation, core 1504 will be performing a TMS input operation to receive the data from core 1502 via the TMS connection. If core 1504 is performing a TMS output operation, core 1502 will be performing a TMS input operation to receive the data from core 1504 via the TMS connection. During these operations, the TMS output of controller 420 of FIG. 4 , or the output of an internal buffer in the IC being driven by the TMS output of controller 420 will need to be disabled to allow the TMS terminal of the outputting core to drive the TMS connection between the cores.
In all of the examples in FIGS. 13-15 , the TMS I/O data communication between the devices (IC and controller, IC and IC, core and core) is performed directly and without introducing any communication latency by having to pass the communicated data through any other devices. Further, devices not involved in the TMS I/O communication are not affected by the TMS I/O communication.
FIG. 16 illustrates a scan path system 1602 of ICs/cores that include Tap domains plus additional TCK I/O circuitry. The combination of the Tap domain and TCK I/O circuitry is referred to as TAPIO 1616 . FIG. 16 is similar to FIGS. 3 and 4 in regard to the way the TDI, TDO, TCK, TMS, and TRST signals are coupled between the TAPIOs 1616 and controller 1620 . FIG. 16 is different from FIG. 4 in that communication is provided between the controller 1620 and TAPIO 1616 via the TCK signal 314 instead of via the TMS signal 316 . Controller 1620 is different from controller 420 of FIG. 4 in that it has been improved according to the present disclosure to include the capability of communicating data to and from the TAPIOs 1616 via the TCK connection. As with controller 420 , controller 1620 maintains the conventional ability of controller 320 to communicate the Tap domains of the TAPIOs 1616 using the standard IEEE 1149.1 serial protocol. As seen, the TCK connection between controller 1620 and TAPIOs 1616 is shown as a bidirectional signal path, as opposed to the unidirectional signal path of the TCK connection in FIG. 3 . When a TAPIO 1616 is selected for sending data to the controller 1620 according to the present disclosure, the TCK connection will become an output from the TAPIO and an input to the controller. When a TAPIO 1616 is selected for receiving data from the controller 1620 according to the present disclosure, the TCK connection will become an output from the controller and an input to the TAPIO. As can be seen in FIG. 16 , data is transferred directly between a selected TAPIO 1616 and controller 1620 . Therefore the data latency problem mentioned in regard with FIG. 3 does not exist in FIG. 16 .
Additionally, according to the present disclosure, one TAPIO of an IC/core in the scan path may communicate to another TAPIO 1616 of an IC/core in the scan path via the common bidirectional TCK connection. To achieve this mode of operation, the controller 1620 selects one TAPIO to transmit and another TAPIO to receive. The controller then disables its TCK output driver so that the transmitting TAPIO can output on its TCK terminal to send data to the TCK terminal of the receiving TAPIO. Again, the data is directly transferred between the TAPIOs without the aforementioned latency problem.
FIG. 17 illustrates the TAPIO circuit 1616 in more detail. As seen the TAPIO 1616 consists of a Tap domain 502 , a TCK communication circuit 1714 , And gates 506 - 508 , a Clock Source circuit 528 , and a D flip flop 1702 . The Clock Source 528 can be a clock producing circuit within the IC or it can come from a pin of the IC. Tap domain 502 is similar to Tap domain 102 with the exception that it includes the previously described And gate 504 for detecting when the Tap controller 104 is in the Run Test/Idle (RTI) state 202 of FIG. 2 , and that it includes an Enable TCK Output signal 1710 and an Enable TCK Input signal 1712 . D flip flop 1702 has a data (D) input and a reset (R) input coupled to the output of And gate 504 , an inverted clock input coupled to TCK 314 , and a data (Q) output (RTI) coupled to an input of And gates 506 and 508 . The Enable TCK Output signal is set whenever the TCK communication circuit 1714 is to perform a data output operation on TCK. The Enable TCK Input signal is set whenever the TCK communication circuit 1714 is to perform a data input operation on TCK. As seen, the Enable TCK Input or Enable TCK Output signals can come, by design choice, from either the IR 106 via bus 114 or from a DR 108 via bus 112 .
When the Tap controller 104 is in the Run Test/Idle state 202 the output of And gate 504 will be high, placing a logic one on the data input and the reset input of D flip flop 1702 . With the Tap controller in Run Test/idle, the RTI output of D flip flop 1702 will go high on the falling edge of TCK via the logic one output from And gate 504 . When the Tap controller exits from the Run Test/Idle state, the RTI output of And gate 504 goes low by the output of And gate 504 going low, which resets the RTI output of D flip flop 1702 to a logic zero.
When Enable TCK Output is set high and the RTI output of D flip flop 1702 is high, the output of And gate 506 will go high to enable the TCK communications circuit 1714 to perform a TCK output operation. When Enable TCK Input is set high and the RTI output of D flip flop 1702 is high, the output of And gate 508 will go high to enable the TCK communications circuit 1714 to perform a TCK input operation. During either TCK communication operation, the Tap controller 104 remains in the Run Test/Idle state 202 since the TMS signal 316 input from controller 1620 will be held low.
The structure and operation of TCK communication circuit 1714 is the same as TMS communication circuit 514 of FIG. 5 with the exception that TCK I/O Circuit 1726 has been substituted for TMS I/O Circuit 526 .
When enabled for inputting data from TCK, the TCK I/O Circuit 1726 receives the TCK data and transfers it to the Data Destination circuitry 524 . Data Destination circuitry 524 may be any circuitry within an IC including but not limited to; (1) an address bus, (2) a data bus, (3) a Ram memory, (4) a Cache memory, (5) a register file, (6) a FIFO, (7) a register, (8) a processor, (9) a peripheral circuit, or (10) a bus coupled to circuitry external to the IC.
When enabled for outputting data on TCK, the TCK I/O Circuit 1726 receives data from the Data Source circuitry 522 and outputs the data on TCK. Data Source circuitry 522 may be any circuitry within an IC including but not limited to; (1) an address bus, (2) a data bus, (3) a Ram memory, (4) a Rom memory, (5) a Cache memory, (6) a register file, (7) a FIFO, (8) a register, (9) a processor, (10) a peripheral circuit, or (11) a bus coupled to circuitry external to the IC.
FIG. 18 illustrates TCK I/O Circuit 1726 in more detail. TCK I/O Circuit 1726 is the same as TMS I/O Circuit 526 of FIG. 6 with the exception that it uses the TCK signal 314 for communication instead of the TMS signal 316 .
As described previously in regard to TMS I/O Circuit 526 , the function of the Data & Clock Decoder 604 of FIG. 18 is to receive a frame of Manchester encoded data on TCK terminal 314 , extract the data and clock (CK) components from the encoded data, and input the data serially to Input Register 602 in response to the extract CK signal. Input Register 602 , once filled with a complete serial data frame, outputs the data frame in parallel to Data Destination 524 via data bus 622 . CK signal and Data In Ready control signal controls the Data Destination to receive the parallel data from bus 622 . This process of receiving Manchester encoded serial data frames from TCK terminal 314 , decoding the serial data frames into parallel data patterns, and inputting the parallel data patterns to Data Destination 524 is repeated until the TCK input communication operation is completed.
As described previously in regard to TMS I/O Circuit 526 , the function of the Data & Clock Encoder 614 of FIG. 18 is to control the Output Register 612 to receive parallel data patterns from the Data Source 522 via bus 624 and output the data serially to the Data & Clock Encoder 614 . The Data & Clock Encoder 614 encodes the serial input data 620 with a clock from Clock Source 528 to produce a frame of serial Manchester encoded data to be output on TCK terminal 314 . This process of receiving a parallel data pattern from the Data Source 522 , converting the parallel data pattern into a frame of serial Manchester encoded data, and outputting the frame of serial Manchester encoded data onto TCK terminal 314 is repeated until all the parallel data patterns from Data Source 522 have been serially transmitted from TCK terminal 314 . As seen in FIG. 18 , the Data Out Ready signal 616 , which controls the input of parallel data patterns from the Data Source to the Output Register is also input to Frame Counter 516 to control the frame count. The count value in the Frame Counter 516 controls the number of parallel data patterns that are output as encoded serial frames from TCK 316 . The Frame Counter 516 decrements once per each Data Out Ready signal. As seen in FIG. 17 , when the frame count in Frame Counter 516 expires, the Frame Counter halts the TCK serial output operation by setting the count complete (CC) signal to And gate 520 low.
FIG. 19 illustrates a timing example of the Data & Clock Decoder circuit 604 receiving Manchester encoded data on TCK terminal 314 . The timing example is the same as that described previously in FIG. 7 , with the exception that the TCK signal 314 is used for communication instead of the TMS signal 316 . Also it is seen that the Input Enable goes high on the falling edge 1902 of TCK 314 . Referring back to FIG. 17 , the output of D flip flop 1702 is set high on the falling edge of TCK 314 when the Tap is in the RTI state 202 , which in turn sets the Input Enable output of And gate 508 high if Enable TCK Input 1712 is high. Use of the falling edge of TCK to initiate the TCK input operation allows the operation to start after TCK has transitioned to a low logic state which allows the Start signals 704 (four logic one's in this example) on TCK to be more easily recognized by the Data & Clock Decoder circuit 604 .
As seen the Manchester Decoder circuit 702 in circuit 604 , when enabled by Input Enable, becomes operable to receive Start signals 704 , four logic ones in this example, from TCK 316 . After recognizing the Start signals, the Manchester Decoder receives frames 1 -N of Manchester encoded serial data from TCK 314 . The Manchester Decoder extracts the Data and CK components from each Manchester encoded bit 708 in the frame and shifts the extracted Data into the Serial Input Parallel Output (SIPO) Register 602 . The Enable output from the Manchester Decoder enable the SIPO Register 602 to receive data. After each frame is decoded and shifted into SIPO Register 602 , the Manchester Decoder outputs the Data In Ready signal to Data Destination 524 . In response to the Data In Ready signal the Data Destination receives (stores and/or processes) the parallel output of Register 602 . This process continues until the Manchester Decoder receives Stop signals 706 , four logic zeros in this example, from TCK 314 , to cause the Manchester Decoder to stop receiving serial frames of encoded TCK data.
FIG. 20A illustrates a more detail example of Manchester Decoder circuit 702 , which is the same as that described in FIG. 8A with the exception that the TCK signal 314 is substituted for the TMS 316 signal. The Manchester Decoder 702 consists of a Manchester Decoder State Machine 802 and a Bit Counter 806 . The state machine 802 receives the TCK signal from TCK terminal 314 , a clock signal from Clock Source 528 , the Input Enable signal from And gate 508 , and a count complete (CC) signal from Bit Counter 804 . The state machine outputs a Data signal to SIPO Register 602 , a clock (CK) signal to SIPO Register 602 and Data Destination 524 , an Enable signal to SIPO Register 602 , the Data In Ready signal to Data Destination 524 , count control to Bit Counter 804 .
FIG. 20B illustrates the operation of state machine 802 , which is the same as described previously in regard to FIG. 8B . When the Input Enable signal is set high, the state machine begins sampling the TCK input for Start signals 704 . The frequency of the Clock Source is set sufficiently high to allow over-sampling of the TCK input signal. After Start signals are detected, the state machine begins sampling the TCK input to decode the Manchester encoded bit pairs 708 . Each time a bit pair is decoded, the appropriate Data value is clocked into SIPO Register 602 by the CK signal and the Bit Counter is clocked by counter control outputs. During the decode operation, the state machine monitors the CC input from the counter 804 . When a CC signal is detected, indicating that the number of bits received is equal to a full frame of bits, the state machine sets the Data In Ready signal high to enable the Data Destination to receive the full frame of bits from the parallel output from SIPO Register 602 . This process continues until the state machine receives the Stop signals 706 on the TCK signal, indicating the end of the transmission of Manchester encoded data frames. The state machine transitions to the Stop state and waits for the Input Enable signal to be set low by the Tap controller 104 exiting the Run Test/Idle state. A subsequent JTAG scan operation to either the DR 108 or the IR 106 register (i.e. the register from which it came) can set the Enable TCK input signal 1712 low. When Input Enable goes low, the state machine 802 transitions back to the Input Enable state.
FIG. 21 illustrates a timing example of the Data & Clock Encoder circuit 614 outputting Manchester encoded data on TCK terminal 314 . The timing example is the same as that described previously in FIG. 9 , with the exception that the TCK signal 314 is used for communication instead of the TMS signal 316 . Also it is seen that the Output Enable goes high on the falling edge 2102 of TCK 314 . Referring back to FIG. 17 , the output of D flip flop 1702 is set high on the falling edge of TCK 314 when the Tap is in the RTI state 202 , which in turn sets the Output Enable output of And gate 506 high if Enable TCK Output 1710 is high. Use of the falling edge of TCK to initiate the TCK output operation allows the operation to start after TCK has transitioned to a low logic state and the controller 1620 has disabled (“Z”) its TCK output driver.
In the timing diagram, the Start 704 , Data 708 (of frames 1 -N), and Stop 706 signals are again illustrated as they were in FIG. 9 . As seen, the Manchester Encoder circuit 902 in circuit 614 , when enabled by Output Enable, becomes operable to transmit Start signals 704 , four logic ones in this example, onto TCK 314 . As mentioned above, the controller 1620 will have disabled its TCK output driver to allow the output buffer 904 of the Manchester Encoder circuit 902 to drive the TCK 314 terminal.
After transmitting the Start signals, the Manchester Encoder loads parallel data into the Parallel Input Serial Output (PISO) Register 612 from the Data Source 522 and starts shifting the PISO Register 612 . Each bit shifted from the PISO Register to the Manchester Encoder is appropriately encoded as a Manchester bit pair signal 708 and transmitted out of the IC or core via the TCK terminal 314 . The Manchester Encoder combines the data and clock components together such that a Manchester Decoder 702 in the receiving controller 420 or other IC/core can extract the components back into separate data and clock signals. The Enable output from the Manchester Encoder enables the PISO Register 612 to load and shift out data. The serial data shifted out from one parallel load of the PISO Register forms one serial bit frame. After each frame is shifted out of the PISO Register 612 , the Manchester Encoder outputs the Data Out Ready signal to PISO Register 612 and Data Source 522 . In response to the Data Out Ready signal the PISO Register 612 inputs parallel data from Data Source 522 to began the next serial output frame that is encoded and output on TCK 314 . This process continues until the Output Enable input to the Manchester Encoder goes low, at which time the Manchester Encoder outputs Stop signals 706 , four logic zeros in this example, onto TCK 314 and disables the output buffer 904 , ending the TCK output operation.
FIG. 22A illustrates a more detail example of Manchester Encoder circuit 902 , which is the same as that described in FIG. 10A with the exception that the TCK signal 314 is substituted for the TMS 316 signal. The Manchester Encoder 902 consists of a Manchester Encoder State Machine 1002 , Bit Counter 1004 , TCK buffer 904 , and Clock Divider (CD) 906 . The state machine 1002 receives the Data output signal from PISO Register 612 , a clock signal from Clock Source 528 via Clock Divider 906 , the Output Enable signal from And gate 520 , and a count complete (CC) signal from Bit Counter 1004 . The state machine outputs a clock (CK) signal to PISO Register 612 and Data Source 522 , an Enable signal to PISO Register 612 , a Data Out Ready signal to PISO Register 612 and Data Source 522 , count control to Bit Counter 1004 , and encoded data to TCK 314 via buffer 904 .
FIG. 22B illustrates the operation of state machine 1002 . When the Output Enable signal is set high, the state machine enables the output buffer 904 and outputs Start signals 704 onto TCK 314 . Also the first parallel data pattern from Data Source 522 is loaded into PISO Register 612 . After sending the Start Bits, the state machine begins encoding the serial output data shifted from PISO Register 612 into Manchester encoded outputs on TCK 314 . The frequency of the CK output from the state machine 1002 is sufficiently less than the frequency of the clock output from the Clock Divider 906 to allow each data bit shifted out of PISO Register 612 to be encoded into the appropriate Manchester bit pair signal 708 . Each time an encoded bit pair is output on TCK 314 , the Bit Counter counts in response to control inputs from state machine 1002 . During the encoding operation, the state machine monitors the CC input from the Bit Counter 1004 . When a CC signal is detected, indicating that the last bit of the current bit frame is being shifted out of PISO Register 612 , the Data Out Ready signal is set to cause the next parallel data pattern from Data Source 522 to be loaded into PISO Register 612 to allow starting the next frame of data bit outputs from the Register 612 . Each data bit of each new frame of data loaded and shifted out of PISO Register 612 is encoded into Manchester bit pairs and output on TCK 314 . This process continues until the state machine 1002 detects the Output Enable signal going low, as a result of the count in Frame Counter 516 expiring and setting its frame count complete CC signal low, which in turn sets the Output Enable signal low via And gate 520 . When Output Enable is detected low, the state machine 1002 outputs the Stop signals 706 to indicate to controller 1620 or other IC/core that the transmission of Manchester encoded data frames has come to an end. The state machine then disables output buffer 904 from driving the TCK terminal 314 and transitions to the Output Enable state of the diagram. When the output operation is ended, the controller 1620 enables its TCK output and sets the Enable TCK Output signal low by a JTAG scan operation to either the DR 108 or the IR 106 register from whence it came.
As with the TMS I/O communication, it is preferable that the Clock Sources 528 in transmitting and receiving devices (i.e. controller 1620 , IC, or core) be at the same frequency. This would ensure that, by the use of Clock Divider 906 of Manchester Encoder 902 , the data encoded and output from a transmitting device's Manchester Encoder 902 will be at a bit rate easily over-sampled and decoded by the non-divided Clock Source 528 driving the Manchester Decoder 702 in a receiving device. A test that TCK data transmitted from Encoder 902 at the divided Clock Source rate is properly received by Decoder 702 at the full Clock Source rate can be achieved by performing the test previously describe with the TMS I/O communication.
As seen in the TCK Manchester communication timing diagrams of FIGS. 19 and 21 , the format of a TCK output operation is the same as the format a TCK input operation. Both formats include a header of Start signals 704 followed by frames of Manchester data signals 708 followed by a trailer of Stop signals 706 . This allows simple and standardized data communication between a TCK transmitting device (i.e. controller 1620 , IC, or core) and a TCK receiving device (i.e. controller 1620 , IC, or core). As with the previously described TMS communication of FIGS. 7 and 9 , TCK communication may be expanded to include other more complex formats as the need arises, such as formats that include frames for addressing and commanding operations.
FIG. 23 illustrates how a TCK I/O operation is initiated by the Tap controller transitioning into the Run Test/Idle state 202 . Prior to transitioning into the Run Test/Idle state, a scan operation will have been performed to set the Enable TCK Output 1710 or Enable TCK Input 1712 signal high, depending upon whether a TCK input or TCK output is desired. Also if it is a TCK output operation, the Frame Counter 516 is scanned to load the frame count value. Once this setup procedure is accomplished, the Tap controller 104 is transitioned into the Run Test/Idle state as shown in FIG. 23 . Once in the Run Test/Idle state, and after the RTI output of D flip flop 1702 goes high, the selected TCK input or output operation can begin.
The RTI signal is set high on the falling edge of TCK at time 2302 which enables And Gates 506 and 508 to pass the Enable TCK Input or Output signals 1710 and 1712 to TCK communication circuit 1714 . If a TCK output operation is to be performed, the controller 1620 will disable its TCK output driver after the falling edge of TCK at time 2302 and before time 2304 to allow a transmitting device to drive the TCK signal 314 . The selected TCK input or TCK output operation begins at time 2304 and is executed during time 2306 as shown in FIG. 23 while the Tap is in the Run Test/Idle state. When the TCK input or TCK output operation is competed at time 2308 , the TCK signal may once again be driven by the controller 1720 to conventionally operate Tap controller 104 using IEEE 1149.1 protocols. As can be seen, with the Tap controller in the Run Test/Idle state with TMS held low, TCK input and TCK output operations are completely transparent to the Tap controllers and all IEEE 1149.1 circuitry connected to Tap controllers.
FIG. 24 is provided to illustrate that other Tap controller states, other than Run Test/Idle, may be used to perform TCK input and TCK output operations. For example, the Pause-DR state 1204 or the Pause-IR state 1208 may be used in addition to the Run Test/Idle state 202 for TCK input and output operation modes. To use these additional Tap controller states as states in which TCK input and output operations may be performed is simply a matter of providing And gates 2402 to detect when the Tap controller is in one of the states, as And gate 504 did for detecting the Run Test/Idle state, and providing an Or gate 2404 for indicating when any of the And gate 2402 outputs are high. The output of the Or gate 2404 would be substituted for the output of And gate 504 in FIG. 17 as input to D flip flop 1702 . The output of D flip flop 1702 , renamed “TCK I/O State” in FIG. 24 , would maintain its connection to And gate 506 and 508 as shown in FIG. 17 . With this substitution made, the Tap controller 104 could be transitioned into any one of these states, and held there by asserting a low on TMS, to allow a TCK I/O operation to be started, executed, and stopped, as was shown and described in regard to the Run Test/Idle state of FIG. 23 . While it is possible to also use the Shift-DR state 1202 and Shift-IR state 1206 for TCK input and output operations, as was shown and described in the TMS input and output operations of FIG. 12 , one must be aware that data will be shifting through the ICs/cores of scan path 1602 from TDI to TDO during the TCK input or output operations, since the TCK signal will be active. This may or may not be a desired situation and is therefore left up to the user of the disclosure to determined whether TCK input and output operations are also allowed in the Shift-DR and Shift-IR Tap states. If allowed, then additional And gates 2402 would be assigned to detect these additional Tap states and the Or gate 2404 would be equipped with additional inputs for receiving the outputs from the additional And gates 2402 .
FIG. 25 illustrates an example of the TCK I/O operation of the present disclosure being performed between an IC 2502 of a scan path 1602 and a controller 1620 as shown in FIG. 16 . If the controller is performing a TCK output operation, the IC will be performing a TCK input operation to receive the data from the controller via the TCK connection. If the IC is performing a TCK output operation, the controller will be performing a TCK input operation to receive the data from the IC via the TCK connection.
FIG. 26 illustrates an example of the TCK I/O operation of the present disclosure being performed between a first 2602 and second 2604 IC of a scan path 1602 . If IC 2602 is performing a TCK output operation, IC 2604 will be performing a TCK input operation to receive the data from IC 2602 via the TCK connection. If IC 2604 is performing a TCK output operation, IC 2602 will be performing a TCK input operation to receive the data from IC 2604 via the TCK connection. During these operations, the TCK output of controller 1620 of FIG. 16 will need to be disabled to allow the TCK terminal of the outputting IC to drive the TCK connection between the ICs.
FIG. 27 illustrates an example of the TCK I/O operation of the present disclosure being performed between a first 2702 and second 2704 core circuit within an IC of scan path 1602 . If core 2702 is performing a TCK output operation, core 2704 will be performing a TCK input operation to receive the data from core 2702 via the TCK connection. If core 2704 is performing a TCK output operation, core 2702 will be performing a TCK input operation to receive the data from core 2704 via the TCK connection. During these operations, the TCK output of controller 1620 of FIG. 16 , or the output of an internal buffer in the IC being driven by the TCK output of controller 1620 will need to be disabled to allow the TCK terminal of the outputting core to drive the TCK connection between the cores.
In all of the examples in FIGS. 25-27 , the TCK I/O data communication between the devices (IC and controller, IC and IC, core and core) is performed directly and without introducing any communication latency by having to pass the communicated data through any other devices. Further, devices not involved in the TCK I/O communication are not affected by the TCK I/O communication.
While the Manchester encoding and decoding circuits described herein to achieve the TMS and TCK I/O communication have been described as being state machines operating synchronous to a clock source 528 , the disclosure is not limited to a particular type of Manchester encoding and decoding circuit. Indeed, other types of Manchester encoding and decoding circuits may be readily substituted for the example circuits shown herein and used to achieve the Manchester based TMS and TCK I/O communication objective of the present disclosure.
While the TMS and TCK I/O communication circuit examples were shown as residing in ICs and/or cores, it should be clear that similar TMS and TCK I/O communication circuits or software that can emulate the TMS and TCK I/O communication circuit functionality also resides in the controllers that connect to the ICs and/or cores to enable the controllers to communicate with the ICs and/or cores during TMS and TCK I/O communication operations.
Although the present disclosure has been described in detail, it should be understood that various changes, substitutions and alterations may be made without departing from the spirit and scope of the disclosure as defined by the appended claims. | The present disclosure describes using the JTAG Tap's TMS and/or TCK terminals as general purpose serial Input/Output (I/O) Manchester coded communication terminals. The Tap's TMS and/or TCK terminal can be used as a serial I/O communication channel between; (1) an IC and an external controller, (2) between a first and second IC, or (3) between a first and second core circuit within an IC. The use of the TMS and/or TCK terminal as serial I/O channels, as described, does not effect the standardized operation of the JTAG Tap, since the TMS and/or TCK I/O operations occur while the Tap is placed in a non-active steady state. | 6 |
CROSS-REFERENCES TO RELATED APPLICATIONS
This application claims the benefit of German patent application 10 2005 022 187.4, filed May 13, 2005, herein incorporated by reference.
BACKGROUND OF THE INVENTION
The invention relates to a joining method on a jet spinning machine, as well as a spinning device and a jet spinning machine for carrying out the joining method.
Jet spinning machines generally comprise spinning devices, to which a fibre band drawn to a fibre bundle is supplied from a drawing frame. The fibre band runs through a spinning nozzle, in which it is acted upon by swirling air currents and is thereby provided with a true torsion or true twist. Positioned downstream from the spinning nozzle is a hollow spinning cone, through which the fibre band is drawn off as a thread from an outlet opening and then wound onto a take-up bobbin as the upper thread.
German Patent Publication DE 3611050 A1 describes a spinning unit, which is intended to produce bobbins being used a feed bobbins for twisting. Substantially untwisted thread components are wound onto the feed bobbins. For joining, two auxiliary threads are in each case drawn off from an auxiliary bobbin. The ends of the auxiliary threads are transferred with the aid of thread clamps to a suction device and then placed by the thread clamps in a draw-off mechanism configured as a pair of rollers, then into the false twist mechanism and finally, from the side, into the pair of withdrawal rollers of a drawing frame. The activated false twisting mechanism acts upon the auxiliary threads with a false twist. The auxiliary threads transport the false twist counter to the thread running direction to the withdrawal rollers of the drawing frame. For joining, a fibre strand is fed onto the running auxiliary threads, in each case, from the drawing frame. The auxiliary threads and the fibre strand supplied to them in each case are now together provided with a false twist by the false twist mechanism from the withdrawal rollers of the drawing frame to the false twist mechanism. The spinning unit of German Patent Publication DE 3611050 A1 is not suitable for producing a spun thread with a true twist. Inserting the auxiliary threads according to the disclosure of German Patent Publication DE 3611050 A1, from the side, is not possible when using jet spinning devices, which operate with a twist retaining mechanism and a hollow spinning cone.
A jet spinning machine is described in European Patent Publication EP 1 072 702 A2, as prior art, in which during a start or when a thread breaks the end of the upper thread is transported by means of a transfer arm into the vicinity of the outlet opening of the spinning cone designated a spindle. From there, the upper thread runs from the direction opposed to the thread delivery side through the spinning cone and the spinning nozzle and is sucked into a suction element. The fibre bundle on the delivery side, which exits from the drawing frame is also sucked into the suction element and intertwined with the upper thread. The two intertwined threads are then sucked into the spinning nozzle for connection. In this method, the upper thread has to be advanced from the spinning device to the suction element in the direction opposing the spinning operation. During this preparation phase for thread connection, errors frequently occur which disturb the formation of a thread connection or even prevent it. A further disadvantage is that the thread portion, which contains the connection between the upper thread and thread bundle is clearly recognisably thicker than the remaining thread. A thick location of this type has a disruptive effect in the end product, for example a woven fabric and is a quality defect. Apart from the disadvantage that the thread connection process is frequently unsuccessful, the length of the thread portion, which forms the piecer can hardly be controlled. Approximately the same lengths of the piecer are not ensured.
In order to overcome these problems, European Patent Publication EP 1 072 702 A2 proposes a spinning device for an alternative joining method. This spinning device has a spinning cone with joining nozzles close to the tip and an axially extending spinning thread channel, through which the spinning thread is drawn off. The spinning thread channel widens towards its thread outlet side in a stepped manner. These joining nozzles are used to generate swirling air currents in the spinning cone by means of supplied compressed air, by means of which a reduced pressure is generated at the tip of the spinning cone. If compressed air acts on the conventional spinning nozzles and also the joining nozzles arranged downstream from the spinning nozzles in the spinning cone, the fibre bundle supplied by the drawing frame is firstly acted upon by a rotational flow and conveyed to the mouth of the spinning thread channel at the tip of the spinning cone. Owing to the reduced pressure produced there by the activated joining nozzles, the fibre bundle is sucked into the spinning thread channel, acted upon by a rotational flow revolving counter to the spinning nozzles when passing through the joining nozzles and transported by the outflowing compressed air to the thread outlet end. The joining nozzles provide the fibre bundle with a false twist briefly during joining. Once the thread has reached the take-off rollers arranged downstream from the spinning cone and is clamped there, the joining nozzles are deactivated, and a normal thread with a true twist is then spun. The thread portion which has been spun with a false twist, is cut off and the end of the newly spun yarn is connected to the end of the upper thread drawn off from the take-up bobbin by a splicing device.
So the tip of the fibre bundle can be sucked into the spinning cone during the joining process, the bore diameter of the mouth of the spinning thread channel has to have a minimum size, which is, for example, a diameter of 1 mm. The limitation of the bore diameter leads decisively to limitations in the influencing of the yarn character.
SUMMARY OF THE INVENTION
The object of the invention is to eliminate the aforementioned disadvantages.
This object is achieved by a method of joining executed on a spinning device of a jet spinning machine, and by a spinning device for a jet spinning machine and an improved jet spinning machine.
According to the joining method of the present invention, a fibre band drawn to yarn thickness is supplied by a drawing frame to the spinning device, between an input-side mechanical twist retaining mechanism and a spinning cone, a rotational flow is produced by a spinning nozzle mechanism, which collects fibres forming free fibre ends and winds them producing a true twist around fibres which do not take part in the rotation and are already incorporated, and the thread thus formed from the fibre band is drawn through the hollow spinning cone. For joining, an auxiliary thread is used, which is firstly threaded by its free end into the spinning device and drawn through the spinning cone. Joining then takes place on the continuous auxiliary thread not taking part in the torsion, in that the fibres of the fibre band are fed onto the auxiliary thread and wound around it. The auxiliary thread being subjected to the withdrawal is guided off and after passing the auxiliary thread end, the newly spun thread, which is free of auxiliary thread, is separated and connected to the end of the upper thread by a knot or a splice.
The invention also provides a spinning device for a jet spinning machine for carrying out the joining method above, which comprises a spinning nozzle mechanism for producing an injector flow and a spinning cone for thread formation. According to the invention, a first clamping device for temporary clamping of the upper thread and a second clamping device for temporary clamping of the auxiliary thread are associated with the spinning device.
The jet spinning machine of the invention has spinning stations arranged next to one another in a row for carrying out the joining method above. According to the invention, a storage mechanism for storing the auxiliary thread and the newly spun thread, a separating mechanism for separating the auxiliary thread from the thread and a splicing mechanism for connecting the newly spun thread to the upper thread are arranged only on at least one operating carriage which can be displaced along the spinning station.
The invention allows a simple threading in of a joining thread and reduces the number of unsuccessful joining attempts. The yarn character can be better influenced. If a splicing connection is selected, only a splice connection which is practically identical to the yarn remains in the finished yarn which leads to no reduction in quality of the finished product.
If the auxiliary thread differs with respect to its properties from the remaining thread, the auxiliary thread can be selected such that a better threading in is achieved with it. Particularly suitable is an auxiliary thread, which is stiffer and/or smoother than the remaining thread. It may also be advantageous if the auxiliary thread is stronger or finer than the remaining thread.
Compared with the method of introducing the end of an upper thread counter to the normal thread running direction during spinning operation, into the spinning device, before joining takes place, the use of an auxiliary thread allows a significant improvement in insertion. In particular, an improvement is to be noted, if instead of introducing only a fibre bundle in the normal thread running direction during spinning operation into the spinning device, an auxiliary thread is used before joining takes place.
In order to reduce the occurrence of errors in joining, the auxiliary thread is introduced into the spinning device in two stages. In this case, in a first stage, the auxiliary thread is introduced into the fibre band channel prior to the spinning nozzle mechanism by means of the injector flow and, in a second stage, the auxiliary thread is introduced into the spinning cone by acting upon the spinning cone by means of reduced pressure. For the introduction of the auxiliary thread, the spinning nozzle mechanism and the spinning cone are temporarily placed so far apart from one another that the auxiliary thread can be manually grasped between the spinning nozzle mechanism and the spinning cone. This allows threading to be carried out in a simple manner, substantially manually. However, it is also possible to automate the handling, at least partially.
If, during joining, a joining speed is adjusted, which is lower than the speed during normal spinning operation, the risk of disruptions of the joining process occurring can be reduced.
A splicing of the thread ends can be expediently prepared if the spinning device has a first clamping mechanism for temporary clamping of the upper thread and a second clamping mechanism for temporary clamping of the auxiliary thread.
The second clamping device is preferably a transporting means for conveying the auxiliary thread and the newly spun thread which then follows. The spinning device preferably has the following components:
A storage mechanism for storing the auxiliary thread and the newly spun thread, a separating device for separating the auxiliary thread from the thread and a splicing mechanism for connecting the newly spun thread to the upper thread.
These components may be stationarily arranged at the spinning station of the jet spinning machine. Alternatively, with a large number of spinning stations at the jet spinning machine, these components may be exclusively arranged at least one operating carriage which can be displaced along the spinning devices of the jet spinning machine. The outlay for construction at the jet spinning machine can thus be reduced.
At least one clamping mechanism for temporary clamping of the auxiliary thread is advantageously arranged at the operating carriage.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be described in more detail with the aid of the figures, in which:
FIG. 1 shows a simplified view of a jet spinning machine,
FIG. 2 shows a spinning device of a jet spinning machine with an upstream drawing frame, partially in section and simplified, in an enlarged view compared to FIG. 1 ,
FIG. 3 shows a divided spinning device in the threading position,
FIG. 4 shows the spinning device of FIG. 3 with a threaded auxiliary thread,
FIG. 5 shows a schematic view of a spinning station with an operating carriage in a side view, prior to the splicing process,
FIG. 6 shows the spinning station of FIG. 5 after the splicing process,
FIG. 7 shows the spinning station of FIG. 5 during normal spinning operation,
FIG. 8 shows a schematic view of a spinning station in a side view with a splicing mechanism and thread store in normal spinning operation,
FIG. 9 shows the spinning station of FIG. 8 prior to the splicing process during the joining process,
FIG. 10 shows the spinning station of FIG. 8 during the splicing process.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The jet spinning machine 1 shown in FIG. 1 has a plurality of spinning stations 2 arranged next to one another in a row. Each spinning station 2 comprises a fibre band source 3 , which may be configured, for example, as a spinning can, a drawing frame 4 , a spinning device 5 , a pair of take-off rollers 6 , a yarn clearer 7 , a thread transfer mechanism 8 and a take-up bobbin configured as a cross-wound bobbin 9 . An operating carriage 10 is guided along the spinning stations 2 , on bars 11 , 12 . A drive unit 13 is arranged at one end of the jet spinning machine.
FIG. 2 shows a drawing frame with a subsequent spinning device 5 and the passage of fibres. The fibre band 14 drawn off from the fibre band source 3 is drawn in by the pair of upper and lower rollers 15 , 15 A arranged as feed rollers and drawn with the pairs of upper and lower rollers 16 , 16 A; 17 , 17 A; 18 , 18 A. A tweezer-like twist retaining mechanism 54 and a spinning nozzle mechanism 19 are arranged in a first component of the spinning device 5 . The nozzles 20 , 21 are connected to a compressed air source 23 by means of the line 22 . The air flowing out of the nozzles 20 , 21 produces a rotational flow, which acts upon the drawn fibre band 24 . The second component of the spinning device 5 carries a hollow spinning cone 25 . The thread 26 formed in the interaction of the spinning nozzle mechanism 19 and spinning cone 25 is drawn off from the spinning device 5 through the hollow spinning cone 25 . The air chamber 27 surrounding the spinning cone 25 is connected to a reduced pressure source 29 by means of the line 28 .
Further details with respect to the spinning process by means of spinning devices of this type can be inferred from German Patent Publication DE 199 26 492 A1, for example.
An auxiliary thread 30 is used for joining. For this purpose, the first and second component of the spinning device 5 , which are displaceably fastened to a guide, not shown, are displaced so far that a manually assisted threading of the auxiliary thread 30 is possible. As shown in FIG. 3 , the free end of the auxiliary thread 30 is drawn off from the auxiliary thread bobbin 31 , guided through a cutting mechanism 37 and positioned close to the mouth 32 of the fibre band channel 33 . The spinning nozzle mechanism 19 is then briefly acted upon via the line 22 with compressed air from the compressed air source 23 . The air flowing from the nozzles 20 , 21 produces, in the fibre band channel 33 , a reduced pressure by means of which the free end of the auxiliary thread 30 is threaded into the fibre band channel 33 and is transported onward into the vicinity of the mouth 34 of the spinning cone 25 . Reduced pressure is now applied to the outlet 36 of the spinning cone 25 by means of a flexible line 35 connected to the reduced pressure source 29 and the auxiliary thread 30 is sucked through the spinning cone 25 into the line 35 . This state is shown in FIG. 4 . The first and second components are then again displaced into their starting position shown in FIG. 2 .
The positioning of the first and the second component and of the auxiliary thread 30 takes place manually in the embodiment. Automatic or partially automatic positioning is possible using corresponding components.
FIG. 5 shows a first phase of a joining process at a spinning station 2 using an operating carriage 10 . The operating carriage 10 is positioned at the spinning station 2 , at which joining is to take place. The upper thread 38 is drawn off from the cross-wound bobbin 9 , the upper thread 38 running through the thread transfer mechanism 8 and the yarn clearer 7 and being placed in the splicing mechanism 39 . The free end of the upper thread 38 is clamped in a first clamping mechanism 40 . The auxiliary thread 30 is guided by the pair of take-off rollers 6 , 6 A and further manually by the pair of conveying rollers 41 , 41 A and placed in the splicing mechanism 39 . The end of the auxiliary thread 30 is clamped in a second clamping mechanism 42 .
The second clamping mechanism 42 is now released, the suction device 43 is acted upon by reduced pressure and the conveying rollers 41 , 41 A are made to rotate. The fibre band 24 is conveyed to the mouth 32 of the fibre band channel 33 from the pair of rollers of the drawing frame 4 formed from the upper roller 18 and lower roller 18 A and the spinning device 5 is activated. The sucked in fibres of the fibre band 24 are connected onto the running auxiliary thread 30 in the spinning device 5 . After a short time, the auxiliary thread 30 is severed by means of the cutting mechanism 37 and the thread is now only formed from the fibre band 24 supplied. When the auxiliary thread 30 including the portion, on which the fibres of the fibre band 24 are joined, has been taken up by the suction device 43 , the thread 26 is clamped in the clamping mechanism 42 . The thread portion containing the auxiliary thread 30 is separated at the clamping mechanism 42 and sucked up by means of the suction device 43 . The splicing mechanism 39 is then actuated. During the splicing process, the thread 26 being continuously spun by the spinning device 5 is taken up by the thread store 44 and stored. Further explanations regarding spinning mechanisms on jet spinning machines are contained, for example, in DE 38 24 850 A1.
Once the splicing process has ended, the friction roller 45 is placed on the cross-wound bobbin 9 as shown in FIG. 6 . The cross-wound bobbin 9 is made to rotate by means of the driven friction roller 45 and winds the upper thread 38 . The upper thread 38 is wound on slightly faster than it is delivered from the spinning device 5 until the thread store 44 is emptied again.
The thread 26 is now released by the operating carriage 10 , the friction roller 45 pivoted away from the cross-wound bobbin 9 and the normal spinning operation resumed, as shown in FIG. 7 . The operating carriage 10 travels to the next spinning station 2 , by which it is required for a joining process.
FIG. 8 shows an alternative configuration of the spinning station 2 during spinning operation. The spinning station 2 shown comprises a fibre band source, a drawing frame 4 , a spinning device 5 , a pair of take-off rollers 6 , 6 A, a yarn clearer 7 , a thread transfer mechanism 8 and a cross-wound bobbin 9 as a take-up bobbin, here. The spinning station 2 shown in FIG. 8 also comprises an auxiliary thread bobbin 31 A, a cutting mechanism 46 , a splicing mechanism 47 , a first clamping mechanism 48 for the upper thread 38 , a cutting mechanism 49 associated with the splicing mechanism 47 , a pivotably mounted suction tube 50 , and a thread store 51 . For joining after a bobbin change or a thread break, the auxiliary thread 30 is drawn off from the auxiliary thread bobbin 31 A, guided through the cutting mechanism 46 and threaded into the spinning device 5 by the method already described above with the aid of FIGS. 2 to 4 and then guided manually through the pair of take-off rollers 6 , 6 A.
The upper thread 38 is drawn off from the cross-wound bobbin 9 , inserted in the clamping mechanism 48 and clamped there. The suction tube 50 is pivoted from its starting position into the position shown by dashed lines. At its free end, the suction tube 50 carries a clamping mechanism 52 . A line, not shown, with which the suction tube 50 can be temporarily connected to the reduced pressure source 29 , opens at the pivot pin 53 of the suction tube 50 . The free end of the auxiliary thread 30 is sucked in, by applying reduced pressure, into the suction tube 50 and clamped by the clamping mechanism 52 . The suction tube 50 pivots back into the starting position. The auxiliary thread 30 is placed in the process in the splicing mechanism 47 and in the cutting mechanism 49 . The clamping mechanism 52 is opened, the joining process is started and the fibres of the fibre band 24 fed by the drawing frame 4 are connected onto the auxiliary thread 30 . This phase is shown in FIG. 9 . After a short time, the auxiliary thread 30 is severed by the cutting mechanism 46 . When the separated end of the auxiliary thread 30 has passed the clamping mechanism 52 , the clamping mechanism 52 is activated. For this purpose, a time span may be predetermined between severing the auxiliary thread 30 and activation of the clamping mechanism 52 , which is sufficiently great to completely suck the thread portion with the auxiliary thread 30 reliably into the suction tube 50 . The thread portion containing the auxiliary thread 30 is severed by means of the cutting mechanism 49 and sucked up by means of the suction tube 50 . The splicing mechanism 47 carries out a splicing process to connect the upper thread 38 and the thread 26 . The thread 26 no longer contains an auxiliary thread 30 . The thread 26 which was spun during the splicing process is sucked into the thread store 51 , as shown in FIG. 10 .
After the splicing process has ended, the upper thread 38 is released by the splicing mechanism 47 and the cross-wound bobbin 9 is made to rotate in the arrow direction by a drive, not shown, to wind the upper thread 38 . The upper thread 38 is firstly wound at a slightly higher thread speed than the thread 26 is delivered from the spinning device 5 , until the thread store 51 is emptied again. The normal spinning operation is now resumed, as shown in FIG. 8 . | A joining method wherein fibers of a fiber band are wound around an auxiliary thread threaded into a spinning device and drawn through a spinning cone. The newly spun thread is separated from the auxiliary thread and connected to the end of an upper thread. A spinning device is provided for a jet spinning machine for carrying out such method, comprising a first clamping device for temporary clamping of the upper thread and a second clamping device for temporary clamping of the auxiliary thread. A jet spinning machine for carrying out the method has a mechanism for storing the auxiliary thread and the newly spun thread, a mechanism for separating the auxiliary thread from the newly spun thread, and a splicing mechanism for connecting the newly spun thread to the upper thread, all arranged only on at least one operating carriage displaceable along multiple spinning stations. | 3 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a locking mechanism of a webbing retractor which has a winding shaft around which a webbing is wound in the form of layers. The locking mechanism is capable to prevent from rotating the winding shaft at excessive movement more than a predetermined amount of acceleration in a horizontal direction of a vehicle.
2. Description of the Related Art
A seat belt apparatus for a vehicle is provided with a webbing retractor which accommodates a webbing for restricting movement of a seat occupant by resiliently winding in a laminating condition the webbing around a winding shaft to which one end of the webbing is fixed. The seat occupant draws the webbing out of this webbing retractor when he puts it on.
The webbing retractor has a locking mechanism for preventing the rotation of the winding shaft when the running speed of the vehicle rapidly drops to prevent the unwinding of the webbing and to thereby restrict the movement of the seat occupant.
FIG. 6 shows a conventional locking mechanism a type described above. In this locking mechanism, rotation of the winding shaft 10 is prevented when ratchet wheels 12 which are fixedly mounted on the winding shaft 10 are engaged with a pawl 14. A pendulum 16 is connected to this pawl 14 near a laminated portion 15 of the webbing. The pawl 14 is engaged with the ratchet wheels 12 by the swing of the pendulum 16. The pendulum 16 swings when a predetermined amount of acceleration acts in a horizontal direction of a vehicle or in a widthwise direction shown in FIG. 6, that is, when the running speed of the vehicle rapidly drops, and thereby causes the pawl 14 to be meshed with the ratchet wheels 12 so as to prevent from rotating the winding shaft 10.
However, in this locking mechanism, the pendulum 16 requires a long rod 16A, and this makes the locking mechanism long in a vertical direction (in a lengthwise direction shown in FIG. 6), which in turn makes a resultant webbing retractor elongated in the vertical direction.
SUMMARY OF THE INVENTION
In view of the aforementioned problem of the related art, an object of the present invention is to provide a locking mechanism for a webbing retractor which does not make the webbing retractor elongated in a vertical direction.
To this end, the present invention provides a locking mechanism for use in a webbing retractor of the type which has a winding shaft around which a webbing is wound in the form of layers, the locking mechanism preventing rotation of the winding shaft at excessive movement more than a predetermined amount of acceleration in a horizontal direction. The locking mechanism of the present invention includes: a locking wheel rotated together with a winding shaft; a locking pawl that can be engaged with the locking wheel to prevent from rotating the winding shaft; and an operating body for bringing a locking pawl into engagement with the locking wheel at excessive movement more than the predetermined amount of acceleration in a horizontal direction. The operating body has a first portion which brings the locking pawl into engagement with the locking wheel when it is slanted, and a pair of second portions extending from the first portion symmetrically with respect to an axis of the winding shaft and in the direction in which they approach an outer periphery of the webbing wound around the winding shaft. The second portions make the first portion inclined when the predetermined amount of acceleration acts in a horizontal direction.
In the present invention, when the predetermined amount of acceleration acts excessively in the horizontal direction, the second portions of the operating body make the first portion inclined, and this allows the locking pawl to be engaged with the locking wheel. The locking pawl which is engaged with the locking wheel prevents from rotating the winding shaft. Thus, rotation of the winding shaft is prevented when the predetermined amount of acceleration acts excessively in the horizontal direction.
The second portions of the operating body are extended in a direction in which they approach an outer periphery of the wound webbing. This allows a resultant webbing retractor to be made small in the vertical direction of the vehicle.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional view of a locking mechanism of a webbing retractor, showing a first embodiment of the present invention;
FIG. 2 is an exploded perspective view of the essential parts of the locking mechanism shown FIG. 1;
FIG. 3 shows a condition of an operation of the locking mechanism of FIG. 1;
FIG. 4 is a cross-sectional view of a locking mechanism of a webbing retractor for a second embodiment of the present invention;
FIG. 5 is an exploded perspective view of essential parts of the locking mechanism shown FIG. 4; and
FIG. 6 is a cross-sectional view of a conventional locking mechanism for a webbing retractor.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIGS. 1 to 3 shows a webbing retractor 22 for a seat belt apparatus which has a locking mechanism 20 of the present invention.
As shown in FIG. 1, the webbing retractor 22 includes a winding shaft 24 around which a webbing 26 for restricting the movement of a seat occupant is wound in a laminating manner. The winding shaft 24 is supported by a frame 28 in such a manner that it extends substantially in a horizontal direction. More specifically, the winding shaft 24 is rotatably supported at the two ends thereof by leg plates 30 and 32 of the frame 28, which are disposed parallel to each other as shown in FIG. 2. A spring cover 34 with a flat spiral spring 36 accommodated therein is mounted on the leg plate 30 of the frame 28. The external end of the spiral spring 36 is locked to the spring cover 34, and the internal end thereof is locked to the one end portion of the winding shaft 24. This allows the spiral spring 36 to urge and rotate the winding shaft 24. The webbing 26 is wound around the winding shaft 24 utilizing this urging force and is thereby accommodated in the webbing retractor. When a seat occupant puts on this webbing 26, he unwinds it from the winding shaft 24 against the urging force.
The locking mechanism includes a ratchet wheel 38 which is a locking wheel, a pawl 40 which serves as a locking pawl, and an operating body 42.
The ratchet wheel 38 is provided in a pair as shown in FIG. 2. The ratchet wheels 38 are coaxially fixed to the winding shaft 24 between the leg plates 30 and 32 at the two sides of a laminated portion 26A of the webbing 26, so that they can be rotated together with the winding shaft 24 when the shaft is rotated.
The pawl 40 is disposed below the laminated portion 26A of the webbing 26. The pawl 40 is extended between the leg plates 30 and 32 of the frame 28 in such a manner as to be pivotal in the direction indicated by an arrow head A in FIG. 1. The pawl 40 becomes engaged with the ratchet wheels 38 when it is lifted upward, by which rotation of the winding shaft 24 in a direction indicated by an arrowhead B in FIG. 1 can be prevented so as to prevent drawing of the webbing.
The operating body 42 has a square portion 50 which serves as an inclined portion or a contact portion, and an inertia plate 43 that constitutes an inertia portion.
The square portion 50 is supported on the frame 28 below the pawl 40 in such a manner that it can be inclined with respect to the frame 28. More specifically, a supporting block 52 is mounted on the frame 28 below the pawl 40, and the square portion 50 is supported by this supporting block 52. The supporting block 52 is fixed to the two leg plates 30 and 32 by means of vises 54 as shown in FIG. 2, and is thereby extended between the leg plates 30 and 32. The supporting block 52 has a square hole 56 having a bottom formed on the upper surface thereof as shown in FIG. 2, and the lower end portion of the square portion 50 is received by this square hole 56. Since the square portion 50 is inserted in the square hole 56, the square portion is prevented from rotating around its axis. The square hole 56 has a size that enables the square portion 50 to be inclined in a direction indicated by an arrowhead C in FIG. 1. Thus, the square portion 50 is supported on the frame 28 in such a manner that it can become inclined with respect to the frame 28.
The lower surface of the pawl 40 is in contact with the upper surface of the square portion 50, as shown in FIG. 2. When the square portion 50 is inclined in the direction indicated by an arrowhead C in FIG. 1, it raises the pawl 40 and thereby brings it into engagement with the ratchet wheels 38.
The inertia plate 43 is extended below the laminated portion 26A of the webbing 26 in a direction in which it intersects the axis of the winding shaft 24. The intermediate portions of the extended portions of the inertia plate 43 are bent to form vane portions 44 and 46 that extend in a direction of the tangent of the laminated portion 26A at the two end portions of the extended portions. The vane portions 44 and 46 serve as the inertia portions. The portion of the inertia plate 43 located between the vane portions 44 and 46 is positioned below the pawl 40. The vane portions 44 and 46 are extended above the pawl 40 with the vane portion 44 being passed through the pawl 40. As viewed from a size portion, the vane portions 44 and 46 overlap the laminated portion 26A of the accommodated webbing 26 as shown in FIG. 1 by a predetermined length (L) in the vertical direction or in the lengthwise direction as viewed in FIG. 1. As viewed from above, the vane portions 44 and 46 do not protrude from the laminated portion 26A. Thus, the inertia plate 43 is disposed as if it surrounds the laminated portion 26A.
The portion of the inertia plate 43 located between the vane portions 44 and 46 is formed integrally with the square portion 50 so that it causes the square portion 50 to become inclined in a direction indicated by the arrowhead C when more than a predetermined amount of horizontal acceleration is exerted in the direction indicated by a arrowhead D in FIG. 1 in a state where the webbing is fastened around the seat occupant. More specifically, in a state where the webbing is fastened around the seat occupant, since the webbing 26 has been drawn out, the diameter of the laminated portion 26A of the webbing is decreased. As a result, a relatively large space is generated between the laminated portion 26A of the webbing 26 and the vane portions 44 and 46, and the square portion 50 can be inclined in the direction indicated by the arrowhead C to occupy this space at the excessive movement more than a predetermined amount of horizontal acceleration in the direction indicated by the arrowhead D.
Next, the operation of the locking mechanism will be described as follows.
FIG. 1 shows a webbing retractor with a webbing accommodated therein. In this state, the pawl 40 is separated from the ratchet wheels 38, and this enables a seat occupant to unwind the webbing 26 from the winding shaft 24 against the urging force of the spiral spring 36 and to put it on.
In a state where the webbing is fastened around the seat occupant, since the webbing 26 has been drawn out from the winding shaft 24, the diameter of the laminated portion 26A of the webbing is decreased. As a result, a relatively large space is generated between the laminated portion 26A of the webbing 26 and the vane portions 44 and 46 of the inertia plate 43, and the square portion 50 can be inclined in the direction indicated by the arrowhead C in FIG. 1 by the inertia plate 43 to occupy this space.
Thus, when the predetermined amount of horizontal acceleration is excessively exerted in the direction indicated by the arrowhead D, e.g., when the running speed of a vehicle rapidly drops, the square portion 50 is inclined by the inertia plate 43 in the direction indicated by the arrowhead C, raising the pawl 40 and thereby bringing it into engagement with the ratchet wheels 38 as shown in FIG. 3, and preventing from rotating the winding shaft 10 in the direction indicated by the arrowhead B in FIG. 1. Thus, the drawing of the webbing 26 is suspended, and movement of the seat occupant is thereby restricted by the webbing 26.
The inertia plate 43 of the locking mechanism 20, in particular, the vane portions 44 and 46 thereof, overlap the laminated portion 26A of the accommodated webbing 26 shown in FIG. 1 in the vertical direction or in the lengthwise direction as shown in FIG. 1, as if they surround the laminated portion 26A of the webbing 26. Consequently, the inertia plate 43 does not downward protrude so much from the laminated portion 26A. Furthermore, since the vane portions 44 and 46 are operated in the space generated when the diameter of the laminated portion 26A is changed, which is caused by the webbing being drawn out by the seat occupant, it is not necessary to provide a large space around the laminated portion 26A of the webbing 26 where the vane portions are operated.
Consequently, the frame 28 of the webbing winding device 22 can be made small in the vertical direction or in the lengthwise direction as viewed in FIGS. 1 and 3 to make the overall size of the webbing winding device 22 in small.
In this embodiment, since the square portion 50 is received by the square hole 56 formed in the supporting block 52 so that it does not rotate around its own axis, rolling of the inertia plate 43 is prevented, thereby preventing the inertia plate from interfering with other components. Further, this structure allows vibrations to be damped effectively.
FIGS. 4 and 5 show a second embodiment of the present invention. In the locking mechanism of the second embodiment, the pawl 40, the operating body 42 and the supporting block 52 are disposed above the laminated portion 26A of the webbing 26, and the operating body 42 has the inertia plate 43 and a supporting rod 62 which acts as an inclined portion, as shown in FIG. 4.
The pawl 40 is bent so that it has substantially an L-shaped form as shown in FIG. 5. The pawl 40 is pivotaly supported on the leg plates 30 and 32 of the frame 28 by means of a pin 60 at the vicinity of the bent portion thereof. This allows the pawl 40 to be engaged with the ratchet wheels 38 when the end portion thereof remote from the portion that faces the ratchet wheels 38 is raised.
One end of the supporting rod 62 is fitted into the portion of the inertia plate 43 located between the vane portions 44 and 46. Below the end portion of the pawl 40 remote from the portion thereof that engages with the ratchet wheels 38, the inertia plate 43 hangs from the supporting block 52 through the supporting rod 62 in such a manner that it surrounds the laminated portion 26A of the webbing 26. The forward ends of the vane portions 44 and 46 overlap the laminated portion 26A of the accommodated webbing 26 shown in FIG. 4 in the vertical portion or in the lengthwise direction as viewed in FIG. 4.
The supporting rod 62 has a square unbrella portion 62A formed at the portion thereof at which it is supported to the supporting block 52. The unbrella portion 62A is inserted by an inserting hole 64 formed in the portion of the pawl 40 which is remote from the portion thereof which is engaged with the ratchet wheels 38. A lug 66 protrudes upward into the inserting hole 64. The lug 66 is in contact with the upper surface of the unbrella portion 62A.
The supporting block 52 has a cylindrical square portion 52A at the portion thereof which faces the unbrella portion 62A of the supporting rod 62. The cylindrical square portion 52A is inserted within the unbrella portion 62A, by which the supporting rod 62 is prevented from being rotated around its own axis.
In consequence, when a predetermined amount of acceleration is excessively exerted in the direction indicated by the arrowhead D in FIG. 4 in the state where the webbing 26 is drawn out and is worn by a seat occupant, the unbrella portion 62A of the supporting rod 62 is inclined by the inertia plate 43 in the direction indicated by the arrowhead C in FIG. 4 to raise the pawl 40 and thereby to bring it into engagement with the ratchet wheels 38.
In this second embodiment, the vane portions 44 and 46 overlap the laminated portion 26A of the accommodated webbing 26 as shown in FIG. 4 in the vertical direction or in the lengthwise direction as viewed in FIG. 4, as described in the first embodiment. In consequence, the frame 28 of the webbing retractor 22 can be made small in the vertical direction or in the lengthwise direction as viewed in FIG. 4, and the overall size of the webbing retractor 22 can thereby be maintained small.
Furthermore, since the cylindrical square portion 52A of the supporting block 52 is inserted into the unbrella portion 62A of the supporting rod 62 so as to prevent the supporting rod 62 from being rotated about it own axis, rolling of the inertia plate 43 can be prevented, thereby preventing it from interfering with other components. Further, the above-described structure enables vibrations to be damped effectively. | A locking mechanism for looking a winding shaft wound a webbing to prevent the winding shaft from rotating at excessive movement more than a predetermined amount of acceleration in a horizontal direction. The locking mechanism has an operating member which is inclined at the excessive movement more than the predetermined amount of acceleration in the horizontal direction to lock the winding shaft. The operating body has a pair of plate-like inertia portions extended symmetrically with respect to the axis of the winding shaft in the direction to approach an outer periphery of the webbing wound around the winding shaft. The operating body is inclined by the inertia portions when the acceleration is exerted. Thus, the locking mechanism locks the winding shaft by means of these inertia portions and the locking mechanism can be made small in the vertical direction. | 1 |
INCORPORATION BY REFERENCE
[0001] The present application claims priority from Japanese application JP 2010-283924 filed on Dec. 21, 2010, the content of which is hereby incorporated by reference into this application.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to an image signal processing apparatus and an image signal processing method.
[0003] As a background technique in the present technical field, for example, JPA-2010-273378 can be mentioned. According to ABSTRACT of JP-A-2010-273378, PROBLEM TO BE SOLVED is to provide an imaging device that can accurately detect a defect even if dark current noise occurs when performing noise reduction, and can prevent as much as possible reduction of an imaging dynamic range caused by increase of dark current noise; and a noise elimination method; and a noise elimination program using the imaging device. According to SOLUTION in ABSTRACT, an imaging device includes: an imaging means including a plurality of pixels for imaging a subject; a bright-state signal acquisition means for acquiring a bright-state signal obtained in a light non-shielding state; a dark-state signal acquisition means for acquiring a dark-state signal obtained in a light-shielding state; a first amplification means for amplifying the obtained bright-state signal or dark-state signal; a subtraction means for subtracting the acquired dark-state signal from the acquired bright-state signal and outputting a subtraction signal; a second amplification means for amplifying the subtraction signal as a result of the subtraction; an imaging condition acquiring means for acquiring an imaging condition when acquiring the bright-state signal; and a gain correcting means for changing gains of the first amplification means and the second amplification means based on the acquired imaging condition.
SUMMARY OF THE INVENTION
[0004] For example, in the typical imaging device such as a digital camera or a digital video camera, an imaging element for conducting photoelectric conversion on incident light is used. In the imaging element, there is the so-called white flaw such as a pixel which is different in output characteristics, or a pixel which outputs an abnormally high level signal. If a signal which is output by the imaging element is used as it is, therefore, a bad influence is exerted upon the picture quality. For attaining a higher picture quality in the digital camera or the digital video camera, means for correcting these flaws are needed.
[0005] Hereafter, typical flaw correcting techniques for correcting such flaws will be described. First, shooting is conducted in a state in which the shutter is closed, and a dark-state image is stored in a memory. Then, ordinary shooting is conducted in a state in which the shutter is opened, and a bright-state image is obtained. Noise reduction is implemented by subtracting the dark-state image from the obtained bright-state image. In this technique, however, correction of a saturated pixel of the bright-state image cannot be conducted accurately. In addition, two images: a dark-state image and a bright-state image must be shot every shooting, and power dissipation increases.
[0006] JP-A-2010-273378 proposes an imaging device which accurately detects a defect even if dark current noise occurs when performing noise reduction, by changing gains for a bright-state signal, a dark-state signal, and a signal obtained by subtracting the dark-state signal from the bright-state signal according to the temperature. If the temperature rises, however, variations of the noise generation quantity and quality due to the gain control are great. As a result, it sometimes becomes insufficient in accurately correcting flaws which increase or decrease according to the temperature change.
[0007] Therefore, an object of the present invention is to provide an image signal processing apparatus and an image signal processing method which accurately corrects flaws which increase or decrease as the temperature changes. For example, an image signal processing apparatus and an image signal processing method which accurately corrects flaws by controlling a threshold for flaw detection according to the temperature are provided. As a result, it is possible to reduce noise. For example, it can be expected to hold down the bit rate at the time of encoding.
[0008] To solve the above problem one of configurations of the claims is adopted.
[0009] According to the present invention, flaws which increase or decrease in the imaging element as the temperature changes can be accurately corrected.
[0010] Problems, configurations and effects other than those described above will be elucidated by ensuing description of embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a diagram for explaining an example of a basic configuration in the present invention;
[0012] FIG. 2 is a diagram for explaining an example of a method for detecting a flaw in a flaw correction unit 102 ;
[0013] FIG. 3 is a diagram showing an example of a flow of flaw correction control in the present embodiment;
[0014] FIG. 4 is a diagram showing an example of a flow of processing for controlling a flaw detection threshold by using temperature information obtained from a temperature measurement unit 105 and a temperature-threshold table which associates thresholds with temperature information at step S 303 ( FIG. 3 );
[0015] FIG. 5 is a diagram showing an example of a flow of processing for controlling exposure time at the time of flaw detection according to temperature information obtained from the temperature measurement unit 105 at step S 304 ( FIG. 3 );
[0016] FIG. 6 is a diagram showing an example of a flow of processing conducted when temperature information obtained from the temperature measurement unit 105 is improper;
[0017] FIG. 7 is a diagram showing an example of a flow of processing for making a decision whether to conduct flaw re-detection according to the number of detected flaws; and
[0018] FIG. 8 is a diagram showing an example of a flow of processing for conducting flaw detection during a time period between start of power supply to an image signal processing apparatus and outputting of a picture.
DETAILED DESCRIPTION OF THE INVENTION
[0019] Hereafter, embodiments of the present invention will be described with reference to the drawings.
[0020] Embodiments of the present invention will be described in detail. FIG. 1 is a diagram for explaining an example of a basic configuration in the present invention. An imaging unit 101 is formed of an iris for adjusting the amount of incident light from a subject, a lens for condensing light passed through the iris, and an imaging element for conducting photoelectric conversion on light condensed by the lens and outputting a resultant signal as an image signal. A flaw correction unit 102 detects flaws contained in the image signal supplied from the imaging unit 101 and corrects them. An image signal correction unit 103 conducts image signal correction processing on an image signal supplied from the flaw correction unit 102 . An image output unit 104 conducts predetermined processing on an image signal supplied from the image signal correction unit 103 . By the way, the predetermined processing is image signal processing such as noise removal, gamma correction, contour emphasis, filter processing, zoom processing, hand shaking correction, and image recognition conducted on the image signal supplied from the image signal correction unit 103 , and output interface processing for conducting conversion to a signal format of an output device such as a TV set or a storage. The output interface processing is, for example, conversion to a video output of the NTSC or PAL, conversion to an HDMI signal, or conversion to a predetermined signal for network transmission. In the present embodiment, the image signal correction unit and the image output unit which conducts the image signal processing are illustrated individually. However, the image signal correction unit may be included in a part of the image output unit. A temperature measurement unit 105 measures a temperature around the imaging element. A system control unit 106 controls the imaging unit 101 , the flaw correction unit 102 , the image signal correction unit 103 , and the image output unit 104 by using information obtained from the temperature measurement unit 107 as occasion demands.
[0021] Owing to the configuration described heretofore, flaws which increase or decrease according to a temperature change can be corrected accurately.
[0022] FIG. 2 is a diagram for explaining an example of a method used by the flaw correction unit 102 to detect a flaw. The abscissa axis represents pixels, and the ordinate axis represents a luminance level of each pixel. In the present embodiment, the flaw correction unit 102 compares the luminance level of each pixel with a flaw detection threshold. If the luminance level is higher than the threshold, then the flaw correction unit 102 judges the pixel to be a defective pixel and detects the pixel as a flaw. According to the present technique, the so-called white flaw can be detected. According to the present technique, detection is possible even if flaws occur consecutively to adjoin each other. Although not illustrated, it is also possible as another means to compare an evaluation value calculated from a luminance level of a noted pixel or peripheral pixels or an evaluation value calculated from luminance levels of both the noted pixel and the peripheral pixels with a threshold, and judge the noted pixel to be a defective pixel when the evaluation value is greater than the threshold, and detect the noted pixel as a flaw. As a result, it is possible to make a decision whether the noted pixels is a flaw by using the relation to adjoining pixels. Even in an image in which the black level is not stabilized and much noise is contained, therefore, desired flaws including white flaws can be detected.
[0023] FIG. 3 is a diagram showing an example of a flow of flaw correction control in the present embodiment. At step S 301 , the temperature measurement unit 105 measures and acquires temperature in the vicinity of the imaging element. At step S 302 , the system control unit 106 sets an AGC. At step S 303 , the system control unit 106 sets a threshold for flaw detection. At step S 304 , the system control unit sets an exposure time. At step S 305 , the flaw correction unit 102 detects a flaw. At step S 306 , the flaw correction unit 102 starts the flaw correction. By the way, the processing between the step S 302 and the step S 304 may be changed in order.
[0024] FIG. 4 is a diagram showing an example of a flow of processing for controlling the flaw detection threshold by using temperature information obtained from the temperature measurement unit 105 and a temperature-threshold table which associates thresholds with temperature information at step S 303 ( FIG. 3 ). For facilitating the flaw detection, the exposure time is set to be long and flaw detection is conducted in a state in which the AGC is applied to some degree. This is because prolonging the exposure time facilitates detection of a pixel which will grow to a prominent flaw when the temperature rises in the future, even in a state in which the temperature in the vicinity of the imaging element is low. If the AGC is changed in a state in which the temperature in the vicinity of the imaging element is high, the change of the picture quality becomes remarkable. Therefore, the AGC is held down to some degree. If the flaw detection processing is started, the system control unit 106 refers to the temperature-threshold table which associates the thresholds with temperature information at step S 401 . As for this table, it is also possible to retain the values in an EEPROM (electrically Erasable Programmable Read-Only Memory) or the like and use it. At step S 402 , the system control unit 106 calculates a threshold on the basis of the table and the temperature information. The system control unit 106 sets the calculated threshold at step S 403 , and finishes the processing. It is possible to prevent the number of detected flaws from becoming large extremely by controlling the threshold according to the temperature. By the way, the threshold may not be calculated on the basis of the temperature-threshold table, but may be calculated on the basis of a function expression and the temperature information. In the case where the function expression is used, it is possible to grasp a relation between the temperature and the proper threshold in detail and retained data can be reduced as compared with the method of retaining data as the table.
[0025] Since the threshold for flaw detection can be controlled according to the temperature in the vicinity of the imaging element, flaws which increase or decrease according to the temperature can be corrected accurately as described heretofore.
[0026] FIG. 5 is a diagram showing an example of a flow of processing for controlling the exposure time at the time of flaw detection according to temperature information obtained from the temperature measurement unit 105 at the step S 304 ( FIG. 3 ). As described above, the exposure time is set to be long in order to facilitate flaw detection. When the temperature rises extremely, however, the number of flaws and sizes of the flaws increase extremely sometimes. In that case, flaw correction causes image degradation sometimes. In order to cope with this problem, in the present embodiment, the exposure time is controlled according to the temperature in the vicinity of the imaging element to prevent the number of detected flaws from becoming extremely large. At step S 501 , the system control unit 106 makes a decision whether the temperature information obtained from the temperature measurement unit 105 is at least the threshold. If the temperature information is at least the threshold, then the system control unit 106 refers to the temperature- exposure time table which associates the thresholds with temperature information at step S 502 . As for the table and the thresholds, it is also possible to retain values in an EEPROM or the like and use it. At step S 503 , the system control unit 106 calculates exposure time on the basis of the table and the temperature information. The system control unit 106 sets the calculated exposure time at step S 504 , and finishes processing. If the temperature of the temperature information is lower than the threshold at the step S 501 , then the system control unit 106 sets an initial value of the exposure time at step S 505 . As a result, the number of flaws and sizes of the flaws can be prevented from increasing extremely when the temperature rises extremely. By the way, the exposure time may not be calculated on the basis of the temperature-exposure time table, but may be calculated on the basis of a function expression and the temperature information. In the case where the function expression is used, it is possible to grasp a relation between the temperature and the proper exposure time in detail and retained data can be reduced as compared with the method of retaining data as the table.
[0027] Even in the case where the temperature rises extremely, flaw correction can be conducted accurately without image degradation.
[0028] FIG. 6 is a diagram showing an example of a flow of processing conducted when temperature information obtained from the temperature measurement unit 105 is improper. For example, when using a temperature measurement unit of a kind which is attached to a lens in a video camera and which measures s a synthetic resistance of a resister of the temperature measurement unit and a resistor on the substrate and acquires temperature information after A/D conversion by using an AD converter in a microcomputer, dispersion occurs in the measured temperature sometimes. Furthermore, an improper value is output due to a failure or a faulty operation sometimes. If in such a case automatic control is conducted on a preset value according to the temperature, then, for example, the number of detected flaws increases abnormally and consequently the flaws cannot be corrected accurately. For avoiding such a problem, in the present embodiment it is inspected whether temperature information obtained from the temperature measurement unit is within an allowable range and a flaw detection condition is controlled according to a result thereof. Processing for controlling the flaw detection threshold according to the result of the inspection will now be described with reference to FIG. 5 . At step S 601 , the system control unit 106 makes a decision whether the temperature information obtained from the temperature measurement unit 105 is in a normal range. It is also possible to retain an upper limit value and a lower limit value of the temperature indicating the normal range in an EEPROM and use them. If the temperature is within the normal range, the system control unit 106 sets an initial value of the flaw detection threshold at step S 602 and finishes processing. If the temperature is not within the normal range, the system control unit 106 refers to a preset value of the threshold for a temperature outside the normal range at step S 603 and sets the obtained value as a flaw detection threshold at step S 604 . It is also possible to retain preset a value of the threshold for each temperature outside the normal range in an EEPROM and use it.
[0029] Even in the case where the temperature measuring unit outputs an improper value due to a failure or a faulty operation, it is possible to prevent the picture quality from being degraded by flaw correction, owing to the processing described heretofore.
[0030] FIG. 7 is a diagram showing an example of a flow of processing for making a decision whether to conduct flaw re-detection according to the number of detected flaws. If an extremely large number of flaws are detected and corrected, an evil such as occurrence of a flaw (noise) in a pixel in which a flaw does not exist originally is caused sometimes. The present embodiment copes with this problem by limiting the number of detected flaws. The number of detected flaws is calculated by the flaw correction unit 102 . At step S 701 , the temperature measurement unit 105 measures and acquires the temperature in the vicinity of the imaging element. At step S 702 , the system control unit 106 sets the AGC. At step S 703 , the system control unit 106 sets a flaw detection threshold. At step S 704 , the system control unit 106 sets an exposure time. At step S 705 , the flaw correction unit 102 conducts the flaw detection. At step S 706 , the system control unit 106 refers to the number of detected flaws calculated by the flaw correction unit 102 and makes a decision whether the number of detected flaws is within an allowable range. If the number of detected flaws is within the allowable range, then the flaw correction unit 102 starts flaw correction at step S 707 , and finishes the processing. If the number of detected flaws is not within the allowable range at the step S 706 , then the processing returns to the step S 702 , and setting of one or more among the AGC, the threshold, and the exposure time is changed and flaw detection is conducted again. It is also possible to retain change quantities of the AGC, the threshold, and the exposure time in an EEPROM and use them. The change quantities may be linked with the number of detected flaws, or may be constants. By the way, the processing between the step S 702 and the step S 704 may be different in order.
[0031] Owing to the processing described heretofore, it is possible to prevent the evil such as occurrence of a flaw (noise) in a pixel in which no flaws exist originally, caused by an extremely large number of detected and corrected flaws.
[0032] FIG. 8 is a diagram showing an example of a flow of processing for conducting flaw detection during a time period between start of power supply to the image signal processing apparatus and outputting of a picture. For detecting a flaw, it is necessary to shield light by, for example, closing the iris. For example, in a video camera, there is little chance of shielding light once the video camera is brought into a recordable state. Therefore, it becomes important to detect as many flaws as possible when the camera is started. In the present embodiment, as many flaws as possible are detected at the time of camera start by closing the iris at the time of camera start and detecting flaws with a prolonged exposure time. At step S 801 , the system control unit 106 sets the AGC, the flaw detection threshold, and the exposure time. At step S 802 , the system control unit 106 instructs the imaging unit 101 to close the iris. At step S 803 , the flaw correction unit 102 conducts the flaw detection. At step S 804 , the system control unit 106 instructs the imaging unit 101 to open the iris. At step S 805 , a picture is output.
[0033] Owing to the processing described hereafter, as many flaws as possible can be detected at the time of camera start. The present invention can provide a video of high picture quality corrected in flaws from immediately after the start of the camera. Furthermore, it is possible to avoid a situation in which light is shielded after the start for the purpose of flaw detection and video recording becomes impossible.
[0034] By the way, the present invention is not restricted to the above-described embodiment, but various modifications are included. For example, the embodiment has been described in detail to explain the present invention intelligibly, and the present invention is not necessarily restricted to an embodiment having all configurations described. Furthermore, it is possible to replace a part of a configuration of a certain embodiment by a configuration of another embodiment, and it is also possible to add a configuration of another embodiment to a configuration of a certain embodiment. Furthermore, it is possible to conduct addition, deletion or replacement of another configuration with respect to a part of a configuration of each embodiment.
[0035] As for each of the above-described configurations, a part or the whole thereof may be formed of hardware or may be implemented by executing a program in a processor. As for control lines and information lines, lines which are considered to be necessary for explanation are shown and all control lines and information lines in the product are not necessarily shown. As a matter of fact, it may be considered that almost all configurations are connected to each other. | An image signal processing apparatus includes an imaging unit having an imaging element to conduct photoelectric conversion on incident light from a subject and output an electric signal, a defective pixel detection unit for detecting a defective pixel in the imaging element, a defective pixel correction unit for correcting the detected defective pixel, an image signal correction unit for conducting image signal correction every arbitrary area on a signal supplied from the defective pixel correction unit, a system control unit for generally controlling those units, and a temperature measurement unit for measuring temperature in the vicinity of the imaging element. The system control unit controls a detection condition to be used when the defective pixel detection unit detects a defective pixel, i.e., one or more of an exposure time, a defective pixel detection threshold, and a gain, by using information of the temperature obtained from the temperature measurement unit. | 7 |
FIELD OF THE INVENTION
The present invention relates generally to data buffers, and more particularly, to reuse of functional data buffers in the memory interface unit for calibrating memory.
DESCRIPTION OF THE RELATED ART
In conventional Dynamic Random Access Memories (DRAMs), data synchronization can be difficult. However, with the introduction of Extreme Date Rate (XDR™) DRAM, which is available from Rambus, Inc., El Camino Real, Los Altos, Calif. 94022, on-chip alignment of data with the clock is possible. An XDR™ DRAM (XDRAM) employs a flexible architecture that allows automatic centering of the data and clock. Having such a dynamic phase alignment system reduces the need for precise Printed Circuit Board (PCB) timing constraints and PCB trace length matching when designing control hardware.
Part of the phase alignment architecture employs initialization hardware that incorporates calibrations. Referring to FIG. 1 of the drawings, the reference numeral 100 generally designates a flow chart depicting a conventional XDRAM calibration.
With such a calibration technique, pattern loads are required so that the dynamic phase alignment can occur by aligning the predetermined outcomes from the loaded patterns. The calibration process begins by calibrating current and impedances of the differential Input/Output (I/O) devices in step 102 . The period of time in which the differential I/O devices are calibrated is referred to as the ICAL-ZCAL period. Once the differential I/O devices have been calibrated, the serial and pattern loads occur in step 104 . The external XDRAMs are serially loaded and the memory controller is loaded with the pattern. Based on the loaded serial data and patterns loaded, calibration for the receive data (RX_CAL) occurs in step 106 . Then, calibration for transmit data (TX_CAL) occurs in step 108 .
However, XDRAMs, as with many other DRAMs and semiconductor devices, strive to conserve area with a high degree of flexability. Specifically, pattern buffer space for calibrations can occupy a great deal of silicon. Therefore, there is a need for a method and/or apparatus that makes XDRAM calibrations more efficient, requiring less area that addresses at least some of the problems associated with conventional XDRAM calibrations.
SUMMARY OF THE INVENTION
The present invention provides a method, an apparatus, and a computer program for effecting calibration of Random Access Memories (RAMs) with data patterns and commands. At least one store queue to provide the data and the commands is established. Then, the queues are revalidated to permit storing of flexible addresses and data into a pattern buffer whereby the flexible addresses and data are reusable for differing iterations and phases of the calibration.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of the present invention and the advantages thereof, reference is now made to the following descriptions taken in conjunction with the accompanying drawings, in which:
FIG. 1 is a flow chart depicting a conventional XDRAM calibration;
FIG. 2A is a block diagram depicting a modified XDRAM memory unit;
FIG. 2B is a block diagram depicting an XIO Controller of the modified XDRAM memory unit;
FIG. 3 is a block diagram depicting front end circuitry for switching writes to reads;
FIG. 4 is a flow chart depicting the operation the front end circuitry; and
FIG. 5 is a flow chart depicting operations of the modified XDR™ Input/Output Unit (XIO).
DETAILED DESCRIPTION
In the following discussion, numerous specific details are set forth to provide a thorough understanding of the present invention. However, those skilled in the art will appreciate that the present invention may be practiced without such specific details. In other instances, well-known elements have been illustrated in schematic or block diagram form in order not to obscure the present invention in unnecessary detail. Additionally, for the most part, details concerning network communications, electromagnetic signaling techniques, and the like, have been omitted inasmuch as such details are not considered necessary to obtain a complete understanding of the present invention, and are considered to be within the understanding of persons of ordinary skill in the relevant art.
It is further noted that, unless indicated otherwise, all functions described herein may be performed in either hardware or software, or some combinations thereof. In a preferred embodiment, however, the functions are performed by a processor such as a computer or an electronic data processor in accordance with code such as computer program code, software, and/or integrated circuits that are coded to perform such functions, unless indicated otherwise.
Referring to FIG. 2A of the drawings, the reference numeral 200 generally designates a modified XDRAM memory unit. The memory unit 200 comprises a chip 202 and XDRAMs 204 . Commands are transmitted from the chip 202 to the XDRAMs 204 through a unidirectional bus 220 . Serial data is transmitted from the chip 202 to the XDRAMs 204 through a bi-directional serial link 224 . Data, however, is intercommunicated between the chip and the XDRAMs 204 through a bidirectional bus 222 .
Specifically, components on the chip 202 communicate with one another and with the XDRAMs 204 in order for the memory to function. The chip 202 comprises a memory interface unit 206 and an XIO 208 . The XIO 208 performs communication between the chip 202 and the XDRAMs 204 , which include the commands, data, and serial data. The memory interface unit 206 , however, transmits commands to the XIO 208 through a unidirectional bus 216 , while data is transmitted between the XIO 208 and the memory interface unit 206 through two unidirectional buses 218 .
The difference between the memory unit 200 and more conventional memory units lies in the memory interface unit. The memory control unit comprises address and holding control 210 , an XIO controller 212 , and dataflow pattern buffers 214 . More particularly, buffers are utilized in calibrations for both reads and writes, but in the modified memory an entire class of buffers specifically designated for either reads or writes is eliminated. The memory interface unit 206 instead utilizes the store path for all phases of operation. In normal operation, the memory interface unit 206 has the data and addresses for 32 cache lines (each having 128 bytes) or a total of 4096 bytes.
In conventional memories, calibrations occur in three distinct phases. During the first phase, data loading occurs with two functions in mind. The first function being a loading of pattern data into the conventional memory interface unit (not shown). The second function is to have the memory control unit (not shown) send commands to XDRAMs, such as the XDRAMs 204 , to serially load the XDRAMs, such as the XDRAMs 204 , with data and then send writes to commit the data to memory. This calibration data can occupy some or all of the 32 cache lines.
During the second and third phase, receive and transmit calibrations are performed. Receive calibration is performed during the second phase where the memory control unit (not shown) sources the read commands and provides expected data to calibrate the XIO (not shown). Transmit calibrations occur during the third phase where the memory control unit (not shown) stores the data and then provides read commands with expected data.
In contrast, the modified memory 200 reorders the sequences. The memory control unit 206 reorders the sequence so that serially loaded data is loaded first so that the data is committed to the XDRAMs by single writes. The modified memory 206 sends the serial patterns to the XDRAMs 204 and uses the command buses 216 and 220 .to commit the data to the cores of the XDRAMs 204 . These commands are normal stores with an addressing width of the XDRAMs. Once all of the data has been stored in the XDRAMs, stores, containing addresses and pattern data, are loaded and kept in a waiting pattern in anticipation of a receive calibration. The store addresses and datum are contained by the address and holding control 210 and the dataflow pattern buffer 214 , respectively.
Then, within the second phase, receive calibrations can occur. When the XIO 208 wants to perform a receive iteration, XIO controller 212 turns stores into reads with expects. Hence, each store becomes a read. The new reads will launch the expected data to the XIO 208 at the correct time. The process by the XIO controller 212 of changing stores into read and launching the new reads will continue for the 32 cache lines. Then, the XIO 208 will start the process again until the calibration is complete.
Once the receive calibration is complete, phase three can be initiated to perform transmit calibrations. The XIO 208 informs the XIO controller 212 to perform a transmit calibration sequence. The XIO controller 212 takes store addresses from the address control 210 and launches the store data from the dataflow pattern buffer 214 . Once all of the pattern cache lines are stored, the XIO controller 212 informs the control 210 to send the address again and changes the store addresses into reads with expects. The data from the XDRAMs 204 is compared with the data from the dataflow pattern buffer 214 . This is repeated as many times as necessary until the calibration is complete.
To perform the changes to the command from store to read, additional logic is employed. Referring to FIG. 2B of the drawings the reference numeral 212 generally designates the XIO controller. The XIO controller 212 comprises front end circuitry 252 , command addressing logic 254 , a write path 256 , a read path 258 , XIO command generation logic 260 , and initialization logic 262 .
Operation of the XIO controller is initiated with information provided to the front end circuitry 252 . The front end circuitry 252 receives information from the address and holding control 210 of FIG. 2A through the communication channel 264 . Then, the front end circuitry 252 can change write commands into read commands and provide control signals to other components. Specifically, the front end circuitry 252 provides control information to the write path 256 , the read path 258 , the command addressing logic 254 , and the generation logic 260 through the communication channels 266 , 270 , 276 , and 274 , respectively.
Each of the remaining components of the XIO controller 212 , then, can perform a specific function during normal operations. The command addressing logic provides information to the XIO 208 of FIG. 2A through the communication channel 278 . The initialization logic 262 receives pattern enable and type signals and sends pattern marker signal to the XIO 208 of FIG. 2A through the communication channel 282 . The write path 256 and the read path 258 provide store and read controls to the dataflow pattern buffer 214 of FIG. 2A through the communication channels 284 and 286 . Additionally, the generation logic 260 provides control information to the write path 256 and the read path 258 through the communication channels 268 and 272 , respectively.
In cases, however, where reads with expects are utilized, the remaining components have a slightly different functionality. The write path 256 starts a write-data-out of the dataflow pattern buffer 214 of FIG. 2A using timing parameters for expected data. The read path 258 stores away the information but does not use it functionally. The generation logic 260 is initially told to perform a read by the front end circuitry 252 ; however, a change signal from the front end circuitry 252 informs the generation logic 260 to initiate a write at the correct time for expected data.
The functionality of the front end circuitry 252 then becomes significant in the operation of the XIO controller 212 . Referring to FIG. 3 of the drawings, the reference numeral 300 generally designates front end circuitry for switching writes to reads. The circuitry 300 is contained within the XIO controller 212 of FIG. 2B and comprises a state machine 302 , eight latches 306 , 312 , 316 , 318 , 320 , 324 , 334 , and 336 , five AND gates 304 , 310 , 314 , 330 , and 332 , and four operation modules 308 , 322 , 326 , and 328 .
The state machine 302 is a main component within the logic 300 that assists generating the proper signal. The state machine 302 outputs a control signal to the operation module 308 through the communication channel 344 . Based on the control signal, the operation module 308 can enable a read operation or a write operation. If the operation is a write operation, then a signal is output to the AND gate 304 through the communication channel 340 . Additionally, a signal is output from the state machine 302 to the AND gate 304 through the communication channel 338 . Once engaged, the AND gate 304 outputs a signal to the latch 306 through the communication channel 339 . The latch 306 can then provide a Data Location Valid signal through the communication channel 342 to start write data operations. However, if the operation is a read with expects operation, then a signal is communicated from the operation module 308 to the AND gate 310 through the communication channel 346 . The state machine 302 also transmits a signal to the AND gate 310 through the communication channel 348 . A change-write-to-read signal is also communicated to the AND gate 310 through the communication channel 350 . Based on the AND gate 310 inputs, the AND gate 310 can output a signal to the latch 312 through the communication channel 352 . The latch 312 , then, provides a Data Location Valid for Read with expects signal through the communication 354 .
In addition to providing control for data location valid signals, the state machine 302 also relays taken commands. A command taken is output from the state machine 302 through the communication channel 341 . The AND gate 314 receives the command taken signal in addition to another signal received through the communication channel 358 . A latch 316 then receives the AND gate signal through the communication channel 356 to latch the command taken to inform the Address and Control 210 that the command has been taken. Bank sequencer latches 318 also receive the command taken signal to start an operation or series of operations.
In order for the state machine 302 to function, however, indications of commands are relayed to the state machine 302 . The latch 320 receives control data for the type of operation from the Address control 210 of FIG. 2A through the communication channel 372 . The latch 320 , then, relays the control data to the operation module 322 , which is a write-to-read module, through the communication channel 370 . Based on the input signals, the operation module 322 output control signals to the state machine 302 , bank sequencing latches 324 , a command counter (not shown), and two operations modules 326 and 328 through the communication channel 368 .
Based on the control signal from the operation module 322 , write or read operations can be started. If the operation module 322 indicates read operations, then the read module 328 outputs a signal through the communication channel 366 to the AND gate 332 . The AND gate 332 also receives a command taken signal from the communication channel 341 . The AND gate 332 then can relay a signal to the latch 336 , through communication channel 360 , to provide read First-In-First-Out (FIFO) control.
On the other hand, if the operation module 322 indicates write operations, different logic is employed. Indications of write operations are transmitted to the write module 326 through the communication channel 368 . Based on the indication, the write module 326 transmits a control signal to the AND gate 330 through the communication channel 364 . The AND gate 330 also receives a command taken through the communication channel 341 . A signal is then relayed from the AND gate 330 to the latch 334 through the communication channel 362 . The latch 334 reflects a write start operation.
Referring to FIG. 4 of the drawings, the reference numeral 400 generally designates a simplified operation of the front end circuitry 300 of FIG. 3 .
At the onset of operation, a determination is made as to the operation to be performed in step 402 . Specifically, there are three types of operations that can be performed: write operations, read operations, and reads with expects. Each of the respective operations has a different procedure.
For write operations, specific components, paths, and procedures are employed. In step 404 , write operations from the address holding control 210 of FIG. 2A are utilized. Normal write parameters are employed in step 406 , and normal write commands are sent in step 408 .
For read operations, other components, paths, and procedures are employed. In step 410 , read operations from the address holding control 210 of FIG. 2A are utilized. Normal read parameters are employed in step 412 , and normal read commands are sent in step 414 .
For reads with expects, a combination of components, paths, and procedures from write and read operations are employed. In step 416 , reads with expects from the address holding control 210 of FIG. 2A are utilized. In step 418 , write operations from the address holding control 210 of FIG. 2A are utilized. Write with expects parameters are employed in step 420 , and normal read commands are send in step 414 .
Referring to FIG. 5 of the drawings, the reference numeral 500 generally designates the operation of the XIO controller 212 of FIG. 2 . The XIO controller 212 begins in an idle state in step 502 . A determination is then made as to whether a receive calibration or transmission calibration is to occur in step 504 .
In the case of a receive calibration, the state machine 302 waits in steps for 506 and 508 for proper timing from the XIO 208 before proceeding. Once all timing parameters are met the store data is converted into read with expect data and sent to the XIO 208 . Once ready, write-to-read signals are propagated in step 510 , where data is read from the XDRAMs 204 . The pattern enable signal in steps 520 and 524 transitions to logic low to indicate completion of the calibration loop. When the calibration is complete, deferred refreshes are performed in step 522 , and the XIO controller 212 returns to idle in step 502 .
When a transmit calibration is to be performed, no store data is converted. There is a wait period in step 512 , so that all XDRAM parameters are met. Once the calibration is ready, in step 514 , data is written to the XDRAMs 204 in step 516 . Next, write-to-read signals are propagated in step 518 , where data is read from the XDRAMs 204 and compared against data from dataflow pattern buffer 214 . The pattern enable signal in steps 520 and 524 transitions to logic low to indicate completion of the calibration loop. When the calibration is complete, deferred refreshes are performed in step 522 , and the XIO 212 returns to idle in step 502 .
It is understood that the present invention can take many forms and embodiments. Accordingly, several variations may be made in the foregoing without departing from the spirit or the scope of the invention. The capabilities outlined herein allow for the possibility of a variety of programming models. This disclosure should not be read as preferring any particular programming model, but is instead directed to the underlying mechanisms on which these programming models can be built.
Having thus described the present invention by reference to certain of its preferred embodiments, it is noted that the embodiments disclosed are illustrative rather than limiting in nature and that a wide range of variations, modifications, changes, and substitutions are contemplated in the foregoing disclosure and, in some instances, some features of the present invention may be employed without a corresponding use of the other features. Many such variations and modifications may be considered desirable by those skilled in the art based upon a review of the foregoing description of preferred embodiments. Accordingly, it is appropriate that the appended claims be construed broadly and in a manner consistent with the scope of the invention. | A method, an apparatus, and a computer program are provided to reuse functional data buffers. With Extreme Data Rate (XDR™) Dynamic Random Access Memory (DRAM), test patterns are employed to dynamically calibrate data with the clock. To perform this task, data buffers are employed to store data and commands for the calibration patterns. However, there are different procedures and requirements for transmission and reception calibrations. Hence, to reduce the amount of hardware needed to perform transmission and reception calibrations, the data buffers employ additional front end circuitry to reuse the buffers for both tasks. | 6 |
FIELD AND BACKGROUND OF THE INVENTION
The present invention relates in general to circular weaving machines and, in particular, to a new and useful shedding device for such machines. The device of the invention utilizes a cam follower support which has cam means engaged in a rotating cam groove. The cam groove lies in a horizontal plane and, with its rotation, causes horizontal alternating movement of the cam follower support. Control rods are connected between the cam follower support and cranks. The cranks have arms which are connected to adjacent pairs of shedding rods of the circular weaving machine so that rotation of the cam groove causes reciprocal up and down movement of the shedding rods.
Circular weaving machines are different from other types of knitting machines which utilize hook needles to knit a fabric. Other knitting machines use a large number of hook needles which move alternately in a line. A circular weaving machine weaves a fabric utilizing horizontal yarns which are used in conjunction with the vertical yarns that are caused to make a shedding motion through which the vertical yarns pass. In other words, the horizontal yarns pass through loops of the vertical yarns when the vertical yarns are shed. The vertical yarns are shed by the motion of shedding rods. The vertical motion of the shedding rods is the same as the vertical motion needed for the vertical yarns.
In conventional circular weaving machines, the shedding rods each have a yarn guide (not shown) which guides a length of vertical yarn. The shedding rods are distributed in a circular path around the machine. Tappet rods are engaged with the shedding rods for moving the shedding rods up and down and, in turn, moving the lengths of yarn up and down. Several difficulties, however, have been discovered in such conventional circular weaving machines.
In a conventional circular weaving machine, a cam is provided with annular grooves. Each of the grooves receives a cam follower. The cam follower is located at one end of a lever arm. Each lever arm is pivotally mounted at a bearing post. Opposite ends of lever arms are connected to sliding guides or attachments 106 that are mounted on respective shedding rods. Cam is rotated by a motor and transmission means, to transmit an undulating path of cam grooves to the cam followers. This causes lever arms to pivot on bearing posts and transmit up and down movement to the shedding rods.
A shuttle for the horizontal yarns weaves the vertical yarns into a circular fabric which is drawn off the top of a circular weaving machine. Since a lever arm is provided for each of the shedding rods, the diameter of the circular fabric is limited by the number of shedding rods which can be distributed in a circle around the fabric in the machine. The capacity of the conventional circular weaving machine is thus limited by the fact that an equal number of lever arms and shedding arms must be used. The number of arms and rods can only be increased with difficulty. The lever arms move with a pivotal action and must be made sufficiently strong. They must also be made longer when larger circular fabrics are to be woven. The lever arms must be made strong to avoid fatigue and fractures in the material.
It is according difficult to enlarge the diameter of a circular fabric to be woven by a conventional circular weaving machine.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a shedding device for a circular weaving machine which utilizes a grooved cam that rotates in a periodic motion to drive a cam follower support in a horizontal direction, the horizontal movement being transferred to the vertical movement of shedding rods through a control rod and crank arrangement.
According to the invention, fewer connecting structures are necessary between the cam and the shedding rods. The connection is also simpler so that the circular weaving machine can be modified for weaving larger and smaller diameter fabrics.
A further object of the invention is to provide a shedding device for moving the shedding rods of a circular weaving machine having a rest base on which the shedding rods are mounted for vertical movement, and which comprises a cam mounted for rotation about a vertical axis and having a cam path lying in a horizontal plane. A cam follower support rides in the cam path and carries a pair of control rods extending outwardly from the cam. A cantilever arm is rotably mounted on the rest base and pivotally connected to the cam follower support for holding the cam follower support in a selected rotational position with respect to the cam. The cantilever arm also follows the horizontal movement of the cam follower support.
Cranks are pivotally mounted to the rest base and have arms connected to outer ends of the control rods. Each crank, in turn, has a pair of arms connected to a pair of shedding rods. The two control rods thus control the reciprocating vertical movement of four shedding rods.
A further object of the present invention is to provide shedding device for moving shedding rods of a circular weaving machine which is simple in design, rugged in construction and economical to manufacture.
The aforementioned objects and other objects of the present invention will become apparent with reference to the following description taken in conjunction with the attached drawings wherein similar reference numerals are utilized to designate the same or similar elements.
BRIEF DESCRIPTION OF THE DRAWINGS
In the accompanying drawings, forming a part of this specification, and in which reference numerals shown in the drawings designate like or corresponding parts throughout the same,
FIG. 1 is a side elevational view, partly in section, of a circular weaving machine embodying the invention; and
FIG. 2 is a top perspective view of the improved shedding device of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 2, the shedding device of the present invention is shown on an enlarged scale and in simplified form. The shedding device comprises a drive shaft 2 mounted for rotation about a vertical axis. A motor (not shown) is connected to shaft 2 for rotating the shaft in the direction of the curved arrow. A cam 1 is fixed to shaft 2 and defines a groove or cam path 6 which lies in a substantially horizontal plane. A motion curve of cam path 6 is designed for the shedding timing of vertical yarns in the circular weaving machine. Cam path 6 is designed to be large enough to accommodate an appropriate number of a cam follower support 9, one of which is shown in FIG. 2. Cam follower support 9 has a substantially rectangular block shape with two circular sides. A pair of cam follower shafts 4, 4' extend through the support 9. Each follower shaft 4, 4' is fixed to the support by set screws 81 and 81'. Shafts 4 and 4' are provided near the opposite rounded sides of the rectangular block shape for support 9. Support 9 also includes a rectangular opening on its outer surface which receives the outer free end of a cantilever arm 8. Cantilever arm 8, which has a rectangular cross section and a curved beam from, is pivotally mounted to a rest base of the machine at a pivot bolt 7. Cantilever arm 8 can thus rock in a horizontal plane responsive to the movements of support 9. For this purpose, the outer free end of arm 8 is pivotally mounted to support 9 by a pivot bolt 3. Pivot bolt 3 is positioned at a rocking center for support 9. Since support 9 is fixed with respect to the rotating cam 1, arm 8 holds the support 9 in a correct angular or rotational position with respect to the cam.
Upper rollers 10 and 11 are connected respectively to follower shafts 4 and 4'. Additional follower shafts are fixed to support 10 which carry follower rollers 10' an 11'. The rollers 10, 10' 11 and 11' are distributed at the ends of support 9 so that they roll against inner surface 13 and outer surface 14 of cam path 6. In this way cam follower support 9 accurately follows the changing position of cam groove 6 as cam 1 rotates.
A cantilever arm 8 is provided for each support 9 and an appropriate number of supports 9 are utilized to activate the shedding rods as will be described hereafter.
A main object of the present invention is to improve the shedding device for fabrics having large diameter. When cam 1 and its cam path or groove 6 rotate, follower support 9 slides and cantilevers in appropriate movements which depend on the shape of the groove 6.
The inner and outer surfaces 13, 14 of cam groove or path 6 are selected to induce the correct motion of the upper and lower rollers 10, 10'. The movement of support 9 is also influenced by the swinging cantilever beam 8 and the other upper and lower rollers 11, 11'. The rollers can advantageously be made of hard steel to avoid wearing. Cam 1 can also be made of such steel. The correct shaping of cam path 6 produces the correct periodic curvilinear motion which is necessary for timing the movements of the vertical yarns through the shedding rods.
As cam 1 rotates in the clockwise direction, as shown in FIG. 2, a rocking curvilinear motion is imparted on support 9. This motion is applied to control rods 15 and 15' which are connected to sleeves through threaded connectors 5 and 5' respectively. The sleeves are engaged around upper ends of the follower shafts 4 and 4'. Control rods 15 an 15' are connected by threaded connectors 20 and 20' to the first crank arms 21 and 21' of a pair of cranks which are pivotally mounted at pin connections 28 to the rest bases 22, 22'.
Each of the cranks have a pair of second crank arms 19, 19'. The crank arms 19 of the crank connected to rod 15 have pivot pins 18, 23 which are respectively connected to connecting links 17, 24. In a similar manner, arm 19' of the crank connected to control rod 15' are pivotally connected to links 17' and 24'.
Clamps 12 and 16 are fixedly connected to two shedding rods 30, 29, respectively, which are mounted for sliding up and down movement to a portion of the rest base at 26, 27. A pair of adjacent rods 29', 30' carry clamps 16', 12' respectively.
Links 17, 17' and 24, 24' are respectively connected to clamps 16, 12 and 16', 12'.
Each of the pivot connections has an appropriate coupling to avoid loosening. As cam follower support 9 pivots and rocks in a horizontal plane due to the rotation of cam 1, control rods 15, 15' move horizontally to pivot the cranks which in turn move shedding rods upwardly and downwardly with correct timing for shedding vertical yarns of the circular weaving machine. In this way, a single support 9 can control four shedding rods. This saves substantial space and permits the use of a larger number of shedding rods and thus the weaving of a larger circular fabric.
Support 9 rotates about bolt 3 which acts as its center of rotation. Bolt 3 also moves horizontally toward and away from the shedding rods which produces a pushing and pulling action the control rods 15, 15'. The pushing and pulling of control rods 15, 15' causes rotation of the cranks which in turn causes vertical pivotal movement of the links 17, 17', 24, 24'.
The shedding device of the present invention has many advantages.
For example, when cam 1 rotates, the amount of friction generated between cam paths 6 and the follower means in the form of roller 10, 11, 10', 11' is not exceedingly high. The impact load on the follower means is also satisfactory and the mechanism of power transmission is very smooth without interferring. The circular weaving machine can thus operate for long period of time without readjustment or repair.
The cam 101 of a convention circular weaving machine rotates in order to transmit power to the shedding rods which move in an up and down motion. The friction and impact load of the prior art cam is not satisfactory and the machine cannot operate for long periods of time as with the invention.
In addition, control rods 15, 15' move in a reciprocating horizontal direction. The lever arms 103 of a conventional circular weaving machine as shown in FIG. 1 must transmit power directly to the shedding rods. The lever arms must also be long. For this reason they must be made strong and large to withstand the bending forces applied to them. The control rods 15, 15' can be made smaller and less strong since they are only subjected to tensions and compression and to bending forces. The fact that they move in a horizontal plane also saves vertical space which is not the case with the pivotally mounted lever arms 103.
By using cranks and connecting links in the vicinity of the shedding rods, relatively little motion is necessary for the cam follower support 9 as it is moved by the cam path 6. Even with this small amount of horizontal movement, satisfactroy vertical lifting and dropping of the shedding rods is possible.
Also, a single cam follower support 9 can service a pair of control rods 15, 15' which, in turn, can service four shedding rods 29, 30, 29', 30'. This permits the weaving of large diameter fabrics because a large number of shedding arms can be serviced by a relatively small number of follower supports.
The connecting mechanism between the cam and the shedding rods in the conventional circular weaving machine of FIG. 1 requires a single lever arm 103 for each shedding rod 104. It is not, therefore, easy to enlarge the number of shedding rods since the amount of space around cam 101 is limited and cannot accommodate an overly large amount of lever arms 103. There are also limits on the length of the lever arms since if they become too long their structure must be so large that it will not be readily accommodated within the circular weaving machine. Accordingly, the diameter of fabric which can be woven by conventional circular weaving machines is limited to relatively small diameter fabrics.
While a specific embodiment of the invention has been shown and described in detail to illustrate the application of the principals of the invention, it will be understood that the invention may be embodied otherwise without departing from such principals. | A shedding device for moving the shedding rods of a circular weaving machine includes a drive shaft which rotates a cam. The cam has a cam groove which lies in a horizontal plane and receives a plurality of cam follower supports. The supports are pivotally mounted near their center to a cantilever arm which is rotatably mounted about a vertical axis at a location spaced from the drive shaft. The cantilever arms hold the supports at correct angular positions with respect to the cam paths. Vertical swinging and pivoting of the follower supports are transmitted through horizontally moving control rods through cranks which convert the horizontal movement to vertical movement. Clamps are connected to the shedding rods and links connect the clamps to the cranks. A single follower can service a pair of connecting rods which in turn service a pair of shedding rods to save space around the cam. | 3 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] The present application claims the benefit under 35 U.S.C. § 119(e) to U.S. Provisional Patent Application No. 60/696,203 (“the '203 application”), which was filed on Jun. 30, 2005 and entitled “Lock Lever Mounting Bracket For Headrails on Coverings for Architectural Openings.” The '203 application is incorporated by reference into the present application in its entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates generally to systems for mounting a headrail for a covering for an architectural opening and more specifically to a mounting bracket having a lever lock for securing the headrail to the mounting bracket.
[0004] 2. Description of the Relevant Art
[0005] Coverings for architectural openings such as windows, doors, archways and the like typically include a retractable panel of material supported by a headrail. The coverings are typically movable between extended positions wherein the panel of material extends across the architectural opening and a retracted position where the panel of material is either wrapped or gathered within or immediately adjacent to the headrail. The headrail further includes control systems for moving the covering between extended and retracted positions and in the case of *Venetian blinds for tilting the slats of the blind between open and closed positions.
[0006] Headrails are provided in various forms and configurations dictated partly by aesthetics and partly by function. In any circumstance, mounting brackets are provided that can be secured to a frame around the architectural opening and utilized to support the headrail.
[0007] In most instances, the mounting brackets have some form of a release mechanism so that the headrail is releasably secured to the mounting bracket whereby when in use it is reliably secure to prevent an inadvertent removal but can be released and removed for cleaning purposes or the like.
[0008] Systems for releasably securing a headrail to mounting brackets have taken numerous forms including brackets with detents, depressible release arms, snap-on fingers or the like and efforts are continuing for devising more reliable and easy to operate systems.
SUMMARY OF THE INVENTION
[0009] The present invention embodies a system for releasably mounting a headrail for a covering for an architectural opening to mounting brackets in a reliable, efficient, and easy to operate manner. The headrail and mounting brackets are complementary in that the headrail can be temporarily snapped onto the mounting brackets and then firmly locked in a mounted position with a readily accessible lever arm.
[0010] The mounting bracket has a depressible catch arm that is automatically depressed by a ledge on the headrail as the headrail is advanced to a predetermined position relative to the mounting bracket at which point the catch arm snaps into a temporarily secured position. A lever arm on the bracket can then be manually pivoted to a lock position to activate a slide-lock bar that prevents the catch arm from again being depressed thereby securely locking the headrail to the mounting bracket to prevent an inadvertent removal of the headrail. The lever arm of course can be moved to a release position to permit depression of the catch arm by applying reasonable manual force to the headrail.
[0011] Other aspects, features, and details of the present invention can be more completely understood by reference to the following detailed description of a preferred embodiment, taken in conjunction with the drawings and from the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is an isometric of a headrail for a covering for an architectural opening mounted on the mounting brackets of the present invention with lock levers in a locked position.
[0013] FIG. 2 is an exploded isometric similar to FIG. 1 with the lock levers in a release position.
[0014] FIG. 3 is an enlarged section taken along line 3 - 3 of FIG. 1 .
[0015] FIG. 4 is a section similar to FIG. 3 with the lock lever in a release position.
[0016] FIG. 5 is an enlarged fragmentary view taken along line 5 - 5 of FIG. 3 .
[0017] FIG. 6 is an enlarged fragmentary view taken along line 6 - 6 of FIG. 4 .
[0018] FIG. 7 is a section taken along line 7 - 7 of FIG. 5 .
[0019] FIG. 8 is an enlarged fragmentary section taken along line 8 - 8 of FIG. 7 .
[0020] FIG. 9 is a section similar to FIG. 7 with the slide-lock bar in a release position.
[0021] FIG. 10 is a section similar to FIG. 9 with the headrail positioned relative to the mounting bracket as it would be immediately before a temporary connection.
[0022] FIG. 11 is a section similar to FIG. 10 with the headrail removed from the mounting bracket.
[0023] FIG. 12 is an isometric looking downwardly on the mounting bracket.
[0024] FIG. 13 is an isometric looking upwardly at the bottom of the mounting bracket of FIG. 12 .
[0025] FIG. 14 is a left end elevation of the bracket as shown in FIG. 15 .
[0026] FIG. 15 is a top plan view of the mounting bracket.
[0027] FIG. 16 is a side elevation of the mounting bracket.
[0028] FIG. 17 is an enlarged section taken along line 17 - 17 of FIG. 15 .
[0029] FIG. 18 is an enlarged section taken along line 18 - 18 of FIG. 15 .
[0030] FIG. 19 is an isometric looking downwardly on the slide-lock bar of the mounting bracket.
[0031] FIG. 20 is an isometric looking upwardly at the bottom of the slide-lock bar of FIG. 19 .
[0032] FIG. 21 is an end elevation of the slide-lock bar as shown in FIG. 22 .
[0033] FIG. 22 is a top plan view of the slide-lock bar.
[0034] FIG. 23 is a side elevation of the slide-lock bar.
[0035] FIG. 24 is a bottom plan view of the slide-lock bar.
[0036] FIG. 25 is an isometric of the lock lever of the mounting bracket.
[0037] FIG. 26 is a top plan view of the lock lever.
[0038] FIG. 27 is a side elevation of the lock lever.
[0039] FIG. 28 is a top plan view of the lock lever.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0040] With reference first to FIGS. 1 and 2 , a pair of mounting brackets 30 in accordance with the present invention are seen with a headrail 32 for a covering for an architectural opening (not shown). While the frame for the architectural opening to which the brackets 30 can be mounted is not illustrated, the connection will be fully appreciated with the description of a bracket hereafter.
[0041] Before describing a bracket 30 in detail, it is best to understand the structure of the headrail 32 adapted for mounting on the bracket and the headrail is probably best illustrated in FIG. 11 . The headrail can be seen to have a generally flat front wall 34 with an arcuate lower edge 36 and a relatively flat top wall 38 projecting rearwardly from the top edge of the front wall. The top wall has a depressed ledge 40 along its rearwardmost edge defining a bevel surface 42 and a rib spacer 44 projecting downwardly at an intermediate location between the front wall 34 and the ledge 40 . The headrail is typically extruded so that all of its features extend the full length of the headrail. At a predetermined spacing below the top wall, a support arm 46 extends rearwardly from the front wall of the headrail with the support arm having a lip 48 along its rearwardmost edge. The lip 48 , ledge 40 , and rib spacer 44 all cooperate in defining a pocket 50 in which a portion of the mounting bracket can be inserted.
[0042] In FIGS. 3 and 4 , the headrail 32 is shown connected to a mounting bracket 30 of the present invention with FIG. 4 showing the mounting bracket in a release position and FIG. 3 in a locking position. Further, a roller 52 which might be found in a headrail of a roll-up shade is illustrated positioned within the headrail and beneath the mounting bracket for illustrative purposes only. The mounting bracket is probably best seen in FIGS. 12-18 . The bracket is made of a somewhat rigid plastic material having some flexibility depending upon the thickness of the plastic for purposes which will become apparent with the description hereafter.
[0043] The bracket 30 can be seen to have a horizontal base 54 , a downturned back wall 56 off the rear edge of the base, and upper 58 and lower 60 horizontal flanges extending rearwardly from the back wall. The upper flange, the back wall, and the base all have openings 62 therethrough as possibly best seen in FIGS. 12 , 13 , 14 , and 18 through which fasteners (not shown) can extend to secure the bracket to the frame around an architectural opening. The openings 62 are provided in both vertical and horizontal surfaces of the bracket so the bracket can be mounted to a vertical or horizontal surface of the frame depending upon the type of mounting desired for the covering.
[0044] The base 54 has a relatively thick rear portion 64 with a flat upper surface 66 and a slide plate 68 projecting forwardly from the rear portion along a lower edge thereof. The slide plate has a pair of support arms 70 along opposite sides and an integral lead bar 72 connecting the support arms along the forwardmost edge of the slide plate so as to define a rectangular opening 74 therebetween. The opening has a spring catch arm 76 positioned therein with the catch arm having a relatively thin portion 78 integrally connected with and extending forwardly from the relatively thick rear portion 64 of the base in a living hinge and a bevel head 80 at the forwardmost end of the thin portion. The bevel head has front 82 and rear 84 upwardly directed bevel surfaces for purposes to be described hereafter.
[0045] The thin portion 78 is adapted to flex slightly at the living hinge so that the bevel head 80 can be depressed within the rectangular opening 74 in the slide plate 68 . The thin portion of the catch arm itself has a rectangular slot 86 formed therein for a purpose to be described hereafter. A pair of overhanging lips 88 project forwardly from the relatively thick rear portion 64 of the base in spaced overlying relationship with a rear portion of the slide plate 68 . The overhanging lips define a space therebetween that is continuous with a shallow groove 90 formed in the flat upper surface 66 of the rear portion 64 of the base. A vertical hole 92 is provided in the shallow groove for receipt of a removable pivot pin 94 having an enlarged head as seen in FIGS. 7 and 9 - 11 . The pivot pin pivotally secures a lock lever 96 to the base as will be described later.
[0046] As possibly best seen in FIG. 13 , the rectangular opening 74 in the slide plate 68 in which the spring catch arm 76 is positioned is continuous with a relatively narrow recessed channel 98 in the bottom of the relatively thick rear portion 64 of the base, which in turn is continuous with a slot-like opening 100 through the rear portion. As possibly best appreciated by reference to FIGS. 8 and 13 , a pair of support shoulders 102 extend along the sides of the slot-like opening 100 in the base along the bottom thereof.
[0047] A slide-lock bar 104 shown in detail in FIGS. 8 and 19 - 24 is slidably positioned within the opening 74 in the slide plate, the continuous recessed channel 98 and slot-like opening 100 in the rear portion of the base. The slide-lock bar slidably underlies the spring catch arm 76 . Referencing FIGS. 19-24 , the slide-lock bar can be seen to have a flat paddle head 106 with a beveled leading edge 108 , a guide block 110 extending upwardly from a rear portion of the paddle head and a slide arm 112 extending rearwardly from the paddle head. The slide arm has a raised block 114 at approximately its longitudinal center with the raised block having a cylindrical guide pin 116 projecting upwardly. The underside of the slide arm has an elongated centered tongue 118 formed integrally thereon ( FIG. 20 ) which projects downwardly a small amount from the remainder of the slide arm. The tongue is also relatively narrow so as to define support edges 120 along opposite sides of the slide arm which are adapted to ride upon the support shoulders 102 .
[0048] As probably best seen in FIGS. 7-13 , the slide-lock bar 104 is positioned in the base 54 so that the support edges 120 on the underside of the slide-lock bar are supported on the support shoulders 102 for sliding movement and the paddle head 106 is disposed within the rectangular opening 74 in the slide plate 68 immediately beneath the spring catch arm 76 . The guide block 110 on the paddle head projects into the rectangular slot 86 formed in the spring catch arm to assist in guiding sliding movement of the slide-lock bar. The slide-lock bar is also made of a relatively thin plastic so it too has some flexibility along its length. It should be noted that when the spring catch arm is depressed downwardly, it engages the top surface of the paddle head of the slide-lock bar also depressing the paddle head downwardly due to their uniform flexibility.
[0049] The lock lever 122 , which is used to engage and disengage the locking mechanism in the bracket, is seen in detail in FIGS. 25-28 . It can there be seen to have an elongated relatively flat body 124 with a diagonal gripping rib 126 at one end, a semicircular opposite end 128 , a circular passage 130 extending vertically through the body at a location relatively close to the opposite end and an arcuate push-pull slot 132 extending vertically through the flat body between the circular opening and the opposite end of the flat body from the gripping rib. The push-pull slot while being arcuate extends at approximately a 45 degree angle relative to the length of the lever arm for a purpose to be described hereafter.
[0050] The lock lever 122 is secured to the base 54 by positioning the gripping rib 126 at a location beyond the slide plate 68 of the base with the opposite end 128 of the lock lever being positioned within the shallow groove 90 provided in the top surface of the base. The circular passage 130 through the lock lever is aligned with the hole 92 in the shallow groove in the base and the pivot pin 94 is inserted into the hole to pivotally connect the lock lever to the base. It should be appreciated the width of the lock lever body 124 is less than the width of the shallow groove so the lock lever is free to pivot within limits about the pivot pin. A notch 134 is provided in a side of the flat body 124 to accommodate the adjacent overhanging lip 88 when the lock lever is in the locking position of FIG. 3 . With the lock lever attached to the base as described, the guide pin 116 on the slide-lock bar 104 extends into the push-pull slot 132 of the lock lever. As will be appreciated by pivoting the lock lever about the pivot pin, the push-pull slot forces the guide pin to move linearly along the length of the bracket so that the slide-lock bar can be moved reciprocally forwardly and rearwardly along the length of the bracket with pivotal movement of the lock lever.
[0051] As will be appreciated with the description later, when the lock lever 122 is aligned with the base as in FIG. 4 , the slide-lock bar 104 is fully retracted toward the rear of the bracket 30 whereas when the lock lever is pivoted into the position shown in FIG. 3 , the push-pull slot 132 advances the guide pin 116 pulling the slide-lock bar forwardly relative to the base 54 . This movement of the slide-lock bar is probably best appreciated by reference to FIGS. 5 and 6 . The lock lever has arcuately spaced detents 136 in its opposite end 128 that releasably receives vertical beads 138 formed in the adjacent arcuate wall 140 of the shallow groove 90 . The detents and beads assist in retaining the lock lever in either a locking or release position to be described in more detail hereafter.
[0052] Looking next at FIG. 11 , the mounting bracket 30 is shown positioned to receive the headrail 32 with FIG. 10 showing the headrail having been advanced partially onto the mounting bracket so that the lead bar 72 of the slide plate 68 is inserted into the pocket 50 in the headrail between the rib spacer 44 and the support arm 46 . It should be noted in the position of FIG. 10 , the front bevel 82 on the bevel head 80 has engaged and passed by the rear ledge 40 of the top wall 38 . The engagement of the front bevel with the rear ledge cams the bevel head downwardly into the position of FIG. 10 . In FIG. 9 , the headrail is shown fully advanced onto the bracket in a neutral position where it will be appreciated the bevel head is positioned immediately in front of the bevel 42 on the rear ledge 40 of the top wall of the headrail. The rear bevel surface 84 on the catch arm 76 is engaged with the bevel 42 on the top wall of the headrail so that the headrail is temporarily but releasably secured to the bracket. As will be appreciated, if the headrail were to be pulled forwardly from the position illustrated in FIG. 9 , the beveled engagement of the bevel 42 on the top wall with the rear bevel 84 on the catch arm would cam the catch arm downwardly as seen in FIG. 10 which would allow the headrail to be released from the bracket with a predetermined amount of force. As mentioned previously, the catch arm can be depressed from the position of FIG. 9 even though the slide-lock bar 104 is positioned therebeneath because both elements are somewhat flexible.
[0053] With the headrail 32 temporarily connected to the mounting bracket 30 as shown in FIG. 9 , however, the lock lever 122 can be pivoted into the position of FIG. 3 , which as mentioned previously, causes the slide lock bar 104 to move forwardly relative to the base 54 and as seen in FIG. 7 , this extreme forward limited movement of the slide-lock bar causes the paddle head 106 to overlie the lip 48 on the support arm 46 of the headrail which prevents the slide-lock bar and the overlying catch arm 76 from being pivoted downwardly. As will be appreciated, if the catch arm cannot pivot downwardly, the headrail is prevented from removal from the mounting bracket due to the engagement of the bevel surfaces 42 and 84 .
[0054] Obviously, to remove the headrail 32 from the support bracket 30 , the lock lever 122 is simply pivoted into alignment with the base 54 as shown in FIG. 4 causing the slide-lock bar 104 to be retracted further into the base so that the paddle head 106 no longer overlies the lip 48 of the support arm 46 whereby upon an outward pull on the headrail, the beveled engagement of the surfaces 42 and 84 will cause the catch arm 76 to pivot downwardly with the slide-lock bar as in FIG. 10 permitting removal of the headrail from the support bracket.
[0055] As mentioned previously, the transverse profile of the headrail 32 , as illustrated in the drawings, is continuous along the length of the headrail so that any number of support brackets 30 can be positioned for receipt of the headrail. Each support bracket would be operated similarly to remove the headrail from the support bracket or to permit its mounting. It should also be appreciated the gripping rib 126 on the lock lever protrudes forwardly from the front wall 34 of the headrail 32 a sufficient distance to allow an operator to grip the lock lever and move it between locking and release positions. Further, the lock lever can be made of a clear plastic material so as to be less visible for aesthetic purposes.
[0056] Although the present invention has been described with a certain degree of particularity, it is understood the present disclosure has been made by way of example and changes in detail or structure may be made without departing from the spirit of the invention as defined in the appended claims. | A mounting bracket for a covering for architectural openings such as windows, doors, archways, and the like, includes complementary components on the headrail and the mounting bracket to permit the mounting bracket to be inserted into the headrail and a lock lever is provided with access forwardly of the headrail to lock the headrail in position on the mounting bracket or condition the mounting bracket for release of the headrail from a temporarily secured relationship. | 8 |
TECHNICAL FIELD
[0001] The present invention relates to a power router and a control method thereof, a computer readable medium, and a power network system.
BACKGROUND ART
[0002] For building a power supply system, it is a significant challenge to expand a power transmission network more stably and, moreover, configure a system capable of introducing a large amount of natural energy.
[0003] As a novel power network, a power network system called a digital grid (registered trademark) has been proposed (PTL 1 and PTL 2).
[0004] The digital grid (registered trademark) is a power network system in which a power network is divided into small-scale cells and the cells are asynchronously connected to one another. Each power cell which is small has a scale including one house, building, or commercial facility. Each power cell which is large has a scale including a prefecture, a city, a town, and a village. Each power cell includes a load and, in some cases, a power-generating facility and a power storing facility. An example of the power-generating facility is a power-generating facility using natural energy such as solar power generation, wind power generation, and geothermal power generation.
[0005] In order to allow free generation of power in each of the power cells and smooth interchange of power among the power cells, the power cells are asynchronously connected to one another. That is, even when a plurality of power cells are connected to one another, the voltage, phase, frequency of power used in each power cell are not synchronized with those of another power cell.
[0006] FIG. 20 is a diagram illustrating an example of a power network system 810 . In FIG. 20 , a utility grid 811 transmits base power from a large-scale power plant 812 . A plurality of power cells 821 to 824 are arranged. Each of the power cells 821 to 824 has loads such as a house 831 and a building 832 , power generating facilities (for example, a solar power panel 833 and a wind power generator 834 ), and a power storing facility (for example, a storage battery 835 ).
[0007] In addition, in the present specification, the power generating facilities and the power storing facilities will be also collectively called a “distributed power supply”.
[0008] Moreover, the power cells 821 to 824 have power routers 841 to 844 , respectively, as connection ports to be connected to the other power cells or the utility grid 811 . Each of the power routers 841 to 844 has a plurality of legs (The reference numerals of the legs are omitted in FIG. 20 because of limited space. Blank circles attached to the power routers 841 to 844 are to be understood as connection terminals of the legs.).
[0009] The legs have a connection terminal and a power conversion unit, and an address is assigned to each of the legs. Power conversion by a leg includes conversion from an alternating current to a direct current or from a direct current to an alternating current, and a change in the voltage, frequency, and phase of power.
[0010] All the power routers 841 to 844 are connected to a management server 850 via a communication network 860 and are controlled integrally by the management server 850 . For example, the management server 850 instructs the power routers 841 to 844 to transmit or receive power by the legs. By the operation, power interchange is performed among the power cells via the power routers 841 to 844 .
[0011] By realizing power interchange among the power cells, for example, one power generating facility (for example, the solar power panel 833 or the wind power generator 834 ) and one power storing facility (for example, the storage battery 835 ) can be commonly used by a plurality of power cells. When surplus power is interchanged among the power cells, while largely reducing the cost of the facilities, the power demand and supply balance can be stably maintained.
CITATION LIST
Patent Literature
[0012] PTL 1: Japanese Patent Publication No. 4783453
[0013] PTL 2: Japanese Patent Application Laid-open Publication No. 2011-182641
SUMMARY OF INVENTION
Technical Problem
[0014] Asynchronous connection of a plurality of cells through power routers, if realized, would offer great advantages, and strong expectations are placed on an early practical implementation of power routers.
[0015] However, putting power routers into practical use involves particular problems which are not associated with previous power transmission/distribution facilities. While a main power transmission/distribution facility at the present time is based on a power system in which voltage, phase, and frequency are completely synchronized, it is necessary to address new problems relating to power routers that interconnect power systems with different voltages, phases, and frequencies.
[0016] When designated power is transmitted and received among power routers, a reception-side power router may not receive power which corresponds to a target value for the power transmission received by a transmission-side power router. For example, depending on transmission loss of a transmission line, conversion efficiency, voltage and phase differences and the like, a value smaller (or larger) than the target value may be received in the reception-side power router.
[0017] An object of the present invention is to more appropriately manage power routers in building a power network system in which power cells are asynchronously connected to one another.
Solution to Problem
[0018] A power router according to the one aspect of the present invention includes:
[0019] a plurality of master legs;
[0020] one or more legs other than the master legs; and
[0021] a control unit that controls power transmitted/received by each of the plurality of master legs based on power transmitted/received by the one or more legs other than the master legs.
[0022] A power network system according to the one aspect of the present invention includes:
[0023] a power router; and
[0024] a management server that controls power transmission and reception of the power router,
[0025] wherein the power router includes:
[0026] a plurality of master legs;
[0027] one or more legs other than the master legs; and
[0028] a control unit that controls power transmitted/received by each of the plurality of master legs based on power transmitted/received by the one or more legs other than the master legs, in response to an instruction from the management server.
[0029] A control method of a power router according to the one aspect of the present invention includes:
[0030] referring to power transmitted/received by one or more legs other than a master leg; and
[0031] controlling power transmitted/received by each of a plurality of master legs based on the power transmitted/received by the one or more legs other than the master leg.
[0032] A non-transitory computer readable medium storing a control program of a power router according to the one aspect of the present invention, the program causing a computer to perform:
[0033] a process of referring to power transmitted/received by one or more legs other than a master leg; and
[0034] a process of controlling power transmitted/received by each of a plurality of master legs based on the power transmitted/received by the one or more legs other than the master leg.
Advantageous Effects of Invention
[0035] According to the present invention, it is possible to more appropriately manage or control power routers in building a power network system in which power cells are asynchronously connected to one another.
BRIEF DESCRIPTION OF DRAWINGS
[0036] FIG. 1 is a block diagram illustrating a schematic configuration of a power network system 1000 according to an exemplary embodiment 1.
[0037] FIG. 2 is a block diagram of a power router 101 , which illustrates an example of an internal structure of a leg.
[0038] FIG. 3 is a block diagram of a power router 101 , which illustrates an internal structure of a leg in more detail.
[0039] FIG. 4 is a block diagram illustrating a configuration example of a power router 170 having an AC through leg 60 .
[0040] FIG. 5 is a block diagram schematically illustrating a relation between a configuration of a control unit 19 and a leg.
[0041] FIG. 6 is a diagram illustrating an example that a power router is connected to a utility grid, a load, and various distributed supplies.
[0042] FIG. 7A is a diagram illustrating an example of a possible combination in a connection of power routers.
[0043] FIG. 7B is a diagram illustrating an example of a possible combination in a connection of power routers.
[0044] FIG. 8A is a diagram illustrating an example of a prohibited combination in a connection of power routers.
[0045] FIG. 8B is a diagram illustrating an example of a prohibited combination in a connection of power routers.
[0046] FIG. 8C is a diagram illustrating an example of a prohibited combination in a connection of power routers.
[0047] FIG. 8D is a diagram illustrating an example of a prohibited combination in a connection of power routers.
[0048] FIG. 9A is a diagram illustrating an example of a possible combination in a connection of power routers in consideration of an AC through leg.
[0049] FIG. 9B is a diagram illustrating an example of a possible combination in a connection of power routers in consideration of an AC through leg.
[0050] FIG. 9C is a diagram illustrating an example of a possible combination in a connection of power routers in consideration of an AC through leg.
[0051] FIG. 9D is a diagram illustrating an example of a possible combination in a connection of power routers in consideration of an AC through leg.
[0052] FIG. 10 is a diagram illustrating an example that a distance between a first power router 100 and a utility grid 1035 is long.
[0053] FIG. 11 is a table of combination patterns in a connection of power routers.
[0054] FIG. 12 illustrates an example of an interconnection of four power routers.
[0055] FIG. 13 is a block diagram illustrating a schematic configuration of a power network system 1000 , which illustrates a configuration of a management server 1010 .
[0056] FIG. 14 is a block diagram schematically illustrating a configuration of a power router 600 according to an exemplary embodiment 1.
[0057] FIG. 15 is a diagram illustrating a power router 600 when power received in a first stand-alone leg 63 is 2 kW (W 1 =2 kW) and power received in a second stand-alone leg 64 is 1 kW (W 2 =1 kW).
[0058] FIG. 16 is a diagram illustrating a power router 600 when power received in a first stand-alone leg 63 is 1 kW (W 1 =1 kW) and power received in a second stand-alone leg 64 is 1 kW (W 2 =1 kW).
[0059] FIG. 17 is a diagram illustrating a power router 600 when power received in a first stand-alone leg 63 is 2 kW (W 1 =−2 kW) and power received in a second stand-alone leg 64 is 1 kW (W 2 =−1 kW).
[0060] FIG. 18 is a diagram illustrating a power router 600 when power received in a first stand-alone leg 63 is 1 kW (W 1 =1 kW) and power received in a second stand-alone leg 64 is 1 kW (W 2 =−1 kW).
[0061] FIG. 19 is a block diagram schematically illustrating a configuration of a power router 700 according to an exemplary embodiment 2.
[0062] FIG. 20 is a diagram illustrating an example of a power network system 810 .
DESCRIPTION OF EMBODIMENTS
[0063] Hereinafter, exemplary embodiments of the present invention will be described in detail with reference to the drawings. In the drawings, the same reference numerals are given to the same elements and repetitive description, if not necessary, will be omitted.
Exemplary Embodiment 1
[0064] A power network system 1000 according to an exemplary embodiment 1 will be described. FIG. 1 is a block diagram illustrating a schematic configuration of the power network system 1000 according to the exemplary embodiment 1. The power network system 1000 has a management server 1010 and a plurality of power routers. In the present exemplary embodiment, an example in which the power network system 1000 having the management server 1010 , power routers 101 and 102 , and a transmission line 1200 will be described. The power routers 101 and 102 are specific examples of the above-described power routers 841 to 844 (see FIG. 23 ). Hereinafter, the management server is also called a management means.
[0065] The power network system 1000 and a power network system to be described in the following exemplary embodiment have a configuration for correcting power transmission loss between power routers by power control. In general, when power is transmitted via a transmission line, transmission loss occurs due to the length of a transmission path and the difference of a path. Therefore, even when a power transmission side transmits predetermined power, power received in a power reception side is lower than the output power of the power transmission side. Thus, the power network system 1000 and the power network system to be described in the following exemplary embodiment have a function of controlling the output power of the power transmission side such that power received in the power reception side reaches an appropriate value.
[0066] The power router 101 has, roughly, a DC bus 15 , a communication bus 16 , a first leg 11 , a second leg 12 , a third leg 13 , a fourth leg 14 , and a control unit 19 . In the drawing, because of limited space, the first leg to the fourth leg are indicated by a leg 1 to a leg 4 , respectively. The first leg 11 , the second leg 12 , the third leg 13 , and the fourth leg 14 are connected to the outside via terminals 115 , 125 , 135 , and 145 , respectively.
[0067] To the DC bus 15 , the first leg 11 to the fourth leg 14 are connected in parallel. The DC bus 15 is for passing DC power. The control unit 19 controls the operation states (such as an operation of transmitting power to the outside, an operation of receiving power from the outside, or the like) of the first leg 11 to the fourth leg 14 via the communication bus 16 , thereby maintaining the bus voltage V 15 of the DC bus 15 to a predetermined value. That is, the power router 101 is connected to the outside via the first leg 11 to the fourth leg 14 , but converts all of power to be outputted/inputted to/from the outside to a direct current and transmits the current to the DC bus 15 . Conversion to the direct current thus allows asynchronous connections among power cells that are different in frequency, voltage, and phase.
[0068] The configuration of the power router 101 will be described in detail. FIG. 2 is a block diagram of the power router 101 , which illustrates an example of an internal structure of the leg. The first leg 11 to the fourth leg 14 have a similar configuration, but, for the simplification of the drawing, FIG. 2 illustrates the internal structures of the first leg 11 and the second leg 12 and does not illustrate the internal structures of the third leg 13 and the fourth leg 14 .
[0069] The first leg 11 to the fourth leg 14 are connected in parallel to the DC bus 15 . As described above, the first leg 11 to the fourth leg 14 have a similar configuration. In the present exemplary embodiment, an example in which the power router 101 having four legs will be described; however, this is for illustrative purposes only. A power router may have any number of legs more than one. In the present exemplary embodiment, the first leg 11 to the fourth leg 14 have a similar configuration, but two or more legs included in a power router may have a similar configuration or have different configurations. Hereinafter, the leg is called a power conversion leg.
[0070] As illustrated in FIG. 2 , the first leg 11 has a power conversion unit 111 , a current sensor 112 , a switch 113 , and a voltage sensor 114 . The first leg 11 is connected to a transmission line 1200 via a connection terminal 115 . The power conversion unit 111 converts AC power to DC power or converts DC power to AC power. Since DC power flows in the DC bus 15 , the power conversion unit 111 converts the DC power of the DC bus 15 to AC power of predetermined frequency and voltage and passes the AC power to the outside from the connection terminal 115 . Alternatively, the power conversion unit 111 converts AC power flowing in from the connection terminal 115 to DC power and passes the DC power to the DC bus 15 .
[0071] The configuration of the leg will be described in detail. FIG. 3 is a block diagram of the power router 101 , which illustrates the internal structure of the leg in more detail. The first leg 11 to the fourth leg 14 have a similar configuration, but, for the simplification of the drawing, FIG. 3 illustrates the internal structure of the first leg 11 and does not illustrate the internal structure of the second leg 12 , nor include the third leg 13 , the fourth leg 14 , or a communication bus 16 .
[0072] The power converter 111 has the configuration of an inverter circuit. Concretely, as illustrated in FIG. 3 , the power converter 111 has transistors Q 1 to Q 6 and diodes D 1 to D 6 . One end of each of the transistors Q 1 to Q 3 is connected to a high-potential-side power supply line. The other ends of the transistors Q 1 to Q 3 are connected to one ends of the transistors Q 4 to Q 6 , respectively. The other ends of the transistors Q 4 to Q 6 are connected to a low-potential-side power supply line. To the high-potential-side terminals of the transistors Q 1 to Q 6 , the cathodes of the diodes D 1 to D 6 are connected, respectively. To the low-potential-side terminals of the transistors Q 1 to Q 6 , the anodes of the diodes D 1 to D 6 are connected.
[0073] From the node between the transistors Q 1 and Q 4 , the node between the transistors Q 2 and Q 5 , and the node between the transistors Q 3 and Q 6 , for example, by properly controlling the on/off timings of the transistors Q 1 to Q 6 , phases of three-phase alternating current are outputted.
[0074] As described above, the power conversion unit 111 has a configuration in which six antiparallel circuits configured by transistors and diodes are three-phase-bridge connected. A wire is led from the node between the transistors Q 1 and Q 4 , a wire is led from the node between the transistors Q 2 and Q 5 , and a wire is led from the node between the transistors Q 3 and Q 6 , and these wires connecting the nodes and connection terminals are called branch lines BL. Since three-phase AC is used, one leg has three branch lines BL.
[0075] Since three-phase AC is used, a three-phase inverter circuit is employed here. In some cases, a single-phase inverter circuit may be used. As the transistors Q 1 to Q 6 , various self-commutated power conversion elements such as MOSFET (Metal-Oxide-Semiconductor Field-Effect Transistors) or IGBT (Insulated Gate Bipolar Transistor) can be used.
[0076] The switch 113 is disposed between the power conversion unit 111 and the connection terminal 115 . By switching of the switch 113 , the branch lines BL are switched. By the operation, the connection between the outside and the DC bus 101 are interrupted or established. The detection values of the current sensor 112 and the voltage sensor 114 are outputted to the control unit 19 via the communication bus 16 .
[0077] In the above description, it is assumed that the power conversion unit uses an inverter circuit and the other side of the connection of a leg uses an alternating current. However, there is also a case where the other side of the connection of a leg uses a direct current like a storage battery (for example, the third leg 13 in FIG. 1 is connected to a storage battery 1032 ). The power conversion in this case is DC-DC conversion.
[0078] Accordingly, an inverter circuit and a converter circuit may be provided in parallel to the power conversion unit and the inverter circuit and the converter circuit may be properly used according to AC or DC being used by the other side of the connection. Alternatively, the power conversion unit may be provided with a leg dedicated for DC-DC conversion as a DC-DC conversion unit.
[0079] From the viewpoint of size and cost, a power router having a leg dedicated for AC-DC conversion and a leg dedicated for DC-DC conversion is more advantageous than a power router in which an inverter circuit and a converter circuit are provided in parallel in each of all of the legs.
[0080] The second leg 12 has a power conversion unit 121 , a current sensor 122 , a switch 123 , and a voltage sensor 124 . The second leg 12 is connected, for example, to a load 1031 via a connection terminal 125 . The power conversion unit 121 , the current sensor 122 , the switch 123 , and the voltage sensor 124 of the second leg 12 correspond to the power conversion unit 111 , the current sensor 112 , the switch 113 , and the voltage sensor 114 of the first leg 11 , respectively. The connection terminal 125 connected to the second leg 12 corresponds to the connection terminal 115 connected to the first leg 11 . The power conversion unit 121 has a configuration in which an antiparallel circuit 121 P configured with a thyristor 121 T and a feedback diode 121 D is three-phase-bridge connected. The thyristor 121 T, the feedback diode 121 D, and the antiparallel circuit 121 P correspond to a thyristor 111 T, a feedback diode 111 D, and an antiparallel circuit 111 P, respectively.
[0081] The third leg 13 has a power conversion unit 131 , a current sensor 132 , a switch 133 , and a voltage sensor 134 . The third leg 13 is connected, for example, to the storage battery 1032 via a connection terminal 135 . The power conversion unit 131 , the current sensor 132 , the switch 133 , and the voltage sensor 134 of the third leg 13 correspond to the power conversion unit 111 , the current sensor 112 , the switch 113 , and the voltage sensor 114 of the first leg 11 , respectively. The connection terminal 135 connected to the third leg 13 corresponds to the connection terminal 115 connected to the first leg 11 . The power conversion unit 131 has a configuration in which an antiparallel circuit 131 P configured with a thyristor 131 T and a feedback diode 131 D is three-phase-bridge connected. The thyristor 131 T, the feedback diode 131 D, and the antiparallel circuit 131 P correspond to the thyristor 111 T, the feedback diode 111 D, and the antiparallel circuit 111 P, respectively. For the simplification of the drawing, FIG. 2 does not illustrate the internal structure of the third leg 13 .
[0082] The fourth leg 14 has a power conversion unit 141 , a current sensor 142 , a switch 143 , and a voltage sensor 144 . The fourth leg 14 is connected, for example, to a utility grid 1035 via a connection terminal 145 . The power conversion unit 141 , the current sensor 142 , the switch 143 , and the voltage sensor 144 of the fourth leg 14 correspond to the power conversion unit 111 , the current sensor 112 , the switch 113 , and the voltage sensor 114 of the first leg 11 , respectively. The connection terminal 145 connected to the fourth leg 14 corresponds to the connection terminal 115 connected to the first leg 11 . The power conversion unit 141 has a configuration in which an antiparallel circuit 141 P configured with a thyristor 141 T and a feedback diode 141 D is three-phase-bridge connected. The thyristor 141 T, the feedback diode 141 D, and the antiparallel circuit 141 P correspond to the thyristor 111 T, the feedback diode 111 D, and the antiparallel circuit 111 P, respectively. For the simplification of the drawing, FIG. 2 does not illustrate the internal structure of the fourth leg 14 .
[0083] The control unit 19 receives a control instruction 51 from the external management server 1010 via a communication network 1100 . The control instruction 51 includes information for instructing an operation of each leg of the power router 101 . Furthermore, the control unit 19 can output information 52 indicating an operation situation of the power router 101 to the management server 1010 via the communication network 1100 . In addition, the operation instruction to each leg includes, for example, designation of power transmission/power reception, designation of an operation mode, designation of power to be transmitted or received, or the like. More specifically, the control unit 19 monitors a bus voltage V 15 of the DC bus 15 via a voltage sensor 17 and controls the direction of power, the frequency of AC power, or the like. That is, the control unit 19 controls switching of the transistors Q 1 to Q 6 and switching of the switches 113 , 123 , 133 , and 143 via the communication bus 16 .
[0084] In the above description, the legs are described as having a power conversion unit; however, it is also possible to provide a leg with no power conversion unit. Hereinafter, a leg with no power conversion unit is provisionally called an AC (Alternating Current) through leg 60 . FIG. 4 is a block diagram illustrating a configuration example of a power router 170 having the AC through leg 60 . The power router 170 is described as having a configuration in which the AC through leg 60 is added to the power router 101 . For simplification of the drawing, FIG. 4 does not illustrate the third leg 13 .
[0085] The AC through leg 60 has a current sensor 162 , a switch 163 , and a voltage sensor 164 . The AC through leg 60 is connected, for example, to another power cell via a connection terminal 165 . A branch line BL of the AC through leg 60 is connected to a branch line BL of another leg having a power conversion unit via the switch 163 . That is, the connection terminal 165 , to which the AC through leg 60 is connected, is connected to a connection terminal to which another leg having a power conversion unit is connected. For example, FIG. 4 illustrates the case where the connection terminal 165 , to which the AC through leg 60 is connected, is connected to the connection terminal 145 to which the fourth leg 14 is connected. Only the switch 163 is provided between the connection terminal 165 of the AC through leg 60 and the connection terminal 145 to which the fourth leg 14 is connected, so that the AC through leg 60 has no power conversion unit. Therefore, power is conducted without being subjected to any conversion between the connection terminal 165 to which the AC through leg 60 is connected and the connection terminal 145 to which the fourth leg 14 is connected. Therefore, a leg having no power conversion unit is called an AC through leg.
[0086] FIG. 5 is a block diagram schematically illustrating a relation between a configuration of the control unit 19 and the leg. FIG. 5 illustrates the case where the control unit 19 controls the first leg 11 . The control unit 19 has a storage unit 191 , an operation mode management unit 192 , a power conversion instruction unit 193 , a DA/AD conversion unit 194 , and a sensor value reading unit 195 .
[0087] The storage unit 191 holds the control instruction 51 from the management server 1010 as a control instruction database 196 (a first database indicated by #1DB in the drawing). In addition to the control instruction database 196 , the storage unit 191 holds a leg identification information database 197 (a second database indicated by #2DB in the drawing) for identifying each of the first leg 11 to the fourth leg 14 . The storage unit 191 can be realized, for example, by various storage units such as a flash memory. The leg identification information database 197 is information, such as an IP address, URL, and URI, assigned in order to specify each of the first leg 11 to the fourth leg 14 . Furthermore, on the basis of information INF from the operation mode management unit 192 , the storage unit 191 holds the information 52 indicating the operation situation of the power router 101 and outputs the information 52 indicating the operation situation of the power router 101 to the outside as necessary.
[0088] The operation mode management unit 192 is configured, for example, by CPU. The operation mode management unit 192 reads operation mode designation information MODE which is included in the control instruction database 196 and designates an operation mode (which will be described later) of a leg (the first leg 11 ) to be stopped. Furthermore, the operation mode management unit 192 reads information (for example, an IP address) corresponding to the leg (the first leg 11 ) to be stopped by referring to the leg identification information database 197 of the storage unit 191 . By the operation, the operation mode management unit 192 can output a start instruction for the leg (the first leg 11 ) to be stopped. The operation mode management unit 192 outputs a waveform instruction signal SD 1 which is a digital signal. Furthermore, the operation mode management unit outputs a switching control signal SIG 1 to a switch (for example, the switch 113 ) of the leg to be stopped.
[0089] The waveform instruction signal SD 1 is subjected to digital-to-analog conversion in the DA/AD conversion unit 194 and is outputted to the power conversion instruction unit 193 as a waveform instruction signal SA 1 which is an analog signal. The power conversion instruction unit 193 outputs a control signal SCON to a power conversion unit (for example, the power conversion unit 111 ) in response to the waveform instruction signal SA 1 .
[0090] The sensor value reading unit 195 reads a value of the bus voltage V 15 detected by the voltage sensor 17 , a detection value Ir of the current sensor 112 of the leg (the first leg 11 ) to be stopped, and a detection value Vr of the voltage sensor 114 . The sensor value reading unit 195 outputs a reading result as a reading signal SA 2 which is an analog signal. The reading signal SA 2 is subjected to analog-to-digital conversion in the DA/AD conversion unit 194 and is outputted to the operation mode management unit 192 as a reading signal SD 2 which is a digital signal. On the basis of the reading signal SD 2 which is a digital signal, the operation mode management unit 192 outputs the information INF indicating the operation situation of a leg to the storage unit 191 .
[0091] Next, an operation mode of the legs of the power router 101 will be described. In the present exemplary embodiment, the operation mode designation of each leg is included in the control instruction 51 .
[0092] Firstly, the operation mode will be described. It has been already described that the first leg 11 to the fourth leg 14 have the power conversion units 111 , 121 , 131 , and 141 , respectively, and the switching operation of the transistors in the power conversion units is controlled by the control unit 19 .
[0093] The power router 101 is a node in the power network system 1000 and has an important role of connecting the utility grid 1035 , the load 1031 , a distributed power supply, a power cell, or the like. The connection terminals 115 , 125 , 135 , and 145 of the first leg 11 to the fourth leg 14 are connected to the utility grid 1035 , the load 1031 , the distributed power supply, and power routers of other power cells, respectively. The inventors have noticed that since the roles of the first leg 11 to the fourth leg 14 vary according to the other side of connections, if the first leg 11 to the fourth leg 14 do not perform proper operations according to the roles, the power routers do not work. By the inventors, the structures of legs are the same but the way of operating the legs is changed according to the other side of the connection.
[0094] The way of operating the legs is called an “operation mode”.
[0095] By the inventors, three kinds are prepared as operation modes of a leg, and the mode is switched according to the other side of the connection.
[0096] As the operation modes of the leg, there are a master mode, a stand-alone mode, and a designated power transmission/reception mode.
[0097] Hereinafter, the modes will be described in order.
[0098] (Master Mode)
[0099] The master mode (Mastar) is an operation mode in the case where a leg is connected to a stable power supply source such as a grid, and an operation mode for maintaining the voltage of the DC bus 15 . In the master mode, a leg is connected to a stable AC power supply source and an AC bus voltage is maintained, or a leg is connected to a stable DC power supply source and a DC bus voltage is maintained. FIG. 1 illustrates an example that the connection terminal 145 of the fourth leg 14 is connected to the utility grid 1035 . In the case of FIG. 1 , the fourth leg 14 is controlled so as to operate in the master mode and plays the role of maintaining the bus voltage V 15 of the DC bus 15 . Since the other first leg 11 to third leg 13 , are connected to the DC bus 15 , power may flow in from the first leg 11 to the third leg 13 to the DC bus 15 , or power may flow out to the first leg 11 to the third leg 13 . In the case where the bus voltage V 15 of the DC bus 15 drops from a rated voltage due to the outflow of power from the DC bus 15 , the fourth leg 14 in the master mode makes up for the amount of power which has become insufficient due to the outflow, with power from the other side of the connection (in this case, the utility grid 1035 ). In the case where the bus voltage V 15 of the DC bus 15 rises from the rated voltage due to inflow of power to the DC bus 15 , the amount of power which has become excessive due to the inflow is passed on to the other side of the connection (in this case, the utility grid 1035 ). By such an operation, the fourth leg 14 in the master mode maintains the bus voltage V 15 of the DC bus 15 .
[0100] Consequently, in one power router, at least one leg has to be operated in the master mode. Otherwise, the bus voltage V 15 of the DC bus 15 is not maintained constant. Although two or more legs may be operated in the master mode in one power router, it is advantageous that the number of legs in the master mode in one power router is one.
[0101] A leg in the master mode may be connected to, other than a utility grid, for example, a distributed power supply (including a storage battery) having a self-commutated inverter. A distributed power supply having an externally commutated inverter and a leg in the master mode cannot be connected to each other.
[0102] In the following description, the leg operated in the master mode may also be called a “master leg”.
[0103] Operation control of the master leg will be described.
[0104] The start-up of the master leg is as follows.
[0105] First, the switch 143 is set to an open (broken) state. In this state, the connection terminal 145 is connected to the other side of a connection. In this case, the other side of the connection is the utility grid 1035 . The voltage sensor 144 measures the voltage of a grid as a connection destination, and obtains the amplitude, frequency, and phase of the voltage of the grid by using PLL (Phase-Locked-Loop) or the like. After that, the output of the power conversion unit 141 is adjusted such that the voltage of the obtained amplitude, frequency, and phase is outputted from the power conversion unit 141 . That is, the on/off pattern of the transistors Q 1 to Q 6 is decided. When the output becomes stable, the switch 143 is turned on, the power conversion unit 141 and the utility grid 1035 are connected to each other. At this time point, the output of the power conversion unit 141 and the voltage of the utility grid 1035 are synchronized with each other, so that no current flows.
[0106] Operation control at the time of operating the master leg will be described.
[0107] The voltage sensor 17 measures the bus voltage V 15 of the DC bus 15 . When the bus voltage V 15 of the DC bus 15 exceeds a predetermined rated bus voltage, the power conversion unit 141 is controlled so that power transmission is performed from the master leg (the fourth leg 14 ) toward the grid (at least one of the amplitude and phase of the voltage outputted from the power conversion unit 141 is adjusted, so that power transmission is performed from the DC bus 15 toward the utility grid 1035 via the master leg (the fourth leg 14 )). The rated voltage of the DC bus 15 is predetermined by a setting.
[0108] On the other hand, when the bus voltage V 15 of the DC bus 15 is lower than the predetermined rated bus voltage, the power conversion unit 141 is controlled so that the master leg (the fourth leg 14 ) can receive power from the utility grid 1035 (at least one of the amplitude and phase of the voltage outputted from the power conversion unit 141 is adjusted, so that power transmission is performed from the utility grid 1035 to the DC bus 15 via the master leg (the fourth leg 14 ). It will be understood that by performing such operation of the master leg, the bus voltage V 15 of the DC bus 15 can maintain the predetermined rated voltage.
[0109] (Stand-Alone Mode)
[0110] The stand-alone mode (Stand Alone) is an operation mode of generating a voltage having amplitude and frequency designated by the management server 1010 and transmitting/receiving power to/from the other side of a connection.
[0111] For example, it is an operation mode of supplying power to a power consumption side such as the load 1031 or an operation mode of receiving power transmitted from the other side of the connection. The stand-alone mode is an operation mode of creating designated voltage and frequency and supplying the created voltage and frequency to the other side of the connection.
[0112] FIG. 1 illustrates an example that the connection terminal 125 of the second leg 12 is connected to the load 1031 . The second leg 12 is controlled so as to be operated in the stand-alone mode and supplies power to the load 1031 .
[0113] When a leg is connected to another power router, there is a case where the leg is operated in the stand-alone mode as a mode of transmitting an amount of power required by the other power router.
[0114] When a leg is connected to another power router, there is a case where the leg is operated in the stand-alone mode as a mode of receiving power transmitted from the other power router.
[0115] Although not illustrated in the drawing, also in the case where the second leg is connected to a power generating facility instead of the load 1031 , the second leg can be operated in the stand-alone mode. In this case, the power generating facility is provided with an externally commutated inverter.
[0116] An operation mode in the case of interconnecting power routers will be described later.
[0117] A leg operated in the stand-alone mode will be called a “stand-alone leg”. In one power router, there may be a plurality of stand-alone legs.
[0118] Operation control of a stand-alone leg will be described.
[0119] First, the switch 123 is opened (broken). The connection terminal 125 is connected to the load 1031 . The amplitude and frequency of power (a voltage) to be supplied to the load 1031 are instructed from the management server 1010 to the power router 101 . The control unit 19 performs control so that the power (the voltage) of the instructed amplitude and frequency is outputted from the power conversion unit 121 toward the load 1031 (that is, the control unit 19 decides the on/off pattern of the transistors Q 1 to Q 6 ). When the output becomes stable, the control unit 19 connects the power conversion unit 121 to the load 1030 by turning on the switch 123 . After that, when the power is consumed by the load 1031 , the power of the consumed amount flows from the stand-alone leg (the second leg 12 ) to the load 1301 .
[0120] (Designated-Power Transmission/Reception Mode)
[0121] A designated-power transmission/reception mode (Grid Connect) is an operation mode for transmitting/receiving power of an amount decided by designation. In the designated-power transmission/reception mode, designated active power is transmitted/received between connection destinations. Designated reactive power is generated. That is, there are a case of transmitting designated power to the other side of a connection and a case of receiving designated power from the other side of a connection.
[0122] When a leg is connected to a leg of another power router, power of a decided amount is interchanged from one side to the other side.
[0123] The third leg 13 is connected to the storage battery 1032 .
[0124] In such a case, the power of the decided amount is transmitted toward the storage battery 1032 , so that the storage battery 1032 is charged.
[0125] Alternatively, a distributed power supply (including a storage battery) having a self-commutated inverter and a designated-power transmission/reception leg may be connected to each other. However, a distributed power supply having an externally commutated inverter and a designated-power transmission/reception leg cannot be connected to each other.
[0126] A leg operated in the designated-power transmission/reception mode will be called a “designated-power transmission/reception leg”. In one power router, a plurality of designated-power transmission/reception legs may exist.
[0127] Operation control of a designated-power transmission/reception leg will be described. Since the control at the time of startup is basically the same as that of the master leg, a description thereof will not be repeated.
[0128] Operation control at the time of operating a designated-power transmission/reception leg will be described. In FIG. 1 , the first leg 11 transmits/receives power designated power to/from a first leg 21 of a power router 102 operating in the stand-alone mode via the transmission line 1200 . In the first leg 11 of the power router 101 , the voltage of a grid of the other side of a connection is measured by the voltage sensor 114 and the frequency and phase of the voltage of the other side of the connection are obtained using PLL (Phase-Locked-Loop) or the like. On the basis of an active power value and a reactive power value designated by the management server 1010 and the frequency and phase of the voltage of the other side of the connection, the power conversion unit 111 obtains a target value of a current which is inputted/outputted. The current sensor 112 measures a present current value. The power conversion unit 111 is adjusted so that a current corresponding to the difference between the target value and the present value is additionally outputted (by adjusting at least one of the amplitude and phase of the voltage outputted from the power conversion unit 111 , desired power flows between the designated-power transmission/reception leg and the other side of the connection).
[0129] As described above, it will be understood that the first leg 11 to the fourth leg 14 having the same configuration can play the roles of three patterns according to the way of the operation control.
[0130] The power router 101 can operate each leg in the above-described three operation modes by referring to the designation information of operation modes included in the control instruction 51 . The power router 101 can thus appropriately operate each leg in accordance with the role of each leg.
[0131] Next, connection restrictions between power routers will be described. Since the operations of legs vary according to the operation modes, restriction naturally occurs between the selection of the other side of a connection and the selection of an operation mode. That is, when the other side of the connection is decided, an operation mode which can be selected is decided. Conversely, when an operation mode is decided, the other side of the connection which can be selected is decided (when the other side of the connection changes, it becomes necessary to change the operation mode of the leg accordingly).
[0132] Patterns of possible connection combinations will be described below.
[0133] In the following description, signage in the drawings will be simplified as illustrated in FIG. 6 .
[0134] That is, the master leg is expressed by “M”.
[0135] The stand-alone leg is expressed by “5”.
[0136] The designated-power transmission/reception legs are expressed by “D”.
[0137] The AC through leg is expressed by “AC”.
[0138] By assigning numbers like “#1” at the shoulder of a leg as necessary, the legs may be distinguished.
[0139] In FIG. 6 to FIG. 12 , systematic reference numerals are assigned. However, the same reference numerals are not always designated to the same elements among the drawings.
[0140] For example, reference numeral 200 in FIG. 6 and reference numeral 200 in FIG. 4A do not refer to the same element.
[0141] Connection combinations illustrated in FIG. 6 are possible connections. A first leg 210 is connected as a master leg to the utility grid 1035 as also already described. A second leg 220 is connected as a stand-alone leg to the load 1031 as also already described. A third leg 230 and a fourth leg 240 are connected as designated-power transmission/reception legs to the storage battery 1032 as also already described.
[0142] A fifth leg 250 is an AC through leg. The AC through leg 250 is connected to a designated-power transmission/reception leg of another power router 300 and is also connected to the storage battery 1032 via a connection terminal 245 of the fourth leg 240 . Since the AC through leg 250 does not have a power conversion unit, the connection relation is equivalent to that of the designated-power transmission/reception leg of another power router 300 being directly connected to the storage battery 1032 . It will be understood that such a connection is allowed.
[0143] A sixth leg 260 is connected to the utility grid 1035 as a designated-power transmission/reception leg. When it is assumed that determined power is received from the utility grid 1035 via the sixth leg 260 , it will be understood that such a connection is allowed. As for the relation with the first leg 210 , which is the master leg, if the power received by the sixth leg 260 is insufficient to maintain a rated voltage of a DC bus M 201 , the master leg 210 receives necessary power from the utility grid 1035 . Conversely, when the power received by the sixth leg 260 exceeds an amount necessary to maintain the rated voltage of the DC bus M 201 , the master leg 210 passes excessive power to the utility grid 1035 .
[0144] Next, the case of connecting power routers will be described. Connection of power routers means connection of a leg of one power router and a leg of another power router. In the case of connecting legs, there is a restriction in an operation mode for the combination.
[0145] Both of combinations of connections illustrated in FIGS. 7A and 7B are examples of possible combinations. In FIG. 7A , the master leg 110 of the first power router 100 and the stand-alone leg 210 of the second power router 200 are connected to each other. Although it will not be specifically described, the master leg 220 of the second power router 200 is connected to the utility grid 1035 , thereby maintaining the voltage of the DC bus M 201 of the second power router 200 at the rated voltage.
[0146] In FIG. 7A , when power is supplied from the first power router 100 to the load 1031 , the voltage of the DC bus M 101 drops. The master leg 110 obtains power from the other side of a connection so as to maintain the voltage of the DC bus M 101 . In other words, the master leg 110 draws power of an insufficient amount from the stand-alone leg 210 of the second power router 200 . The stand-alone leg 210 of the second power router 200 transmits power of the amount required from the other side of the connection (in this case, the master leg 110 ). In the DC bus M 201 of the second power router 200 , although the voltage drops only by the power transmission amount from the stand-alone leg 210 , it is compensated from the utility grid 1035 by the master leg 220 . In such a manner, the first power router 100 can obtain the power of a necessary amount from the second power router 200 .
[0147] As described above, even when the master leg 110 of the first power router 100 and the stand-alone leg 210 of the second power router 200 are connected, since the role of the master leg 110 and that of the stand-alone leg 210 fit together, no inconvenience occurs in the operations. It is therefore understood that a master leg and a stand-alone leg may be connected as illustrated in FIG. 7A .
[0148] In FIG. 7B , a designated-power transmission/reception leg 310 of the third power router 300 and a stand-alone leg 410 of a fourth power router 400 are connected to each other. Although it will not be specifically described, a master leg 320 of the third power router 300 and a master leg 420 of the fourth power router 400 are connected to the utility grid 1035 , so that DC buses M 301 and M 401 of the third and fourth power routers 300 and 400 maintain the rated voltage.
[0149] It is assumed that, by an instruction from the management server 1010 , the designated-power transmission/reception leg 310 of the third power router 300 is instructed to receive designated power. The designated-power transmission/reception leg 310 draws the designated power from the stand-alone leg 410 of the fourth power router 400 . The stand-alone leg 410 of the fourth power router 400 transmits power of an amount required by the other side of a connection (in this case, the designated-power transmission/reception leg 310 ). In the DC bus M 401 of the fourth power router 400 , although the voltage drops only by the amount of power transmitted from the stand-alone leg 410 , it is compensated from the utility grid 1035 by the master leg 420 .
[0150] As described above, even when the designated-power transmission/reception leg 310 of the third power router 300 and the stand-alone leg 410 of the fourth power router 400 are connected, since the role of the designated-power transmission/reception leg 310 and that of the stand-alone leg 410 fit together, no inconvenience occurs in the operations. It is therefore understood that a designated-power transmission/reception leg and a stand-alone leg may be connected as illustrated in FIG. 7B .
[0151] Although the case where the third power router 300 receives power from the fourth power router 400 has been described, it will be understood that there is similarly no inconvenience also in the case where power is conversely given from the third power router 300 to the fourth power router 400 .
[0152] In such a manner, designated power can be given between the third and fourth power routers 300 and 400 .
[0153] In the case of directly connecting legs having power converters, only two patterns illustrated in FIGS. 7A and 7B are allowed. In other words, only the pattern of connecting a master leg and a stand-alone leg and the pattern of connecting a designated-power transmission/reception leg and a stand-alone leg are allowed.
[0154] Next, combinations of legs which cannot be connected will be described.
[0155] FIGS. 8A to 8D illustrate patterns of legs which cannot be connected to each other.
[0156] As will be seen from FIGS. 8A, 8B, and 8C , legs in the same operation mode cannot be connected to each other.
[0157] For example, in the case of FIG. 8A , master legs 510 and 610 are connected to each other.
[0158] As described above in relation to the operation, first, a master leg performs the process of generating power synchronized with the voltage, frequency, and phase of the other side of the connection.
[0159] In the case where the other side of the connection is also a master leg, the master legs try to synchronize with the voltage and frequency of the other side. However, since the master legs do not autonomously establish the voltage and frequency, such a synchronizing process cannot succeed.
[0160] Therefore, the master legs cannot be connected to each other.
[0161] There is also another reason.
[0162] A master leg has to draw power from the other side of the connection in order to maintain the voltage of the DC bus (or has to pass excessive power to the other side of the connection in order to maintain the voltage of the DC bus). When the master legs are connected to each other, they cannot mutually satisfy requirements of the other sides of connection (if master legs are connected to each other, neither of the power routers cannot maintain the voltages of respective DC buses. Therefore, problems such as black-out may occur in each of the power cells). As described above, since the roles of the master legs conflict (do not fit together), the master legs cannot be connected to each other.
[0163] FIG. 8B illustrates designated-power transmission/reception legs being connected to each other, but it will be understood that this is not successful, either.
[0164] Like the above master legs and as described above in relation to the operation, first, a designated-power transmission/reception leg performs the process of generating power synchronized with the voltage, frequency, and phase of the other side of a connection.
[0165] In the case where the other side of the connection is also a designated-power transmission/reception leg, the legs try to synchronize with the voltage and frequency of the other side. However, since the designated-power transmission/reception legs do not autonomously establish a voltage and frequency, such a synchronizing process cannot succeed.
[0166] Therefore, the designated-power transmission/reception legs cannot be connected to each other.
[0167] There is also another reason.
[0168] Even if designated transmission power to be transmitted from one designated-power transmission/reception leg 510 and designated reception power to be received by the other designated-power transmission/reception leg 610 are matched, such the designated-power transmission/reception legs cannot be connected to each other. For example, it is assumed that the one designated-power transmission/reception leg 510 adjusts a power conversion unit to transmit the designated transmission power (for example, the designated-power transmission/reception leg 510 allows an output voltage to be higher than the output voltage of the other side of a connection by a predetermined value). On the other hand, the other designated-power transmission/reception leg 610 adjusts a power conversion unit to receive the designated reception power (for example, the other designated-power transmission/reception leg 610 allows the output voltage to be lower than that of the other side of the connection by a predetermined value). When such adjusting operations are performed simultaneously in both of the designated-power transmission/reception legs 510 and 610 , it will be understood that both of the legs become out of control.
[0169] FIG. 8C illustrates stand-alone legs being connected to each other. However, such a connection is not allowed.
[0170] A stand-alone leg generates a voltage and a frequency by itself.
[0171] If any of the voltages, frequencies, and phases generated by two stand-alone legs differ even slightly in a state where the stand-alone legs are connected to each other, an unintended power flows between the two stand-alone legs.
[0172] Since it is difficult to keep a state in which the voltages, frequencies, and phases generated by two stand-alone legs are perfectly matched, it is not allowed to connect stand-alone legs to each other.
[0173] FIG. 8D illustrates a master leg and a designated-power transmission/reception leg being connected to each other.
[0174] From the above description, it will be understood that this connection does not work, either. Even when the master leg 510 tries to transmit/receive power to/from the other side of a connection so as to maintain the voltage of a DC bus M 501 , the designated-power transmission/reception leg 610 does not transmit/receive power in response to a request of the master leg 510 . Therefore, the master leg 510 cannot maintain the voltage of the DC bus M 501 . Even when the designated-power transmission/reception leg 610 tries to transmit/receive designated power to/from the other side ( 510 ) of a connection, the master leg 510 does not transmit/receive the power in response to a request of the designated-power transmission/reception leg 610 . Therefore, the designated-power transmission/reception leg 610 cannot transmit/receive the designated power to/from the other side of the connection (in this case, the master leg 510 ).
[0175] Although the cases in which legs having a power conversion unit are connected with each other have been considered, patterns illustrated in FIGS. 9A to 9D are also possible when an AC through leg is taken into consideration. Since an AC through leg has no power conversion unit, it is simply a bypass. Therefore, as illustrated in FIGS. 9A and 9B , a connection of the master leg 110 of the first power router 100 to the utility grid 1035 via the AC through leg 250 of the second power router 200 is substantially the same as a direct connection of the master leg 110 to the utility grid 1035 . Similarly, as illustrated in FIGS. 9C and 9D , a connection of the designated-power transmission/reception leg 110 of the first power router 100 to the utility grid 1035 via the AC through leg 250 of the second power router 200 is substantially the same as a direct connection of the designated-power transmission/reception leg 110 to the utility grid 1035 .
[0176] Even so, when an AC through leg is provided, there are the following advantages. For example, a case is considered in which, as illustrated in FIG. 10 , the distance from the first power router 100 to the utility grid 1035 is very long and the first power router 100 has to be connected to the utility grid 1035 via some power routers 200 and 300 . If there is no AC through leg, the first power router 100 has to be connected via one or more stand-alone legs as illustrated in FIG. 7A . When the first power router 100 is connected via a leg having a power converter, output is subjected to conversion from AC power to DC power and conversion from DC power to AC power. In the power conversion, although only a few percent, energy loss occurs. Therefore, a plurality of times of power conversion required only for a connection to the utility grid is insufficient. Therefore, it is meaningful to provide a power router with an AC through leg having no power conversion unit.
[0177] FIG. 11 illustrates the summary of the above description. FIG. 12 is a diagram illustrating an example of the case of connecting the four power routers 100 , 200 , 300 , and 400 to one another. In FIG. 12 , by reference numeral “ 71 A” is designated power transmission lines as a part of the utility grid, and by reference numeral “ 71 B” is designated power transmission lines detached from the utility grid. When a connection line connecting a power router and a load (or a distributed power supply) is called a power distribution line 72 , the power distribution lines 72 are detached from the utility grid 1035 . That is, the power distribution line 72 connecting the power router to the load (or the distributed power supply) is not connected to the utility grid 1035 . Reference numerals 1035 A to 1035 C indicate utility grids. Since all of the connection relations are described above, each connection destinations will not be described in detail. However, it will be understood that all the connection relations are allowable connection relations.
[0178] Next, referring once again to FIG. 1 , the power router 102 will be described. The power router 102 has a configuration similar to that of the power router 101 . The power router 102 has, roughly, the DC bus 15 , the communication bus 16 , a first leg 21 , a second leg 22 , a third leg 23 , a fourth leg 24 , and the control unit 19 . In the drawing, because of limited space, the first leg to the fourth leg are indicated as leg 1 to leg 4 , respectively. The first leg 21 , the second leg 22 , the third leg 23 , and the fourth leg 24 have configurations similar to those of the first leg 11 , the second leg 12 , the third leg 13 , and the fourth leg 14 of the power router 101 , respectively. The first leg 21 , the second leg 22 , the third leg 23 , and the fourth leg 24 are connected to the outside via terminals 215 , 225 , 235 , and 245 , respectively. Operation modes of the power router 102 are similar to those of the power router 101 , a description thereof will not be repeated.
[0179] In the present exemplary embodiment, the first leg 11 of the power router 101 and the first leg 21 of the power router 102 are connected to each other via the transmission line 1200 . The second leg 22 is connected to a load 1033 via the terminal 225 . The third leg 23 is connected to a storage battery 1034 via the terminal 235 . The fourth leg 24 is connected to the utility grid 1035 via the terminal 245 . Thus, the fourth leg 24 operates as a master leg.
[0180] Next, the management server 1010 will be described. FIG. 13 is a block diagram illustrating a schematic configuration of the power network system 1000 , which illustrates a configuration of the management server 1010 . The management server 1010 can be configured, for example, as hardware such as a computer. The management server 1010 has a storage device 1012 . The storage device 1012 stores information required for the control of power routers.
[0181] An operation of a power router according to the present exemplary embodiment will be described below in detail. As described above, the power router is normally provided with a plurality of legs. In the state in which a bus voltage is maintained at a predetermined value, when each of the plurality of legs performs power transmission and reception, it is necessary to balance transmission power and reception power in terms of an entire power router. In order to balance the transmission power and the reception power in terms of the entire power router, the control unit 19 has to control each leg.
[0182] In the present exemplary embodiment, based on the above-described assumption, the case where a plurality of master legs exist in one power router will be described. Providing a plurality of master legs has the following technical meaning. For example, there is considered a case where a power router is requested to transmit power to a destination requiring large power such as a high power household appliance. In this case, a designated-power transmission/reception leg or a stand-alone leg is connected to the destination. Therefore, in order to satisfy a request of the destination, it is necessary to use a high-output designated-power transmission/reception leg or stand-alone leg. In this case, in order to normally perform power transmission and reception of a leg other than a master leg of the power router, the capacity (rating) of the master leg has to be large. However, an increase in the capacity of the master leg causes an increase in the size and the cost of the master leg.
[0183] On the other hand, in the present exemplary embodiment, a plurality of master legs are provided. The entire capacity of the plurality of master legs can be increased thereby. However, when the plurality of master legs are provided, a special problem occurs as compared with the case where one master leg is provided. For example, when one master leg is provided, it is sufficient if the master leg performs power transmission and reception with the outside such that a bus voltage is simply maintained constant. However, when a plurality of master legs exist, if each of the master legs independently performs power transmission and reception similarly to the case where one master leg is provided, it is probable that an amount to be transmitted and received will be excessively increased. In this case, it is probable that overshoot and undershoot of a bus voltage, destabilization of the bus voltage, and extension of a time required for stabilizing the bus voltage will occur. Therefore, in the present exemplary embodiment, when a plurality of master legs perform power transmission and reception with the outside, amounts to be transmitted and received by the respective master legs are decided and set for the respective master legs, thereby preventing the occurrence of such a problem.
[0184] More specifically, in the present exemplary embodiment, in the state in which a plurality of master legs exist in one power router and a bus voltage is maintained to a predetermined value, the plurality of master legs are controlled to balance transmission power and reception power in terms of the entire power router.
[0185] When a target voltage value of the DC bus 15 is Vdc target , an actually measured value of the DC bus 15 is Vdc measure , and an actually measured value of an AC current flowing in the master leg is I measure , a target value I target of the AC current to flow in the master leg can be defined by the following Equation 1 by using a coefficient s (s is a real number).
[0000] Equation 1
[0000] I target =s ( Vds target −Vdc measure )· I measure (1)
[0186] An AC voltage value Vac target to be set for the master leg so as to achieve the target voltage value of the DC bus 15 at Vdc target is expressed by the following Equation 2, by using the target value I target of the AC current to flow in the master leg and a coefficient t (t is a real number).
[0000] Equation 2
[0000] Vac target =t·I target (2)
[0187] The aforementioned coefficient s and coefficient t are determined by the characteristics of a power router and a leg such as a structure and a manufacturing error. For example, the coefficient s and the coefficient t can be determined by actually measuring current/voltage characteristics of a leg.
[0188] In the master leg, the AC voltage value Vac target to be set in the master leg is set, so that it is possible to control transmission power or reception power.
[0189] In a power router according to the present exemplary embodiment, a plurality of legs serve as master legs. Therefore, the control unit 19 needs to control the AC voltage value with respect to each of the plurality of master legs. A description will be provided below for power control which is performed for each of the plurality of master legs. For the sake of simplicity, the following description will be provided for the case where the control unit 19 controls transmission and reception power of the master legs.
[0190] A description will be provided below for an example in which a power router having a plurality of master legs has two master legs and two stand-alone legs other than the master legs. FIG. 14 is a block diagram schematically illustrating a configuration of a power router 600 according to an exemplary embodiment 1.
[0191] The power router 600 has a first master leg 61 , a second master leg 62 , a first stand-alone leg 63 , and a second stand-alone leg 64 . A rated value of the first master leg 61 is represented as RM 1 , a rated value of the second master leg 62 is RM 2 , a rated value of the first stand-alone leg 63 is RS 1 , and a rated value of the second stand-alone leg 64 is RS 2 .
[0192] Although not illustrated, the first master leg 61 and the second master leg 62 are connected to a utility grid and a power supply such as a storage battery. Although not illustrated, the first stand-alone leg 63 and the second stand-alone leg 64 are connected to a power supply such as a storage battery, an exterior load or the like.
[0193] In the power router 600 , the control unit 19 distributes power, which is to be received by or transmitted from a master leg, to the first master leg 61 and the second master leg 62 in response to the situation of power transmission and power reception of the first stand-alone leg 63 and the second stand-alone leg 64 .
[0194] The transmission and reception power of the first stand-alone leg 63 and the second stand-alone leg 64 is designated, for example, by the management server 1010 in accordance with the control instruction 51 . The transmission and reception power of the first stand-alone leg 63 and the second stand-alone leg 64 designated in accordance with the control instruction 51 is stored, for example, in the storage unit 191 of the control unit 19 . The control unit 19 can thereby appropriately refer to the transmission and reception power of the first stand-alone leg 63 and the second stand-alone leg 64 stored in the storage unit 191 .
[0195] An operation to be described below can be performed, for example, when the management server 1010 has newly designated the transmission and reception power of the first stand-alone leg 63 and the second stand-alone leg 64 or when the management server 1010 has changed the designation of the transmission and reception power of the first stand-alone leg 63 and the second stand-alone leg 64 .
[0196] Hereinafter, power transmitted to the outside of the power router 600 from the first master leg 61 , the second master leg 62 , the first stand-alone leg 63 , or the second stand-alone leg 64 is taken as negative. Power received by the first master leg 61 , the second master leg 62 , the first stand-alone leg 63 , or the second stand-alone leg 64 from the outside of the power router 600 is taken as positive.
[0197] The transmission and reception power of the first master leg 61 is represented as P 1 [kW]. When the first master leg 61 transmits power to the outside, P 1 has a negative value (P 1 <0). When the first master leg 61 receives power from the outside, P 1 has a positive value (P 1 >0).
[0198] The transmission and reception power of the second master leg 62 is represented as P 2 [kW]. When the second master leg 62 transmits power to the outside, P 2 has a negative value (P 2 <0). When the second master leg 62 receives power from the outside, P 2 has a positive value (P 2 >0).
[0199] The transmission and reception power of the first stand-alone leg 63 is represented as W 1 [kW]. When the first stand-alone leg 63 transmits power to the outside, W 1 has a negative value (W 1 <0). When the first stand-alone leg 63 receives power from the outside, W 1 has a positive value (W 1 >0).
[0200] The transmission and reception power of the second stand-alone leg 64 is represented as W 2 [kW]. When the second stand-alone leg 64 transmits power to the outside, W 2 has a negative value (W 2 <0). When the second stand-alone leg 64 receives power from the outside, W 2 has a positive value (W 2 >0).
[0201] Accordingly, W total , which is the total power transmitted/received by the first stand-alone leg 63 and the second stand-alone leg 64 is (W 1 +W 2 ) [kW]. In this case, when W total >0, it is necessary to transmit power to the outside via a master leg in order to maintain the voltage of the DC bus 15 to the target voltage value Vdc target . When W total <0, it is necessary to receive power from the outside via the master leg in order to maintain the voltage of the DC bus 15 to the target voltage value Vdc target . The control unit 19 distributes transmission power or reception power to the first master leg 61 and the second master leg 62 , so that power transmission and reception are performed.
[0202] First, the control unit 19 calculates a coefficient u (also called a first coefficient) for defining the output of the first master leg 61 and the second master leg 62 . The coefficient u is calculated by the following Equation.
[0000]
Equation
3
u
=
W
1
+
W
2
RM
1
+
RM
2
(
3
)
[0203] That is, the coefficient u is calculated by dividing the sum of the transmission and reception power of legs other than the master legs by the sum of the rating of the master legs.
[0204] As expressed by Equation 4 below, the control unit 19 multiplies the rating RM 1 of the first master leg 61 by the coefficient u, thereby calculating the power instruction value P 1 of the first master leg 61 .
[0000] Equation 4
[0000] P 1= u·RM 1 (4)
[0205] As expressed by Equation 5 below, the control unit 19 multiplies the rating RM 2 of the second master leg 62 by the coefficient u, thereby calculating the power instruction value P 2 of the second master leg 62 .
[0000] Equation 5
[0000] P 2= u·RM 2 (5)
[0206] Detailed examples (cases 1 to 4) will be described below.
Case 1
[0207] The case where power received in the first stand-alone leg 63 is 2 [kW] (W 1 =2 [kW]) and power received in the second stand-alone leg 64 is 1 [kW] (W 2 =1 [kW]) will be described. FIG. 15 is a diagram illustrating the power router 600 when power received in the first stand-alone leg 63 is 2 kW (W 1 =2 kW) and power received in the second stand-alone leg 64 is 1 kW (W 2 =1 kW). In this case, the power router 600 receives power of 3 [kW] from the outside. Thus, the power router 600 has to be able to transmit power of 3 [kW] at maximum via the master legs. In this case, the control unit 19 calculates the coefficient u from Equation 3 above as expressed by the following Equation 6.
[0000]
Equation
6
u
=
2
+
1
3
+
2
=
0.6
(
6
)
[0208] In this case, the coefficient u is 0.6. Thus, by Equation 4 above, the transmission power of the first master leg 61 is 1.8 [kW] (=0.6×3 [kW]). By Equation 5 above, the transmission power of the second master leg 62 is 1.2 [kW] (=0.6×2 [kW]).
Case 2
[0209] The case where power received in the first stand-alone leg 63 is 1 [kW] (W 1 =1 [kW]) and power received in the second stand-alone leg 64 is 1 [kW] (W 2 =1 [kW]) will be described. FIG. 16 is a diagram illustrating the power router 600 when power received in the first stand-alone leg 63 is 1 kW (W 1 =1 kW) and power received in the second stand-alone leg 64 is 1 kW (W 2 =1 kW). In this case, the power router 600 receives power of 2 [kW] from the outside. Thus, the power router 600 has to be able to transmit power of 2 [kW] at maximum via the master leg. In this case, the control unit 19 calculates the coefficient u from Equation 3 above as expressed by the following Equation 7.
[0000]
Equation
7
u
=
1
+
1
3
+
2
=
0.4
(
7
)
[0210] In this case, the coefficient u is 0.6. Thus, by Equation 4 above, the transmission power of the first master leg 61 is 1.2 [kW] (=0.4×3 [kW]). By Equation 5 above, the transmission power of the second master leg 62 is 0.8 [kW] (=0.4×2 [kW]).
[0211] When, for example, the setting of the transmission and reception power of the first stand-alone leg 63 and the second stand-alone leg 64 has been changed from the case 1 to the case 2 by an instruction of the management server 1010 , the control unit 19 can change the coefficient u from 0.6 to 0.4.
Case 3
[0212] The case where power transmitted in the first stand-alone leg 63 is 2 [kW] (W 1 =−2 [kW]) and power transmitted in the second stand-alone leg 64 is 1 [kW] (W 2 =−1 [kW]) will be described. FIG. 17 is a diagram illustrating the power router 600 when power transmitted in the first stand-alone leg 63 is 2 [kW] (W 1 =−2 [kW]) and power transmitted in the second stand-alone leg 64 is 1 [kW] (W 2 =−1 [kW]). In this case, the power router 600 receives power of 3 [kW] from the outside. Thus, the power router 600 has to be able to receive power of 3 [kW] at maximum via the master legs. In this case, the control unit 19 calculates the coefficient u from Equation 3 above as expressed by the following Equation 8.
[0000]
Equation
8
u
=
-
2
-
1
3
+
2
=
0.6
(
8
)
[0213] In this case, the coefficient u is 0.6. Thus, by Equation 4 above, the reception power of the first master leg 61 is 1.8 [kW] (=0.6×3 [kW]). By Equation 5 above, the reception power of the second master leg 62 is 1.2 [kW] (=0.6×2 [kW]).
Case 4
[0214] The case where power received in the first stand-alone leg 63 is 1 [kW] (W 1 =1 [kW]) and power transmitted in the second stand-alone leg 64 is 1 [kW] (W 2 =−1 [kW]) will be described. FIG. 18 is a diagram illustrating the power router 600 when power received in the first stand-alone leg 63 is 1 [kW] (W 1 =1 [kW]) and power transmitted in the second stand-alone leg 64 is 1 [kW] (W 2 =−1 [kW]). In this case, the power router 600 balances transmission power and reception power between the first stand-alone leg 63 and the second stand-alone leg 64 . Thus, the power router 600 does not need to perform power transmission and reception via the master legs. In this case, the control unit 19 calculates the coefficient u from Equation 3 above as expressed by the following Equation 9.
[0000]
Equation
9
u
=
1
-
1
3
+
2
=
0
(
9
)
[0215] In this case, the coefficient u is 0. Thus, by Equation 4 above, the reception power of the first master leg 61 is 0 [kW] (=0× 3 [kW]). By Equation 5 above, the reception power of the second master leg 62 is 0 [kW] (=0×2 [kW]). By the operation, it can be understood that the first master leg 61 and the second master leg 62 perform no power transmission and reception.
[0216] Furthermore, the case with a generalized configuration of a power router will be described. The number of master legs of the power router is represented as N (N is an integer equal to or more than 2) and the number of legs other than the master legs is M (M is an integer equal to or more than 1). In this case, Equation 3 above can be generalized as expressed by the following Equation 10.
[0000]
Equation
10
u
=
∑
i
=
1
M
Wi
∑
j
=
1
N
RMj
(
10
)
[0217] In this case, Equation 4 and Equation 5 above can be generalized as expressed by the following Equation 11. As expressed by Equation 10 above, j is an integer satisfying the relation of 1≦j≦N.
[0000] Equation 11
[0000] Pj=u·RMj (11)
[0218] So far, according to the present configuration, when a plurality of master legs are used in a power router, power to be transmitted and received via the master legs can be distributed to the respective master legs. A specific power designation value is set for each of the plurality of master legs so that it is possible to maintain a bus voltage to a proper value.
[0219] Legs other than master legs include the above-described AC through leg. However, the AC through leg simply passes the transmission and reception power of another stand-alone leg or designated-power transmission/reception leg and performs no direct power transmission and reception with the outside. Therefore, when the transmission and reception power passing through the AC through leg is included in the sum (the numerator of the right side of Equation 10 above) of the transmission and reception power of the legs other than master legs, the transmission and reception power of a stand-alone leg or a designated-power transmission/reception leg connected to the AC through leg is doubly counted. Thus, when calculating the sum (the numerator of the right side of Equation 10 above) of the transmission and reception power of the legs other than master legs, the transmission and reception power passing through the AC through leg is to be excluded.
Exemplary Embodiment 2
[0220] Next, a power router 700 according to an exemplary embodiment 2 will be described. FIG. 19 is a block diagram schematically illustrating a configuration of the power router 700 according to the exemplary embodiment 2. The power router 700 has a configuration in which the first master leg 61 and the second master leg 62 of the power router 600 according to the exemplary embodiment 1 have been replaced with a first master leg 65 and a second master leg 66 , respectively.
[0221] In the power router 600 according to the exemplary embodiment 1, the ratings of a plurality of legs have been multiplied by the coefficient u. On the other hand, in the power router 700 according to the present exemplary embodiment, a priority is predetermined among a plurality of legs of the power router 900 . The control unit 19 sets a larger power designation value in a master leg with a high priority. The priority is a value indicating the importance of a leg, and for example, is expressed by a numeral value.
[0222] In the present exemplary embodiment, the control unit 19 multiplies the rating RM 1 of the first master leg 65 by an adjustment coefficient v 1 (also called a second coefficient) as well as the coefficient u. Thus, the power instruction value P 1 of the first master leg 65 is expressed by the following Equation 12.
[0000] Equation 12
[0000] P 1= v 1 ·u·RM 1 (12)
[0223] The control unit 19 multiplies the rating RM 2 of the second master leg 66 by an adjustment coefficient v 2 (also called a second coefficient) as well as the coefficient u. Thus, the power instruction value P 2 of the second master leg 66 is expressed by the following Equation 13.
[0000] Equation 13
[0000] P 2= v 2 ·RM 2 (13)
[0224] Here, to a master leg with a higher priority is allocated a larger value of adjustment coefficient which is multiplied into the rating of the leg. For example, when the priority of the first master leg 65 is higher than that of the second master leg 66 , v 1 >v 2 . Bearing in mind, however, that power transmission and reception cannot be performed for the first master leg 65 and the second master leg 66 beyond the ratings of these legs, it is necessary to set v 1 such that 0<(v 1 ×u)<1 and set v 2 such that 0<(v 2 ×u)<1.
[0225] Furthermore, the case with a generalized configuration of a power router will be described. The number of master legs of the power router is represented as N (N is an integer equal to or more than 2) and the number of legs other than the master legs is M (M is an integer equal to or more than 1). In this case, Equation 12 and Equation 13 above can be generalized as expressed by the following Equation 14. As expressed by Equation 10 above, j is an integer satisfying the relation of 1≦j≦N.
[0000] Equation 14
[0000] Pj=v j ·u·RMj (14)
[0226] It is necessary to set v j such that 0<(v j ×u)<1.
[0227] So far, according to the present configuration, it is possible to adjust the power designation value of a master leg in response to the priory among each of a plurality of master legs. Thus it is possible to determine the power designation value so as to correspond to the characteristics of each of the plurality of master legs.
[0228] The priority can be set as follows. For example, it is possible to place a higher priority on a power leg connected to a power supply with high stability such as a commercial power supply system. It is possible thereby to expect stable supply of power to a power router.
[0229] For example, it is also possible to change a priority in accordance with time. By such an operation, a power supply source with a time-variable rates system, such as night hour rates, may be effectively utilized to reduce electricity cost.
[0230] For example, it is also possible to place a higher priority on a master leg with a larger rating. By such an operation, the master leg with a larger rating is mainly used, so that it is possible to achieve stable power transmission and reception. The priority of the master leg may be set by the management server 1010 or the control unit 19 .
[0231] For example, it is also possible to place a higher priority on a master leg with a shorter accumulated operation time. By such an operation, it is possible to reduce a load of the master leg with a longer accumulated operation time and to even out accumulated loads among a plurality of master legs. As a consequence, it is possible to reduce a failure rate and extend a lifetime of a power router.
Other Embodiments
[0232] The present invention is not limited to the aforementioned exemplary embodiments and can be appropriately changed without departing from the spirit thereof. For example, although the control unit 19 is described as the configuration of hardware in the foregoing exemplary embodiments, the present invention is not limited thereto. For example, the control unit 19 can be configured by a computer which performs any processing with a CPU (Central Processing Unit) executing a computer program. Furthermore, a control device is installed in a power conversion unit of a leg, and the control device, for example, is configured as a dynamic reconfiguration logic (FPGA: Field Programmable Gate Array). A control program of the FPGA is adapted to a mode of a leg and operated. By the operation, the FPGA is rewritten in accordance with the type and operation of a leg, so that it is possible to perform control suitable to the operation mode of the leg, thereby reducing hardware capacity requirement and cost. Furthermore, the above-described program is stored by using a non-transitory computer readable medium of various types and can be supplied to a computer. Non-transitory computer readable media includes substantive recording media (tangible storage media) of various types. Examples of the non-transitory computer readable media include magnetic recording media (for example, a flexible disk, a magnetic tape, and a hard disk drive), a magnetic optical recording medium (for example, a magnetic optical disk), a CD-ROM (Read Only Memory) a CD-R, a CD-R/W, semiconductor memories (for example, a mask ROM, a PROM (Programmable ROM), an EPROM (Erasable PROM), a flash ROM, and a RAM (Random Access Memory)). A program may be supplied to a computer by any of transitory computer readable medium of various types. Examples of the transitory computer readable medium include an electric signal, a light signal, and an electromagnetic wave. With the transitory computer readable medium, a program can be supplied to a computer via a wired communication path such as an electric line or an optical fiber or a wireless communication path.
[0233] In the exemplary embodiments 1 and 2, the number of master legs is 2, but this is for illustrative purposes only. The number of master legs can be 3 or more. Furthermore, in the exemplary embodiments 1 and 2, the number of legs other than the master legs is assumed 2, but this is for illustrative purposes only. The number of legs other than the master legs can be any number equal to or more than 1. Furthermore, the legs other than the master legs may be stand-alone legs or designated-power transmission/reception legs.
[0234] So far, the present invention has been described with reference to the exemplary embodiments. However, the present invention is not limited thereto. Various modifications which can be understood by a person skilled in the art can be made to the configuration and details of the present invention within the scope of the invention.
[0235] This application claims priority based on Japanese Patent Application No. 2014-4919 filed on Jan. 15, 2014, the contents of which are incorporated herein in its entirety by reference.
REFERENCE SIGNS LIST
[0000]
BL branch line
D 1 to D 6 diode
INF information
MODE operation mode designation information
P 1 , P 2 power instruction value
Q 1 to Q 6 transistor
RM 1 , RM 2 rating
SA 1 , SD 1 waveform instruction signal
SA 2 , SD 2 reading signal
SCON control signal
SIG 1 switching control signal
V 15 bus voltage
Vr detection value
11 , 21 first leg
12 , 22 second leg
13 , 23 third leg
14 , 24 fourth leg
51 , M 101 , M 201 , M 301 , M 401 , M 501 , M 601 , DC bus
16 communication bus
17 voltage sensor
19 control unit
51 control instruction
52 information
60 through leg
61 , 65 first master leg
62 , 66 second master leg
63 first stand-alone leg
64 second stand-alone leg
71 A, 71 B power transmission line
72 distribution line
100 , 101 , 102 , 170 , 200 , 300 , 400 , 600 , 700 , 841 to 844 power router
821 to 824 power cell
111 , 121 , 131 , 141 power conversion unit
112 , 122 , 132 , 142 , 162 current sensor
113 , 223 , 133 , 143 , 163 switch
114 , 224 , 134 , 144 , 164 voltage sensor
115 , 125 , 135 , 145 , 165 , 215 , 225 , 235 , 245 connection terminal
191 storage unit
192 operation mode management unit
193 power conversion instruction unit
194 DA/AD conversion unit
195 sensor value reading unit
196 control instruction database
197 leg identification information database
110 , 210 , 220 , 320 , 420 , 560 master leg
210 , 410 stand-alone leg
250 AC through leg
610 designated-power transmission/reception leg
810 , 1000 , 2000 power network system
811 , 1035 , 1035 A to 1035 C utility grid
812 large-scale power plant
831 house
832 building
833 solar power panel
834 wind power generator
835 , 1032 , 1034 storage battery
850 , 1010 , 1020 management server
860 , 1100 communication network
1011 power conversion unit
1012 storage device
1031 , 1033 load
1200 , 1201 to 1203 , 1211 to 1213 transmission line
1300 communication line | The purpose of the present invention is to enable a power router to be more suitably managed or controlled when constructing a power network system in which power cells are asynchronously interconnected. A power router has a first master leg, a second master leg, a first stand-alone leg, and a second stand-alone leg. Based on the power transmitted and received by the first stand-alone leg and the second stand-alone leg, a control unit controls the power transmitted and received by the first master leg and the power transmitted and received by the second master leg. | 8 |
REFERENCE TO RELATED APPLICATIONS
This application claims the priority benefit under Title 35, United States Code 119(e) of U.S. Provisional Patent Application No. 61/523,877 filed Aug. 16, 2011.
STATEMENT REGARDING ELECTRONIC SUBMISSION OF A SEQUENCE LISTING
A Sequence Listing in ASCII test format, submitted under 37 C.F.R. 1.821, entitled “73311_US_NP1_15Aug2012_O_Application_NR_SequenceListing.txt”, 5701 bytes in size, generated on Aug. 14, 2012 and filed via EFS-Web is provided in lieu of a paper copy. This sequence listing is hereby incorporated by reference into the specification for its disclosure.
FIELD OF THE INVENTION
The invention relates to RNA methods and compositions that include RNA formulations that are applied to external plant parts, preferably the leaves, wherein the dsRNA is assimilated into the plant cells.
BACKGROUND
Many food sources are produced by crop plants. Environmental conditions such as drought and heat often adversely affect crop growth and yield. Pest pressure may also have a substantial negative impact. Consequently, plants that are capable of withstanding environmental stresses and/or pest challenge are desirable. Plants tolerant or resistant to abiotic and biotic stresses can be obtained by selective breeding or through genetic modification. RNA interference 15 (RNAi) can be used to produce genetically modified plants that are tolerant or resistant to abiotic and biotic stresses.
In the past decade, RNAi has been described and characterized in organisms as diverse as plants, fungi, nematodes, hydra, and humans. Zamore and Haley (2005) Science 309, 1519-24. RNA interference in plants is commonly referred to as post-transcriptional gene silencing or RNA silencing and is referred to as quelling in fungi. The process of post-transcriptional gene silencing is thought to be an evolutionarily conserved cellular defense mechanism used to prevent the expression of foreign genes and is commonly shared by diverse flora and phyla. Fire (1999) Trends Genet. 15, 358-363.
RNA interference occurs when an organism recognizes double-stranded RNA molecules and hydrolyzes them. The resulting hydrolysis products are small RNA fragments of 19-24 nucleotides in length, called small interfering RNAs (siRNAs) or microRNAs (miRNAs). The siRNAs then diffuse or are carried throughout the organism, including across cellular membranes, where they hybridize to mRNAs (or other RNAs) and cause hydrolysis of the RNA. Most plant miRNAs show extensive base pairing to, and guide cleavage of their target mRNAs. Jones-Rhoades et al. (2006) Annu. Rev. Plant Biol. 57, 19-53; Llave et al. (2002) Proc. Natl. Acad. Sci. USA 97, 13401-10406. In other instances, interfering RNAs may bind to target RNA5 molecules having imperfect complementarity, causing translational repression without mRNA degradation.
The mode of action for silencing a plant gene generally includes a double stranded RNA (dsRNA) that associates with a dicer enzyme that cuts the dsRNA into ds fragments 19-24 bps in length (siRNA). There may be more than one dicer enzyme, depending on the organism. Meister and Tuschl, 2004). The siRNA is typically degraded into two single stranded RNAs (ssRNAs), referred to as the passenger strand and the guide strand. A RNA-interference silencing complex (RISC complex) loads the guide strand. The RISC complex associates with a target mRNA that has partial or complete homology to the guide strand. The catalytic RISC component agronaute causes cleavage of the target mRNA preventing it from being used as a translation template. Ahlquist P (2002) RNA - dependent RNA polymerases, viruses, and RNA silencing , Science 296 (5571): 1270-3. The RNAi pathway is exploited in plants by using recombinant technology, which entails transforming a plant with a vector comprising DNA that when expressed produces a dsRNA homologous or nearly homologous to a gene target. The gene target can be homologous to a endogenous plant gene or an insect gene. If the target is an insect gene, the insect eats the plant thereby ingesting the dsRNA, at which the RNAi RISC complex of the insect causes cleavage and targeting of the homologous mRNA, causing disruption of a vital insect process.
To date, plant recombinant technology is the vehicle for delivering gene silencing of target genes, either endogenous plant target genes or target genes of a plant pest organism. In general, a plant is transformed with DNA that is incorporated into the plant genome, and when expressed produces a dsRNA that is complementary to a gene of interest, which can be an endogenous plant gene or an essential gene of a plant pest. Plant recombination techniques to generate transgene and beneficial plant traits require significant investments in research and development, and pose significant regulatory hurdles. Methods and formulations for delivering dsRNA into plant cells by exogenous application to exterior portions of the plant, such as leaf, stem, and/or root surfaces for regulation of endogenous gene expression are not known in the art. Such methods and formulations represent a significant development for gene silencing technology.
Known methods for delivering exogenous dsRNA into plant cells are via particle bombardment or viral RNA infection through wounding the plant tissue (e.g. tobacco and rice leaf tissues). Application by spray or brush of RNA molecules, or other non-tissue evasive techniques, resulting in assimilation of the exogenous RNA molecules into plant tissue, thereby causing endogenous and/or pest gene silencing, has not been reported.
The present invention is directed to methods and formulations to incorporate exogenous RNA, by application to external tissue surface(s) of plants, into the plant cells causing silencing of plant endogenous target gene(s) or of the target genes of plant pests.
The present invention is not directed to any particular RNAi mechanism or mode of action of gene silencing, and should not be construed as limited to any such mechanisms, known or unknown.
SUMMARY OF THE INVENTION
This invention disclosure is a novel approach of dsRNA penetration into plant cells and the subsequent induction of plant endogenous gene silencing by application of the dsRNA to a surface of a plant structure, e.g., a leave surface. More significantly, gene silencing was successful in a crop species (maize) rather than model plants ( Arabidopsis etc). Thus, the present invention establishes that external application of dsRNA can be used to silence or otherwise modulate endogenous plant gene expression.
This invention disclosure is a novel approach of plant hormone-mediated penetration of dsRNA into plant cells and the subsequent induction of plant endogenous gene silencing by application of the dsRNA to a surface of a plant structure, e.g. a leaf surface. Gene silencing was successful in a crop species (maize) rather than model plants ( Arabidopsis etc). Thus, the present invention establishes that external application of dsRNA can be used to silence or otherwise modulate endogenous plant gene expression.
This invention disclosure is a novel approach of plant hormone-mediated penetration of dsRNA into plant cells and the subsequent induction of plant endogenous gene silencing by application of the dsRNA in a formulation to a surface of a plant structure, e.g. a leaf surface. Gene silencing was successful in a crop species (maize) rather than model plants ( Arabidopsis etc). Thus, the present invention establishes that external application of dsRNA can be used to silence or otherwise modulate endogenous plant gene expression.
The invention includes a method of integrating RNA into a plant cell comprising: providing a formulation comprising a gene-specific dsRNA, H2O, and a plant hormone Brassinosteroid and applying the formulation to the leaf surface of a live plant, wherein the RNA is single strand RNA and is assimilated from the external leaf surface into cells of the plant leaf.
It is also understood and it is within the scope of the invention for plant hormones in the formulation and method of the present invention to assist dsRNA processing inside the plant cell for plant endogenous gene silencing.
One aspect of the invention is directed to integrating RNA into a plant cell comprising: providing a formulation comprising a gene-specific dsRNA, H2O, and a plant hormone Brassinosteroid, and applying the formulation to the external surface of a live plant, wherein the dsRNA is assimilated from the external leaf surface into cells of the plant.
One aspect of the invention is directed to integrating RNA into a plant cell comprising: providing a formulation comprising a gene-specific dsRNA, H2O, and a plant hormone Brassinosteroid, and applying the formulation to the external leaf surface of a live plant, wherein the dsRNA is assimilated from the external leaf surface into cells of the plant leaf.
One aspect of the invention is directed to integrating RNA into a plant cell comprising: providing a formulation comprising a gene-specific dsRNA, H2O, and a plant hormone, and applying the formulation to the external surface of a live plant, wherein the dsRNA is assimilated from the external surface into cells of the plant.
Another aspect of the invention includes a formulation including a dsRNA at a concentration of about 250 ng/ul and a Brassinosteroid plant hormone in formulation in range of about 0.8 micromolar to about 1.6 micromolar.
Another aspect of the invention includes using dsRNA in a formulation at a concentration of about 250 ng/ul.
Another aspect of the invention includes using Brassinosteroid plant hormone in formulation in range of about 0.8 micromolar to about 1.6 micromolar.
The invention further includes a formulation comprising a dsRNA, H2O, and a plant hormone to a live plant about 12 days from germination. An aspect of the invention includes applying the formulation to a dicot plant, a maize plant or a tobacco plant.
Another aspect of the invention is a formulation for applying to the external surface of a plant comprising dsRNA, H2O, and a plant hormone Brassinosteroid.
Another aspect of the invention is a wherein the Brassinosteroid in the formulation is at 0.8 micromolar to about 1.6 micromolar.
Yet another aspect of the invention a formulation where the dsRNA in the formulation is at a concentration of about 250 ng/ul.
One aspect of the invention is a method of producing a plant, plant part, or plant cell comprising RNAi for modulating at least one target endogenous gene of the plant.
One aspect of the invention is a method of producing a plant, plant part, or plant cell comprising RNAi for modulating at least one target endogenous gene of the plant.
The present invention includes provides methods and compositions for controlling pest infestation by repressing, delaying, or otherwise reducing gene expression within a particular pest.
BRIEF DESCRIPTION OF THE SEQUENCES
SEQ ID NO 1: depicts 600 nucleotide bases of the ZsGreen gene sequence.
SEQ ID NO 2: depicts 1071 nucleotide bases of the Zea mays Glutamine Synthetase cDNA sequence.
SEQ ID NO 3: depicts 395 nucleotide bases of the Nicotiana tabacum chloroplast FtsH protease cDNA sequence.
SEQ ID NO 4: depicts 1761 nucleotide bases of the Nicotiana tabacum Phytoene Desaturase cDNA sequence
SEQ ID NO 5: depicts ssRNA that is sense to SEQ ID NO. 1
SEQ ID NO 6: depicts ssRNA complementary to SEQ ID NO 5.
SEQ ID NO 7: depicts ssRNA sense to SEQ ID NO. 2.
SEQ ID NO 8: depicts ssRNA complementary to SEQ ID NO 7.
SEQ ID NO 9: depicts ssRNA sense to SEQ ID NO. 3
SEQ ID NO 10: depicts ssRNA complementary to SEQ ID NO 9.
SEQ ID NO 11 depicts ssRNA sense to SEQ ID NO 4.
SEQ ID NO 12: depicts ssRNA complementary to SEQ ID NO 11.
DETAILED DESCRIPTION OF THE INVENTION
This description is not intended to be a detailed catalog of all the different ways in which the invention may be implemented, or all the features that may be added to the instant invention. For example, features illustrated with respect to one embodiment may be incorporated into other embodiments, and features illustrated with respect to a particular embodiment may be deleted from that embodiment. In addition, numerous variations and additions to the various embodiments suggested herein will be apparent to those skilled in the art in light of the instant disclosure, which do not depart from the instant invention. Hence, the following descriptions are intended to illustrate some particular embodiments of the invention, and not to exhaustively specify all permutations, combinations and variations thereof.
Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. The terminology used in the description of the invention herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention.
All publications, patent applications, patents, and other references mentioned herein are incorporated by reference in their entirety
As used herein, “a,” “an” or “the” can mean one or more than one. For example, a cell can mean a single cell or a multiplicity of cells.
As used herein, “and/or” refers to and encompasses any and all possible combinations of one or more of the associated listed items, as well as the lack of combinations when interpreted in the alternative (or).
Further, the term “about,” as used herein when referring to a measurable value such as an amount of a compound or agent, dose, time, temperature, and the like, is meant to encompass variations of ±20%, ±10%, ±5%, ±1%, ±0.5%, or even ±0.1% of the specified amount.
As used herein, the transitional phrase “consisting essentially of” means that the scope of a claim is to be interpreted to encompass the specified materials or steps recited in the claim and those that do not materially affect the basic and novel characteristic(s) of the claimed invention. Thus, the term “consisting essentially of” when used in a claim of this invention is not intended to be interpreted to be equivalent to “comprising.”
It will be understood that, although the terms “first,” “second,” etc. may be used herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another. Thus, a “first” element (e.g., a first promoter sequence) as described herein could also be termed a “second” element (e.g., a second promoter sequence) without departing from the teachings of the present invention.
The term “RNA” includes any molecule comprising at least one ribonucleotide residue, including those possessing one or more natural ribonucleotides of the following bases: adenine, cytosine, guanine, and uracil; abbreviated A, C, G, and U, respectively, modified ribonucleotides, and non-ribonucleotides. “Ribonucleotide” means a nucleotide with a hydroxyl group at the 2′ position of the D-ribofuranose moiety.
As used herein, the terms and phrases “RNA,” “RNA molecule(s),” and “RNA sequence(s),” are used interchangeably to refer to RNA that mediates RNA interference. These terms and phrases include single-stranded RNA, double-stranded RNA, isolated RNA, partially purified RNA, essentially pure RNA, synthetic RNA, recombinant RNA, intracellular RNA, and also includes RNA that differs from naturally occurring RNA by the addition, deletion, substitution, and/or alteration of one or more nucleotides of the naturally occurring RNA.
An “interfering RNA” (e.g., siRNA and miRNA) is a RNA molecule capable of post-transcriptional gene silencing or suppression, RNA silencing, and/or decreasing gene expression. Interfering RNAs affect sequence-specific, post-transcriptional gene silencing in animals and plants by base pairing to the mRNA sequence of a target nucleic acid. Thus, the siRNA is at least partially complementary to the silenced gene. The partially complementary siRNA may include one or more mismatches, bulges, internal loops, and/or non-Watson-Crick base pairs (i.e., G-U wobble base pairs).
The terms “silencing” and “suppression” are used interchangeably to generally describe substantial and measurable reductions of the amount of the target mRNA available in the cell for binding and decoding by ribosomes. The transcribed RNA can be in the sense orientation to effect what is referred to as co-suppression, in the anti-sense orientation to effect what is referred to as anti-sense suppression, or in both orientations producing a double-stranded RNA to effect what is referred to as RNA interference. A “silenced” gene includes within its definition a gene that is subject to silencing or suppression of the mRNA encoded by the gene.
MicroRNAs are encoded by genes that are transcribed but not translated into protein (non-coding DNA), although some miRNAs are encoded by sequences that overlap protein-coding genes. By way of background, miRNAs are processed from primary transcripts known as pri-miRNAs to short stem loop structures called pre-miRNAs that are further processed by action of dicer enzyme(s) creating functional siRNAs/miRNAs. Typically, a portion of the precursor miRNA is cleaved to produce the final miRNA molecule. The stem-loop structures may range from, for example, about 50 to about 80 nucleotides, or about 60 nucleotides to about 70 nucleotides (including the miRNA residues, those pairing to the miRNA, and any intervening segments). The secondary structure of the stem-loop structure is not fully base-paired; mismatches, bulges, internal loops, non-WatsonCrick base pairs (i.e., G-U wobble base pairs), and other features are frequently observed in pre-miRNAs and such characteristics are thought to be important for processing. Mature miRNA molecules are partially complementary to one or more mRNA molecules, and they function to regulate gene expression. siRNAs of the present invention have structural and functional properties of endogenous miRNAs (e.g., gene silencing and suppressive functions). Thus, in various aspects of the invention, siRNAs of the invention can derived from miRNAs, from target gene sequence information, or can be produced synthetically based on predictive models known in the art.
The phrases “target-specific small interfering RNAs,” “target-specific siRNAs,” “target-specific microRNAs,” “target-specific miRNAs,” “target-specific amiRNAs,” and “target-specific nucleotide sequence” refer to interfering RNAs that have been designed to selectively hybridize with nucleic acids in a target organism, but not in a non-target organism, such as a host organism (the organism expressing or producing the miRNA) or a consumer of the host organism. Consequently, “target-specific siRNAs” only produce phenotypes in target organisms and do not produce phenotypes in non-target organisms. In the present invention, the target-specific siRNAs selectively hybridize to nucleic acids that are endogenous to the host organism, which are plants.
MicroRNAs (miRNAs) are non-protein coding RNAs, generally of between about 19 to about 25 nucleotides (commonly about 20-24 nucleotides in plants). miRNAs direct cleavage in trans of target transcripts, regulating the expression of genes involved in various regulation and development pathways (Bartel, Cell, 116:281-297 (2004); Zhang et al. Dev. Biol. 289:3-16 (2006)). miRNAs have been shown to be involved in different aspects of plant growth and development as well as in signal transduction and protein degradation. In addition, growing evidence indicates that small endogenous mRNAs including miRNAs may also be involved in biotic stress responses such as parasite attack. Since the first miRNAs were discovered in plants (Reinhart et al. Genes Dev. 16:1616-1626 (2002), Park et al. Curr. Biol. 12:1484-1495 (2002)), many hundreds have been identified. Further, many plant miRNAs have been shown to be highly conserved across very divergent taxa. (Floyd et al. Nature 428:485-486 (2004); Zhang et al. Plant J. 46:243-259 (2006)). Many microRNA genes (MIR genes) have been identified and made publicly available in a database (“miRBase,” available on line at microrna.sanger.ac.uk/sequences). miRNAs are also described in U.S. Patent Publications 2005/0120415 and 2005/144669A1, the entire contents of which are incorporated by reference herein.
As used herein, “heterologous” refers to a nucleotide sequence that either originates from another species or is from the same species or organism but is modified from either its original form or the form primarily expressed in the cell. Thus, a nucleotide sequence derived from an organism or species different from that of the cell into which the nucleotide sequence is introduced, is heterologous with respect to that cell and the cell's descendants. In addition, a heterologous nucleotide sequence includes a nucleotide sequence derived from and inserted into the same natural, original cell type, but which is present in a non-natural state, e.g. present in a different copy number, and/or under the control of different regulatory sequences than that found naturally in nature.
The terms “increase,” “increased,” “enhance,” “enhanced,” “enhancing,” and “enhancement” (and grammatical variations thereof), as used herein, describe an increase in the resistance of a plant to a parasite (e.g., a soybean plant having increased resistance to the soybean cyst nematode) by the introduction of a heterologous miRNA nucleotide sequence of the present invention into the plant, thereby producing a transgenic plant having increased resistance to the parasite. This increase can be observed by comparing the resistance of the plant transformed with the heterologous miRNA nucleotide sequence of the invention to a plant (e.g., soybean) that is not transformed with the heterologous miRNA nucleotide sequence of the invention (e.g., a soybean plant transformed with the heterologous miR164 nucleotide sequence compared to a soybean plant that is not transformed with the heterologous miR164 nucleotide sequence).
As used herein, the term “nucleic acid,” “nucleic acid molecule,” and/or “nucleotide sequence” refers to a heteropolymer of nucleotides or the sequence of these nucleotides from the 5′ to 3′ end of a nucleic acid molecule and includes DNA or RNA molecules, including cDNA, a DNA fragment, genomic DNA, synthetic (e.g., chemically synthesized) DNA, plasmid DNA, mRNA, and anti-sense RNA, any of which can be single stranded or double stranded. The terms “nucleotide sequence” “nucleic acid,” “nucleic acid molecule,” “oligonucleotide” and “polynucleotide” are also used interchangeably herein to refer to a heteropolymer of nucleotides. Nucleic acid sequences provided herein are presented herein in the 5′ to 3′ direction, from left to right and are represented using the standard code for representing the nucleotide characters as set forth in the sequence rules for the U.S. Patent and Trademark Office, 37 CFR §§1.821-1.825, and the World Intellectual Property Organization (WIPO) Standard ST.25.
As used herein, the term “gene” refers to a nucleic acid molecule capable of being used to produce mRNA, antisense RNA, miRNA, and the like. Genes may or may not be capable of being used to produce a functional protein or gene product. Genes can include both coding and non-coding regions (e.g., introns, regulatory elements, promoters, enhancers, termination sequences and/or 5′ and 3′ untranslated regions). A gene may be “isolated” by which is meant a nucleic acid that is substantially or essentially free from components normally found in association with the nucleic acid in its natural state. Such components include other cellular material, culture medium from recombinant production, and/or various chemicals used in chemically synthesizing the nucleic acid.
The terms “complementary” or “complementarity,” as used herein, refer to the natural binding of polynucleotides under permissive salt and temperature conditions by base-pairing. For example, the sequence “A-G-T” binds to the complementary sequence “T-C-A.” Complementarity between two single-stranded molecules may be “partial,” in which only some of the nucleotides bind, or it may be complete when total complementarity exists between the single stranded molecules. The degree of complementarity between nucleic acid strands has significant effects on the efficiency and strength of hybridization between nucleic acid strands.
The term “nucleic acid fragment” will be understood to mean a nucleotide sequence of reduced length relative to a reference nucleic acid or nucleotide sequence and comprising, consisting essentially of and/or consisting of a nucleotide sequence of contiguous nucleotides identical or almost identical (e.g., 80%, 81%, 82%, 83%, 84%, 85%, 86%, 87%, 88%, 89%, 90%, 91%, 92%, 93%, 94%, 95%, 96%, 98%, 99% identical) to the reference nucleic acid or nucleotide sequence. Such a nucleic acid fragment according to the invention may be, where appropriate, included in a larger polynucleotide of which it is a constituent. In some embodiments, such fragments can comprise, consist essentially of and/or consist of, oligonucleotides having a length of at least about 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 50, 75, 100, 150, 200, 250, 300, 350, 400, 450, 500, 750, or 1000 consecutive nucleotides of a nucleic acid or nucleotide sequence according to the invention.
An “isolated” nucleic acid of the present invention is generally free of nucleic acid sequences that flank the nucleic acid of interest in the genomic DNA of the organism from which the nucleic acid was derived (such as coding sequences present at the 5′ or 3′ ends). However, the nucleic acid of this invention can include some additional bases or moieties that do not deleteriously affect the basic structural and/or functional characteristics of the nucleic acid. “Isolated” does not mean that the preparation is technically pure (homogeneous).
Thus, an “isolated nucleic acid” is present in a form or setting that is different from that in which it is found in nature and is not immediately contiguous with nucleotide sequences with which it is immediately contiguous (one on the 5′ end and one on the 3′ end) in the naturally occurring genome of the organism from which it is derived. Accordingly, in one embodiment, an isolated nucleic acid includes some or all of the 5′ non-coding (e.g., promoter) sequences that are immediately contiguous to a coding sequence. The term therefore includes, for example, a recombinant nucleic acid that is incorporated into a vector, into an autonomously replicating plasmid or virus, or into the genomic DNA of a prokaryote or eukaryote, or which exists as a separate molecule (e.g., a cDNA or a genomic DNA fragment produced by PCR or restriction endonuclease treatment), independent of other sequences. Thus, a nucleic acid found in nature that is removed from its native environment and transformed into a plant is still considered “isolated” even when incorporated into the genome of the resulting transgenic plant. It also includes a recombinant nucleic acid that is part of a hybrid nucleic acid encoding an additional polypeptide or peptide sequence.
The term “isolated” can further refer to a nucleic acid, nucleotide sequence, polypeptide, peptide or fragment that is substantially free of cellular material, viral material, and/or culture medium (e.g., when produced by recombinant DNA techniques), or chemical precursors or other chemicals (e.g., when chemically synthesized). Moreover, an “isolated fragment” is a fragment of a nucleic acid, nucleotide sequence or polypeptide that is not naturally occurring as a fragment and would not be found as such in the natural state. “Isolated” does not mean that the preparation is technically pure (homogeneous), but it is sufficiently pure to provide the polypeptide or nucleic acid in a form in which it can be used for the intended purpose.
The terms “polypeptide,” “protein,” and “peptide” refer to a chain of covalently linked amino acids. In general, the term “peptide” can refer to shorter chains of amino acids (e.g., 2-50 amino acids); however, all three terms overlap with respect to the length of the amino acid chain. As used herein, the terms “protein” and “polypeptide” are used interchangeably and encompass peptides, unless indicated otherwise. Polypeptides, proteins, and peptides may comprise naturally occurring amino acids, non-naturally occurring amino acids, or a combination of both. The polypeptides, proteins, and peptides may be isolated from sources (e.g., cells or tissues) in which they naturally occur, produced recombinantly in cells in vivo or in vitro or in a test tube in vitro, or synthesized chemically. Such techniques are known to those skilled in the art. See, e.g., Sambrook et al., Molecular Cloning: A Laboratory Manual 2nd Ed. (Cold Spring Harbor, N.Y., 1989); Ausubel et al. Current Protocols in Molecular Biology (Green Publishing Associates, Inc. and John Wiley & Sons, Inc., New York).
The term “fragment,” as applied to a polypeptide, will be understood to mean an amino acid sequence of reduced length relative to a reference polypeptide or amino acid sequence and comprising, consisting essentially of, and/or consisting of an amino acid sequence of contiguous amino acids identical to the reference polypeptide or amino acid sequence. Such a polypeptide fragment according to the invention may be, where appropriate, included in a larger polypeptide of which it is a constituent. In some embodiments, such fragments can comprise, consist essentially of, and/or consist of peptides having a length of at least about 4, 6, 8, 10, 12, 15, 20, 25, 30, 35, 40, 45, 50, 75, 100, 150, 200, or more consecutive amino acids of a polypeptide or amino acid sequence according to the invention. A fragment of a polypeptide or protein can be produced by methods well known and routine in the art, for example, by enzymatic or other cleavage of naturally occurring peptides or polypeptides or by synthetic protocols that are well known.
A polypeptide fragment can be a biologically active fragment. A “biologically active fragment” or “active fragment” refers to a fragment that retains one or more of the biological activities of the reference polypeptide. Such fragments can be tested for biological activities according to methods described in the art, which are routine methods for testing activities of polypeptides, and/or according to any art-known and routine methods for identifying such activities. The production and testing to identify biologically active fragments of a polypeptide would be well within the scope of one of ordinary skill in the art and would be routine. Thus, the present invention further provides biologically active fragments of a polypeptide such as a polypeptide of interest and the polynucleotides encoding such biologically active polypeptide fragments.
The term “transgene” as used herein, refers to any nucleic acid sequence used in the transformation of a plant, animal, or other organism. Thus, a transgene can be a coding sequence, a non-coding sequence, a cDNA, a gene or fragment or portion thereof, a genomic sequence, a regulatory element and the like. A “transgenic” organism, such as a transgenic plant, transgenic microorganism, or transgenic animal, is an organism into which a transgene has been delivered or introduced and the transgene can be expressed in the transgenic organism to produce a product, the presence of which can impart an effect and/or a phenotype in the organism.
Different nucleic acids or polypeptides having homology are referred to herein as “homologues.” The term homologue includes homologous sequences from the same and other species and orthologous sequences from the same and other species. “Homology” refers to the level of similarity between two or more nucleic acid and/or amino acid sequences in terms of percent of positional identity (i.e., sequence similarity or identity). Homology also refers to the concept of similar functional properties among different nucleic acids or proteins.
As used herein “sequence identity” refers to the extent to which two optimally aligned polynucleotide or polypeptide sequences are invariant throughout a window of alignment of components, e.g., nucleotides or amino acids. “Identity” can be readily calculated by known methods including, but not limited to, those described in: Computational Molecular Biology (Lesk, A. M., ed.) Oxford University Press, New York (1988); Biocomputing: Informatics and Genome Projects (Smith, D. W., ed.) Academic Press, New York (1993); Computer Analysis of Sequence Data, Part I (Griffin, A. M., and Griffin, H. G., eds.) Humana Press, New Jersey (1994); Sequence Analysis in Molecular Biology (von Heinje, G., ed.) Academic Press (1987); and Sequence Analysis Primer (Gribskov, M. and Devereux, J., eds.) Stockton Press, New York (1991).
An “identity fraction” for aligned segments of a test sequence and a reference sequence is the number of identical components which are shared by the two aligned sequences divided by the total number of components in reference sequence segment, i.e., the entire reference sequence or a smaller defined part of the reference sequence. As used herein, the term “percent sequence identity” or “percent identity” refers to the percentage of identical nucleotides in a linear polynucleotide sequence of a reference (“query”) polynucleotide molecule (or its complementary strand) as compared to a test (“subject”) polynucleotide molecule (or its complementary strand) when the two sequences are optimally aligned (with appropriate nucleotide insertions, deletions, or gaps totaling less than 20 percent of the reference sequence over the window of comparison). In some embodiments, “percent identity” can refer to the percentage of identical amino acids in an amino acid sequence.
Optimal alignment of sequences for aligning a comparison window are well known to those skilled in the art and may be conducted by tools such as the local homology algorithm of Smith and Waterman, the homology alignment algorithm of Needleman and Wunsch, the search for similarity method of Pearson and Lipman, and optionally by computerized implementations of these algorithms such as GAP, BESTFIT, FASTA, and TFASTA available as part of the GCG® Wisconsin Package® (Accelrys Inc., Burlington, Mass.). An “identity fraction” for aligned segments of a test sequence and a reference sequence is the number of identical components which are shared by the two aligned sequences divided by the total number of components in the reference sequence segment, i.e., the entire reference sequence or a smaller defined part of the reference sequence. Percent sequence identity is represented as the identity fraction multiplied by 100. The comparison of one or more polynucleotide sequences may be to a full-length polynucleotide sequence or a portion thereof, or to a longer polynucleotide sequence. For purposes of this invention “percent identity” may also be determined using BLASTX version 2.0 for translated nucleotide sequences and BLASTN version 2.0 for polynucleotide sequences.
The percent of sequence identity can be determined using the “Best Fit” or “Gap” program of the Sequence Analysis Software Package™ (Version 10; Genetics Computer Group, Inc., Madison, Wis.). “Gap” utilizes the algorithm of Needleman and Wunsch (Needleman and Wunsch, J. Mol. Biol. 48:443-453, 1970) to find the alignment of two sequences that maximizes the number of matches and minimizes the number of gaps. “BestFit” performs an optimal alignment of the best segment of similarity between two sequences and inserts gaps to maximize the number of matches using the local homology algorithm of Smith and Waterman (Smith and Waterman, Adv. Appl. Math., 2:482-489, 1981, Smith et al., Nucleic Acids Res. 11:2205-2220, 1983).
Useful methods for determining sequence identity are also disclosed in Guide to Huge Computers (Martin J. Bishop, ed., Academic Press, San Diego (1994)), and Carillo, H., and Lipton, D., ( Applied Math 48:1073 (1988)). More particularly, preferred computer programs for determining sequence identity include but are not limited to the Basic Local Alignment Search Tool (BLAST) programs which are publicly available from National Center Biotechnology Information (NCBI) at the National Library of Medicine, National Institute of Health, Bethesda, Md. 20894; see BLAST Manual, Altschul et al., NCBI, NLM, NIH; (Altschul et al., J. Mol. Biol. 215:403-410 (1990)); version 2.0 or higher of BLAST programs allows the introduction of gaps (deletions and insertions) into alignments; for peptide sequence BLASTX can be used to determine sequence identity; and, for polynucleotide sequence BLASTN can be used to determine sequence identity.
Accordingly, the present invention further provides nucleotide sequences having significant sequence identity to the nucleotide sequences of the present invention. Significant sequence similarity or identity means at least 70%, 75%, 80%, 81%, 82%, 83%, 84%, 85%, 86%, 87%, 88%, 89%, 90%, 91%, 92%, 93%, 94%, 96%, 97%, 98%, 99% and/or 100% similarity or identity with another nucleotide sequence.
“Introducing,” in the context of a nucleotide sequence of interest (e.g., miR164), means presenting the nucleotide sequence of interest to the plant, plant part, and/or plant cell in such a manner that the nucleotide sequence gains access to the interior of a cell. Where more than one nucleotide sequence is to be introduced these nucleotide sequences can be assembled as part of a single polynucleotide or nucleic acid construct, or as separate polynucleotide or nucleic acid constructs, and can be located on the same or different transformation vectors. Accordingly, these polynucleotides can be introduced into plant cells in a single transformation event, in separate transformation events, or, e.g., as part of a breeding protocol. Thus, the term “transformation” as used herein refers to the introduction of a heterologous nucleic acid into a cell. Transformation of a cell may be stable or transient.
Thus, in some particular embodiments, the introducing into a plant, plant part and/or plant cell is via bacterial-mediated transformation, particle bombardment transformation, calcium-phosphate-mediated transformation, cyclodextrin-mediated transformation, electroporation, liposome-mediated transformation, nanoparticle-mediated transformation, polymer-mediated transformation, virus-mediated nucleic acid delivery, whisker-mediated nucleic acid delivery, microinjection, sonication, infiltration, polyethyleneglycol-mediated transformation, any other electrical, chemical, physical and/or biological mechanism that results in the introduction of nucleic acid into the plant, plant part and/or cell thereof, or a combination thereof.
The terms “reduce,” “reduced,” “reducing,” “reduction,” “diminish,” and “decrease” (and grammatical variations thereof), as used herein, describe a decrease in the soybean cyst nematode cyst formation on a plant (e.g., soybean) by the introduction of a miRNA of the present invention into the plant, thereby producing a transgenic plant having decreased or reduced cyst formation on the transgenic plant. This decrease in cyst formation can be observed, by comparing the number of cysts formed on the plant transformed with the heterologous miR164 nucleotide sequence to the number formed on a soybean plant that is not transformed with the heterologous miR164 nucleotide sequence.
By “stably introducing” or “stably introduced” in the context of a polynucleotide introduced into a cell is intended the introduced polynucleotide is stably incorporated into the genome of the cell, and thus the cell is stably transformed with the polynucleotide. “Stable transformation” or “stably transformed” as used herein means that a nucleic acid is introduced into a cell and integrates into the genome of the cell. As such, the integrated nucleic acid is capable of being inherited by the progeny thereof, more particularly, by the progeny of multiple successive generations. “Genome” as used herein also includes the nuclear and the plastid genome, and therefore includes integration of the nucleic acid into, for example, the chloroplast genome. Stable transformation as used herein can also refer to a transgene that is maintained extrachromasomally, for example, as a minichromosome.
Transient transformation may be detected by, for example, an enzyme-linked immunosorbent assay (ELISA) or Western blot, which can detect the presence of a peptide or polypeptide encoded by one or more transgene introduced into an organism. Stable transformation of a cell can be detected by, for example, a Southern blot hybridization assay of genomic DNA of the cell with nucleic acid sequences which specifically hybridize with a nucleotide sequence of a transgene introduced into an organism (e.g., a plant). Stable transformation of a cell can be detected by, for example, a Northern blot hybridization assay of RNA of the cell with nucleic acid sequences which specifically hybridize with a nucleotide sequence of a transgene introduced into a plant or other organism. Stable transformation of a cell can also be detected by, e.g., a polymerase chain reaction (PCR) or other amplification reactions as are well known in the art, employing specific primer sequences that hybridize with target sequence(s) of a transgene, resulting in amplification of the transgene sequence, which can be detected according to standard methods Transformation can also be detected by direct sequencing and/or hybridization protocols well known in the art.
A nucleic acid (e.g., ZsGreen) can be introduced into a cell by any method known to those of skill in the art. In some embodiments of the present invention, transformation of a cell comprises nuclear transformation. In other embodiments, transformation of a cell comprises plastid transformation (e.g., chloroplast transformation).
Procedures for transforming plants are well known and routine in the art and are described throughout the literature. Non-limiting examples of methods for transformation of plants include transformation via bacterial-mediated nucleic acid delivery (e.g., via Agrobacteria ), viral-mediated nucleic acid delivery, silicon carbide or nucleic acid whisker-mediated nucleic acid delivery, liposome mediated nucleic acid delivery, microinjection, microparticle bombardment, calcium-phosphate-mediated transformation, cyclodextrin-mediated transformation, electroporation, nanoparticle-mediated transformation, sonication, infiltration, PEG-mediated nucleic acid uptake, as well as any other electrical, chemical, physical (mechanical) and/or biological mechanism that results in the introduction of nucleic acid into the plant cell, including any combination thereof. General guides to various plant transformation methods known in the art include Mild et al. (“Procedures for Introducing Foreign DNA into Plants” in Methods in Plant Molecular Biology and Biotechnology , Glick, B. R. and Thompson, J. E., Eds. (CRC Press, Inc., Boca Raton, 1993), pages 67-88) and Rakowoczy-Trojanowska ( Cell. Mol. Biol. Lett. 7:849-858 (2002)).
Thus, in some particular embodiments, the introducing into a plant, plant part and/or plant cell is via bacterial-mediated transformation, particle bombardment transformation, calcium-phosphate-mediated transformation, cyclodextrin-mediated transformation, electroporation, liposome-mediated transformation, nanoparticle-mediated transformation, polymer-mediated transformation, virus-mediated nucleic acid delivery, whisker-mediated nucleic acid delivery, microinjection, sonication, infiltration, polyethyleneglycol-mediated transformation, any other electrical, chemical, physical and/or biological mechanism that results in the introduction of nucleic acid into the plant, plant part and/or cell thereof, or a combination thereof.
Agrobacterium -mediated transformation is a commonly used method for transforming plants, in particular, dicot plants, because of its high efficiency of transformation and because of its broad utility with many different species. Agrobacterium -mediated transformation typically involves transfer of the binary vector carrying the foreign DNA of interest to an appropriate Agrobacterium strain that may depend on the complement of vir genes carried by the host Agrobacterium strain either on a co-resident Ti plasmid or chromosomally (Uknes et al. (1993) Plant Cell 5:159-169). The transfer of the recombinant binary vector to Agrobacterium can be accomplished by a tri-parental mating procedure using Escherichia coli carrying the recombinant binary vector, a helper E. coli strain that carries a plasmid that is able to mobilize the recombinant binary vector to the target Agrobacterium strain. Alternatively, the recombinant binary vector can be transferred to Agrobacterium by nucleic acid transformation (Höfgen & Willmitzer (1988) Nucleic Acids Res. 16:9877).
Transformation of a plant by recombinant Agrobacterium usually involves co-cultivation of the Agrobacterium with explants from the plant and follows methods well known in the art. Transformed tissue is regenerated on selection medium carrying an antibiotic or herbicide resistance marker between the binary plasmid T-DNA borders.
Another method for transforming plants, plant parts and plant cells involves propelling inert or biologically active particles at plant tissues and cells. See, e.g., U.S. Pat. Nos. 4,945,050; 5,036,006 and 5,100,792. Generally, this method involves propelling inert or biologically active particles at the plant cells under conditions effective to penetrate the outer surface of the cell and afford incorporation within the interior thereof. When inert particles are utilized, the vector can be introduced into the cell by coating the particles with the vector containing the nucleic acid of interest. Alternatively, a cell or cells can be surrounded by the vector so that the vector is carried into the cell by the wake of the particle. Biologically active particles (e.g., dried yeast cells, dried bacterium or a bacteriophage, each containing one or more nucleic acids sought to be introduced) also can be propelled into plant tissue.
Thus, in particular embodiments of the present invention, a plant cell can be transformed by any method known in the art and as described herein and intact plants can be regenerated from these transformed cells using any of a variety of known techniques. Plant regeneration from plant cells, plant tissue culture and/or cultured protoplasts is described, for example, in Evans et al. ( Handbook of Plant Cell Cultures , Vol. 1, MacMilan Publishing Co. New York (1983)); and Vasil I. R. (ed.) ( Cell Culture and Somatic Cell Genetics of Plants , Acad. Press, Orlando, Vol. I (1984), and Vol. II (1986)). Methods of selecting for transformed transgenic plants, plant cells and/or plant tissue culture are routine in the art and can be employed in the methods of the invention provided herein.
Likewise, the genetic properties engineered into the transgenic seeds and plants, plant parts, and/or plant cells of the present invention described above can be passed on by sexual reproduction or vegetative growth and therefore can be maintained and propagated in progeny plants. Generally, maintenance and propagation make use of known agricultural methods developed to fit specific purposes such as harvesting, sowing or tilling.
Example 1
Silencing of ZsGreen in Transgenic Maize Plants
ZsGreen-transgenic maize vector 15779 was created and is shown in Figure 1. The ZsGreen fluorescent protein is more fully described in a publication entitled: Reef - Coral proteins as visual, non - destructive reporters for plant transformation . Plant Cell Rep (2003) 22:244-251. The vector was transformed into disarmed Agrobacterium tumafaciens strain LBA4404 containing helper plasmid pSB1.
dsRNA was generated from known ZsGreen sequence. Various lengths of dsRNA derived from a target gene may be used according to the invention. By way of example only, the following sequence was used in the formulation of the invention. This sequence is a dsRNA version (SEQ ID NO 5:SEQ ID NO 6) of DNA coding SEQ ID NO 1:
The dsRNA formulation (dsRNA treatment) included about 250 ng/ul dsRNA, H2O, and a plant hormone brassinosteroid (BR) at about 0.8 micromolar to about 1.6 micromolar. The control solution was the same solution, absent ZsGreen dsRNA.
In one embodiment, the Brassinosteroid used in the formulation of the invention is an Epibrassinolide (22R, 23R, 24R-2a, 3a, 22, 23-Tetrahydrosy-B-homo-7-oxa-5a-ergostan-6-one (PubChem Substance ID: 24894426).
It is within the scope of the present invention to use any plant hormone in the formulation and method of the present, provided it is capable of mediating penetration of dsRNA into plant cells and the subsequent induction of plant endogenous gene silencing by application of the formulation to a surface of a plant structure.
It is also within the scope of the present invention to use a combination of two or more plant hormones in the formulation and method of the present invention, provided the combination is capable of mediating penetration of dsRNA into plant cells and the subsequent induction of plant endogenous gene silencing by application of the formulation to a surface of a plant structure.
It is also understood and it is within the scope of the invention that the plant hormone in the formulation or the combination of plant hormones in the formulation and method of the present invention may assist dsRNA processing inside the plant cell for plant endogenous gene silencing. Other plant hormones that could be used according to the method of the present invention include abscisic acid, auxins, cytokinins, gibberellins, jasmonates, ethylene, salicyclic acid, nitric oxide, or strigolactones.
Seeds transformed with binary vector 15760 and shown to express ZsGreen were germinated at 25 C in darkness for 12 days. Once germinated, 4 plants were chosen as control group, and 4 plants as dsRNA treatment group. At around 12 days after germination, the control or dsRNA formulated solution was dripped onto the maize leaf surface. Leakage of the solution from the leaf to root was prevented by wrapping layers of parafilm at the junction part between leaf and stem. ZsGreen fluorescence in the plant leaves was visualized under UV light and was recorded at various time points post-treatment. Silencing was observed as early as 9 days post-treatment. Evaluation of ZsGreen silencing was based on the comparison of green fluorescence between control and dsRNA treated plant leaves. At 20 days post-treatment, ZsGreen silencing in four dsRNA treatment plants were observed under a Zeiss dissecting microscope at 3-4× magnification; this magnification is capable of detecting the silencing phenomena at the cellular level in leaf tissue.
ZsGreen expression was detected in the leaf tissue of the four control plants, demonstrating that silencing of ZsGreen expression did not occur in the control plants. One control plant, however, was contaminated by fungus and the plantlet did not have strong green fluorescence.
In all four plants that were treated with the dsRNA formulation as described above, the expression of the ZsGreen was silenced. The green-fluorescence signal of the treated plant leaves was not detectable under UV light at the same fixed exposure time as in the control group, demonstrating the severe silencing phenotype.
Overall, the data established high efficacy of silencing (100% in treatment vs % in control), demonstrating the efficacy of spraying dsRNA for regulating endogenous gene expression in crop plants.
Example 2
Silencing of Maize Glutamine Synthetase
A similar experiment was performed using dsRNA generated from the known maize glutamine synthetase RNA sequence Zma-GS dsRNA was synthesized using the AmpliScribe™ T7-Flash™ Transcription Kit, Epicentre® (an Illumina Company) according to manufacturer's suggested protocol. The Zma-GS dsRNA molecule (SEQ ID NO 7:SEQ ID NO 8) used in this embodiment is a double stranded RNA version of SEQ ID NO 2. Methods for formulation of dsRNA and control solutions, plant growth conditions, and application of RNAi formulation were as described in the above example, with the exception that another control formulation was added with only Brassinosteroid at 0.1 micromolar.
Results were evaluated from leaf samples taken 2-3 weeks after treatment. Four plants were examined from each treatment group. Phenotypically, bleaching was observed on the dsRNA treated plants. Since glutamine synthetase is a natively expressed gene, qPCR analysis was performed to calculate silencing efficiency. qPCR was performed using the Applied Biosystems 7900HT Fast Real-Time PCR System. Silencing efficiency was calculated according to the publication Analysis of Relative Gene Expression Data Using Real - Time Quantitative PCR and the 2 −ΔΔCt Method. Methods (2001) 25:402-408. Briefly, ΔC t was calculated for each sample, where ΔC t =sample C t -reference C t ; ΔΔC t =experimentalΔC t -controlΔC t ; silencing efficiency=(1-2 −ΔΔCt )×100% The following table displays the results, where “dsGS” is the Zma-GS dsRNA described above:
Event
Formulation
Silencing Efficiency
ZmGS-Tt-1
dsGS + BR + H2O
84.07%
ZmGS-Tt-2
dsGS + BR + H2O
73.37%
ZmGS-Tt-3
dsGS + BR + H2O
86.64%
ZmGS-Tt-4
dsGS + BR + H2O
81.99%
ZmGS-CK-1-1
dsGS + H2O
11.71%
ZmGS-CK-1-2
dsGS + H2O
0%
ZmGS-CK-1-3
dsGS + H2O
12.78%
ZmGS-CK-1-4
dsGS + H2O
0%
ZmGS-CK-2_1
BR + H2O
0%
ZmGS-CK-2_2
BR + H2O
0%
ZmGS-CK-2_3
BR + H2O
12.21%
ZmGS-CK-2_4
BR + H2O
0%
Example 3
Silencing of NtFtsH Transcript in Tobacco
The tobacco gene encoding Filamentation temperature-sensitive H (NtFtsH) protease was evaluated for silencing using dsRNA constructs in combination with BR. Tobacco was chosen as a model dicot plant system, and these experiments demonstrate that this approach is valid in dicotyledenous species as well. Similar to Example 2, dsRNA was synthesized using AmpliScribe™ T7-Flash™ Transcription Kit, Epicentre® (an Illumina Company) according to manufacturer's suggested protocol. The NtFtsH protease dsRNA molecule (SEQ ID NO 9:SEQ ID NO 10) used in this embodiment is a double stranded version of SEQ ID NO. 3.
Once germinated, tobacco plants were transplanted to new soil and grown for an additional 3-4 weeks. Three tobacco plants were chosen for treatment for either the dsRNA or the control formulation. The treatments were applied using methods similar to those described in Example 2. Here, the control formulation contained ZsGreen dsRNA. The tobacco plants did not have the ZsGreen transgene. Similar to Example 2, a bleaching phenotype was observed in the leaves of the dsRNA treated plants, and results were evaluated by performing qPCR on samples taken 2-3 weeks after treatment. As in Example 2, the silencing efficiencies were calculated and are shown in the table below, where dsNtFtsH is dsRNA from NtFtsH protease and dsZsGreen is the dsRNA of ZsGreen:
Event
Formulation
Silencing Efficiency
Spray NtFtsH_1
dsNtFtsH + BR + H2O
73.49%
Spray NtFtsH_2
dsNtFtsH + BR + H2O
82.21%
Spray NtFtsH_3
dsNtFtsH + BR + H2O
77.22%
CK Spray-1
dsZsGreen + BR + H2O
0%
CK Spray-1
dsZsGreen + BR + H2O
0%
CK Spray-1
dsZsGreen + BR + H2O
0%
Example 4
Silencing of NtPDS Transcript in Tobacco
The tobacco gene encoding phytoene desaturase was evaluated for silencing using dsRNA constructs in combination with BR. Similar to Example 2 and 3, dsRNA was synthesized using AmpliScribe™ T7-Flash™ Transcription Kit, Epicentre® (an Illumina Company) according to manufacturer's suggested protocol. The NtPDS dsRNA molecule (SEQ ID NO 10:SEQ ID NO 11) used in this embodiment is a double stranded RNA version of SEQ ID NO 4.
Similar to Example 3, once germinated and grown for 3-4 weeks, three tobacco plants were chosen for treatment for either the dsRNA or the control formulation. Here, the control formulation contained BR and water alone. Similar to Examples 2 and 3, a bleaching phenotype was observed in the leaves of the dsRNA treated plants, and results were evaluated by performing qPCR on samples taken 2-3 weeks after treatment. As in Examples 2 and 3, the silencing efficiencies were calculated and are shown in the table below, where dsPDS is dsRNA from NtPDS.
Event
Formulation
Silencing Efficiency
Spray_NtPDS-1
dsPDS + BR + H2O
75.58%
Spray_NtPDS-2
dsPDS + BR + H2O
85.55%
Spray_NtPDS-3
dsPDS + BR + H2O
67.42%
Spray_NtPDS-CK-1
BR + H2O
0%
Spray_NtPDS-CK-2
BR + H2O
0%
Spray_NtPDS-CK-3
BR + H2O
0%
Overall, these examples demonstrate that application of dsRNA formulations with a plant hormone has silencing effects on both monocotyledonous and dicotyledonous plant cells. In one embodiment, the plant hormone may be a brassinosteroid.
The present invention, therefore, demonstrates the ability to introduce dsRNA into plant cells by application of a formulation to a plant surface and to then silence gene protein expression therein.
All publications and patent applications mentioned in the specification are indicative of the level of skill of those skilled in the art to which this invention pertains. All publications and patent applications are herein incorporated by reference to the same extent as if each individual publication or patent application was specifically and individually indicated to be incorporated by reference.
Although the foregoing invention has been described in some detail by way of illustration and example for purposes of clarity of understanding, it will be obvious that certain changes and modifications may be practiced within the scope of the list of the foregoing embodiments and the appended claims. | This invention provides a method to silence an endogenous target gene expression in plants by applying a specific dsRNA onto the exterior surface of a plant. Application, such as by spraying or brushing a plant with dsRNA is done without wounding the plant tissue and cells such as by mechanical-type wounding, particle bombardment or mechanical infection with viral vectors. The present invention enables the regulation of gene expression in plants. In some embodiments of the invention, the dsRNA is directed to an essential gene of a plant pathogen or pest, whereby the pathogen and/or pest damage is controlled, resulting in desired agronomic performance. | 2 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a national stage application under 35 U.S.C. §371 of international application PCT/EP99/007579 filed on Oct. 9, 1999, the international application not being published in English. This application also claims priority under 35 U.S.C. §119 to DE 198 48 146.2 filed on Oct. 20, 1998.
FIELD OF THE INVENTION
This invention relates to hotmelt adhesives for bonding DVDs of sandwich construction and to a process for the production of !DVDs of sandwich constuction
BACKGROUND OF THE INVENTION
“DVD” is the abbreviation for digital versatile disc or digital video disc. These are optical storage media similar to the known CDs (compact discs). The principal difference between DVDs and CDs and other known storage media is the far higher density of the musical, graphic or data information stored in DVDs. This higher data or information density of the storage medium imposes stringent demands on the manufacturing process and the materials used therein.
One possible structure for a DVD is schematized in FIG. 1 . The DVD in question is a so-called (DVD 5 which consists essentially of two halves,) is one-sided and carries a layer of information; it has a storage capacity of 4.7 gigabytes. In FIG. 1, the layer which carries the information is denoted by the reference numeral “1” while the outer layer which does not carry any information is denoted by the reference numeral “2”. The laser beam required to scan the information is denoted by the reference numeral “7”.
Accordingly, the construction of DVDs differs from that of the generally known CDs (compact discs) in the fact that (DVDs have a sandwich construction) Whereas CDs essentially consist of a 1.2 mm thick disc of polycarbonate or poly(meth)acrylate resin, (DVDs are made of two 0.6 mm thick discs for which polycarbonate is almost exclusively used today.) Through a refined data structure and lasers of minimal wavelength, the information layer of a DVD can contain ca. 4.7 gigabytes of information whereas conventional CDs can only store around 640 megabytes of information.
The sandwich construction of DVDs means that the two layers 1 and 2 have to be joined together. Originally, solvent-based adhesives were used to join the two layers together. More recently, hotmelt adhesives, UV-curable solvent-free liquid adhesives and UV-crosslinkable hotmelt adhesives have been proposed.
The following steps are absolutely essential in the production of a DVD:
The polycarbonate or poly(meth)acrylate blanks have to be made by injection molding.
The blank 1 carrying the layer of information is coated with a reflective layer. This is generally a reflection layer, for example of aluminium, applied by vapor deposition in vacuo.
The reflective layer has to be protected against corrosion immediately after production. In one known embodiment, therefore, a lacquer film cured by UV radiation is applied to the reflective layer. An alternative method comprises applying a protective film of a thermoplastic material.
The blank 2 without a layer of information can be printed with graphics and text by various methods.
The blanks 1 and 2 are bonded together with an adhesive.
DE-A-3224647 describes a process for the production of optical video discs or digital audio discs. According to this document, the layer carrying the information, after coating with a reflective film of aluminium, is provided with a protective film of a thermoplastic film-forming material which melts at a predetermined temperature and hardens at room temperature. In one embodiment, this thermoplastic film-forming material is also the adhesive for bonding the two disc substrate halves together. In another embodiment, this film-forming material is coated with another adhesive which is tacky at room temperature. The two disc substrates are bonded together with this adhesive. DE-A-3224647 does not provide any details of the composition of the thermoplastic film-forming material or of the adhesive tacky at room temperature. In addition, there is nothing in the teaching of DE-A-3224647 to indicate whether these adhesive materials would also be suitable for the production of DVDs.
DE-A-3246857 describes an optical disc comprising a pair of substrates of which at least one has information pits formed on one surface. A metallic layer of a reflective film is applied to this layer of information pits and a protective resin layer is in turn applied to the metallic reflective film. Applied to the protective resin layer is a layer of adhesive which is used to join the two substrate halves. According to DE-A-3246857, hotmelt adhesives containing a mixture of one or more thermoplastic elastomers as basic polymer are used as the adhesive. In addition, it is clear from the teaching of DE-A-3246857 that the hotmelt adhesives described therein contain normal tackifying resins and additives, for example fillers, antioxidants or UV absorbers, to increase their heat and weathering resistance. It is also stated that the melt viscosity of the adhesive should not exceed a value of 1,000 poises at 160° C. to ensure that the adhesive does not have any adverse effects on the metallic film applied by vapor deposition. There is no mention of the suitability of these adhesives for the production of DVDs.
According to the teaching of DE-A-3840391, the use of hotmelt adhesives for bonding substrate pairs in the production of video discs or digital audio discs is problematical on account of their poor thermal stability. The use of UV-curable monomer compositions as the adhesive can cause corrosion of the substrate. For bonding the substrate pairs in the production of video discs, DE-A-3840391 proposes the use of UV-crosslinkable hotmelt adhesives. There is nothing to indicate whether these UV-crosslinkable hotmelt adhesives would be suitable for the production of DVDs.
As mentioned at the beginning, DVDs are distinguished from known CDs or optical discs (also known as laser discs) by a high data or information storage density of the storage medium so that they impose greater demands on the production process and on the materials used therein, for example adhesives. The associated problems are described in detail in EP-A-0 735 530. In view of the high information density and the small diameter of a disc of a DVD, the tolerable deviation from the optimal planar orientation of the disc on insertion into the player is significantly smaller than with conventional laser discs so that a minor deviation of the orientation of the disc can clearly falsify the information signal reproduced. For this reason, a DVD inserted into the player has to be able to stay in the player without warpage or distortion, even under the thermal stress of a relatively long playing time, although the two individual layers of the DVD only consist of about 0.6 mm thick plastic blanks. UV-curing adhesives tend towards adhesion failures, for example when subjected to impact stress, because they are generally very brittle after curing. Also, most UV-curing adhesives and other two-component adhesives are characterized by relatively high inherent shrinkage. The resulting force applied by the adhesive to the reflective layer can impair the information content and operational reliability of the DVD. For this reason, EP-A-0 735 530 proposes a combination of a hotmelt adhesive and a liquid two-component adhesive for bonding the two halves of the DVD together. Compositions for the proposed hotmelt adhesives are not mentioned. It is proposed that cationically polymerizing UV-curing adhesives be used for the liquid two-component adhesives.
WO-A-98/40833 describes the use of a hotmelt adhesive with a melt viscosity of more than 100,000 mPa.s at 160° C. for bonding digital video, discs (DVDs) of sandwich construction. In preferred embodiments, the hotmelt adhesives are said to contain pigments to obtain high-contrast backgrounds for improving the images/graphics and text on the DVDs. WO-A-98140833 does not provide any particulars of the thermal stability of the DVDs thus bonded, particularly with regard to distortion-free scanning of the information stored on the DVD.
JP-A-09 208 919 describes compositions of hotmelt adhesives for optical discs which consist essentially of three components. The first component is a styrene resin consisting of styrene/diene block copolymers or hydrogenated derivatives there of. The second component of the hotmelt adhesives is a tackifier based on rosin, terpene or petroleum resins, the softening point of the tackifier being said to be at least 115° C. and preferably at least 140° C. In addition, the hotmelt adhesives according to the teaching of the document in question are said to contain waxes, preferably paraffin waxes, micro waxes, low molecular weight polyethylene, low molecular weight polypropylene and non-crystalline poly-α-olefin. In particular, it is proposed to use waxes with no functional group in their molecular structure, preferably crystalline polypropylene with an average molecular weight of at most 20,000. Although JP-A-09 208 919 does mention standard adhesive properties, such as ring-and-ball softening point, melt viscosity, peel strength, bond strength and creepage at elevated temperature, the information provided is not conclusive as to the suitability of these adhesives for bonding DVDs.
Among the latest advances in the quality control of optical data carriers, above all DVDs, test systems have recently been developed to enable the tilt and dishing of DVDs to be determined by triangulation. To this end, the deflection of a reflected laser beam is evaluated. The degree of deflection is recorded through a receiver, which converts the position of the deflected beam into electrical signals, and transmitted to the analog/digital converter for evaluation. One example of such a test system is the Optical Disc Test System Advanced Version (ODT-A) of Conttec GmbH.
The adhesive used influences both the tilt and the dishing of a disc to a considerable extent, particularly in the presence of heat and/or: moisture.
Against the background of this prior art, the problem addressed by the present invention was to provide an adhesive which would enable DVDs to be economically produced without the disadvantages of UV-curing adhesives or the hitherto known hotmelt adhesives and which would still meet the strict requirements of the latest quality control standards for DVDs.
SUMMARY OF THE INVENTION
The solution to this problem is defined in the claims and consists essentially in the use of a hotmelt adhesive for the production of digital versatile discs (DVDs) based on
a) at least one thermoplastic elastomer,
b) at least one hydrocarbon resin,
c) at least one poly-α-olefin,
d) at least one polar wax bearing functional groups.
In. addition to the key components mentioned above, the hotmelt adhesives to be used in accordance with the invention may also contain tackifying resins, optionally plasticizers, stabilizers/antioxidants, optionally fillers or extenders, pigments, coupling agents and mixtures therof.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional view of a digital video disc.
FIG. 2 is an enlarged cross-sectional view of a digital video disc of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Examples of the thermoplastic elastomers of component a) are thermoplastic polyurethanes (TPU) which are generally based on aromatic diisocyanates. Block copolymers of the A-B-, A-B-A-, A-(B-A) n -B- and (A-B) n -Y- type, where A is an aromatic polyvinyl block and the B block surrounds a rubber-like middle block which may be partly or completely hydrogenated, are also particularly suitable. Examples of such block copolymers contain a polystyrene block as A and a substantially rubber-like polybutadiene and/or polyisoprene block as B, Y may be a polyfunctional compound and n is an integer of at least 3. To improve thermal stability, the middle block B (i.e. the polybutadiene or polyisoprene block) may optionally be partly hydrogenated so that the double bonds originally present are at least partly removed. Block copolymers such as these are also available from various manufacturers as SBS (styrenelbuta-diene/styrene) copolymers or as SIS (styrene/isoprene/styrene) copolymers or as SEPS (styrene/ethylene/propylene/styrene), SEEPS (styrene/ethylene/ethylene/propylene/styrene) or SEBS (styrene/ethylene/butadiene/styrene) copolymers.
The hydrocarbon resin of component b) may be selected from aliphatic, cycloaliphatic or aromatic hydrocarbon resins or even aliphatic/aromatic hydrocarbon resins, petroleum hydrocarbon resins and hydrogenation products and mixtures ther eof. These hydrocarbon resins are known to be polymers with a molecular weight of, in general, <2,000. They are obtained by the polymerization of C 5 cuts of unsaturated compounds and, in many cases, are hydrogenated in a following step. Actual examples are hydrocarbon resins based on polycyclopentadiene with subsequent hydrogenation —such products are marketed by Exxon under the name of Escorez. Similar products are also marketed by CdF Chemie under the name of Norsolene, by Goodyear under the name of Wing-Tack, by Hercules under the names of Hercures, Kristalex and Piccotac and by Reichhold under the name of Sta-tac and by Idemitsu.
Suitable poly-α-olefins of component c) are the atactic α-olefin copolymers and terpolymers of ethylene, propylene and/or 1-butene with molecular weights in the range from 5,000 to 30,000, the molecular weight being determined as a number average by gel permeation chromatography (GPS) in accordance with DIN 55 672. It is known that copolymers and terpolymers such as these can be obtained from the above-mentioned. monomers by a continuous Ziegler low-pressure polymerization process. They are also known as poly-α-olefins (APAO) although the poly-α-olefins used in a particularly preferred embodiment of the invention have a significant crystalline component. This partial crystallinity can be determined by differential thermoanalysis (DTA) because the partly crystalline poly-α-olefins can have one or more pronounced peak maxima in the melting curve.
The polar waxes bearing functional groups of component d) are preferably selected from the group of functionalized polyolefins —with a molecular weight range (GPC) of about 4,000 to about 80,000 —based on ethylene and/or propylene with acrylic acid, methacrylic acid and C 1-4 esters there of, itaconic acid, fumaric acid, vinyl acetate, carbon monoxide and in particular maleic acid and mixtures there of. The polyolefins in question are preferably ethylene, propylene and ethylene/propylene copolymers grafted or copolymerized with polar monomers which have saponification or acid values of 2 to 50 mg KOH/g.
The hotmelt adhesives according to the invention may optionally contain auxiliaries and additives known per se, including fillers, pigments, plasticizers and stabilizers. Suitable fillers are, for example, calcium carbonate, calcium/magnesium carbonate, talcum, silica, carbon black, zinc white, titanium dioxide or other inorganic pigments.
The plasticizers optionally used are largely determined by the polymer component used. Examples of plasticizers are process oils, more particularly naphthenic process oils, paraffin oils, castor oil, low molecular weight polybutenes or polyisobutylenes or polyisoprenes and dialkyl or alkylaryl esters of phthalic acid.
Stabilizers or antioxidants for reducing oxidative degradation may be selected from a number of commercially available antioxidants. Examples include sterically hindered phenols and/or thioethers and the like. It can be of advantage to combine two or more antioxidants of different chemical composition to obtain particularly high stability.
Accordingly, the hotmelt adhesives according to the invention contain
10 to 40% by weight and preferably 15 to 30% by weight of at least one thermoplastic elastomer
15 to 50% by weight and preferably 25 to 45% by weight of at least one hydrocarbon resin
10 to 40% by weight and preferably 15 to 30% by weight of at least one poly-α-olefins
10 to 45% by weight and preferably 15 to 35% by weight of at least one polar wax bearing functional groups
0 to 10% by weight and preferably 0.5 to 10% by weight of auxiliaries and additives
the total quantity of the above-mentioned constituents being 100% by weight.
The key steps involved in the use of the hotmelt adhesive in accordance with the invention are explained in the following with reference to FIG. 2 .
1.) The two substrate blanks which today consist essentially of polycarbonate are made by injection molding.
2.) The substrate half 3 , which has received the information layer in the form of pits during the injection molding process, is coated with a reflective layer, generally a metallic layer, for example of aluminium applied by vapor deposition in vacuo.
3.) The second substrate half 3 may also contain an information layer. However, it may also be printed on the inside with images/graphics and text by various methods. For example, the inside may be provided with a multicolor mirror-image impression 6 .
4.) Either one or both substrate halves are coated with the hotmelt adhesive 5 . The two substrate halves are then joined together to form the complete DVD.
The hotmelt adhesives to be used in accordance with the invention are normally applied to the substrate halves in a layer thickness of 30 pm or more, generally by roller, at temperatures of at least 140° C. and preferably 160° C. High melt viscosities of 60,000 to 130,000 mPa.s have proved to be highly advantageous for this purpose because the hotmelt adhesive can be cleanly applied, even at the very high rates of application required for the hotmelt adhesive, without the adhesive egressing beyond the outer margins of the DVDs. In addition, stringing is avoided at these high viscosities. Moreover, the hotmelt adhesives have very high cohesion so that the DVD thus produced shows good and quick recovery after bending in the use or handling of the DVD.
The use of the hotmelt adhesives in accordance with the invention affords the following advantages over the known UV-curing adhesives.
Hotmelt adhesives are more economical by a factor of at least 4. The gluing lines for hotmelt adhesives are also less expensive than the machinery and equipment required for UV-curing systems.
The adhesives can be pigmented or colored which opens up many design possibilities for the DVDs.
Hotmelt adhesives show good adhesion behavior, particularly under impact stress, above all at low temperatures.
Hotmelt adhesives are better able to correct inaccuracies or dimensional deviations in the polycarbonate substrates.
Normally, no waste collects during production in the application of hotmelts.
There are no emissions of health-endangering gases such as, for example, ozone or monomer vapors.
In the event of product changes or production stoppages, there are no disposal problems with the hotmelt residues. Such residues can be disposed of in small quantities as factory waste.
The preferred embodiments of the present invention are illustrated by the following Examples which are not intended in any way to limit the scope of the invention. So far as the compositions are concerned, all quantities represent parts by weight unless otherwise indicated.
The compositions listed in Table 1 were mixed to homogeneity in the melt in a heatable mixing and stirring vessel.
Softening point was measured in accordance with ASTM E28, viscosity in accordance with ASTM D3236 using a Brookfield RVT viscosimeter (spindle 27 ). Heat resistance was determined in the bonding of two polycarbonate test strips (PC) with a 25 ×25 mm overlapping bond, a weight of 1360 g being applied to the bonded substrates which were then heated at a rate of 5° C. per 10 mins. The temperature at which the bond failed was recorded in several individual tests (“c”=cohesive failure).
In the spot test, a polycarbonate (PC) substrate of the type used in the production of DVDs is coated with a spot of hotmelt adhesive and then hand-tested for peel strength and impact strength. The evaluation was made on a scale of 0 (=poor) to 15 (=very good).
It is clear from the results shown that the hotmelt adhesives according to the invention have very good heat resistance, good to very good peel strengths and very good impact strength.
TABLE 1
Example
1
2
3
4
5
6
7
8
9
10
Polycyclopentadiene resin 1)
32.0
37.0
30.0
35.0
32.0
30.0
30.0
30.0
Hydrocarbon resin 2)
30.0
30.0
EPDM
14.5
Styrene/ethylene/butylene
11.0
16.0
19.5
10.0
10.0
10.0
copolymer (SEBS) 3)
Styrene/ethylene/butylene
10.0
block copolymer (SEBS) 4)
Styrene/isoprene/block polymer
16.0
19.5
9.5
9.5
9.5
9.5
hydrogenated 5)
APAO 6)
20.0
20.0
25.0
25.0
20.0
25.0
25.0
25.0
25.0
25.0
Irganox 1010 7)
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
Propylene/maieic anhydride
25.0
copolymer 6)
Ethylene/maleic acid copolymer 9)
21.0
21.0
21.0
Ethylene/maleic anhydride
25.0
25.0
25.0
copolymer 10)
Ethylene/maleic anhydride
25.0
25.0
25.0
copolymer 11)
Ethylene/ethyl acrylate/maleic
10.5
10.5
10.5
anhydride terpolymer 12)
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
Softening point ° C.
109.3
103.9
114.2
150.8
134.4
140.4
128.5
136.5
135.1
123.6
Viscosity 160° C.
51250
33350
39333
24120
840000
190750
56625
114000
66875
111000
Viscosity 170° C.
Viscosity 180° C.
23050
18500
17042
8700
140000
49333
23750
43750
33125
46250
Viscosity 200° C.
13475
9600
8000
4950
22250
17000
12594
23550
19094
16000
Heat resistance [° C.]
82/80/84
81/80/76
86/86/85/
76/78/86/
80/80/85
90/91/91/
81/80/86/
87/87/86/
PC/PC 0.02 N/mm 2
(c)
(c)
81 (c)
81 (c)
(c)
84 (c)
86 (c)
86 (c)
PC (peel/impact)
15/10
15/8
15/10
0/—
15/15
15/15
15/15
12/—
15/15
12/12
1) viscosity 180° C.: 850 mPa.s
2) based on hydrogenated dicyclopentadiene, viscosity: 4900 mPa.s/180° C.
3) viscosity 600 mPa.s/25° C. (20% in toluene)
4) viscosity 200 mPa.s/25° C. (20% in toluene)
5) viscosity 30 mPa:s/30° C. (10% in toluene)
6) melt viscosity 8000 mPa.s/190° C.; molecular weight (GPS) 11,600
7) antioxidant (Ciba Specialty Chemicals)
8) molecular weight (GPS) 3900; acid value 45 mg KOH/g
9) molecular weight (GPS) 5600; acid value 2 mg KOH/g
10) graft polymer viscosity 600 mPa.s/140° C.; saponification number 4 mg KOH/g
11) graft polymer, viscosity 4200 mPa.s/140° C.; saponification value 34 mg KOH/g
12) melt index 200 g/10 mins.; acid value 17 mg KOH/g; comonomer content 9%
Hotmelt adhesives according to the invention and a known hotmelt adhesive (based on the teaching of JP-A-09 208 919) were tested for tilt and dishing by the ODT-A method before and after ageing. In the ageing test, the bonded test DVDs were stored for 96 hours at 80° C./95% relative air humidity and, before the measurement, were conditioned for 24 hours in a normal climate. The test DVDs were produced in a Krauss-Maffei injection molding machine and were coated with adhesive in a commercially available hotmelt bonder. The ODT-A measurements were carried out in a Conttec tester. The results are set out in Table 2 below. The specification for 120 mm DVD-RAM allows a maximum and minimum deviation in the radial direction (dishing) of 0.70° and a maximum and minimum tilt of 0.30°. As can be seen from Table 2 below, the Examples according to the invention meet this requirement very well both before and after ageing. The tilt and dishing values of the DVDs bonded with the known adhesive after ageing are far too high.
TABLE 2
11
12
13
Comp. 1
Comp. 2
Dishing
before ageing
minimum (degrees)
−0.27
−0.18
−0.30
n.a.
n.a.
maximum (degrees)
0.04
0.26
0.24
n.a.
n.a.
after ageing
minimum (degrees)
−0.62
−0.53
−0.64
−0.27
−1.74
maximum (degrees)
−0.11
0.16
0.08
1.47
0.68
Tilt
before ageing
minimum (degrees)
−0.23
−0.20
0.28
n.a.
n.a.
maximum (degrees)
0.07
0.16
0.09
n.a.
n.a.
after ageing
minimum (degrees)
−0.27
−0.24
−0.29
−0.48
−0.48
maximum (degrees)
0.10
0.09
0.13
0.81
0.11
n.a. = not available | The present invention relates to a process for preparing a digital versatile disc. The process of the present invention includes providing a hot melt adhesive containing at least one thermoplastic elastomer, at least one hydrocarbon resin, at least one poly-α-olefin, and at least one polar wax, and providing at least two disc blanks. The hot melt adhesive is applied directly or indirectly to at least one of the blanks and the blanks are bonded together using the hot melt adhesive. The present invention also provides a digital versatile disc containing the hot melt adhesive. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a three-dimensional fabric suitable for use as a frame member of a composite that has an irregular, non-rectangular cross section, such as L shape, I shape, T shape or H shape, and a method of producing the same.
2. Description of the Related Art
Composite materials having three dimensional fabrics as their frame members are expected to be widely used as structural materials for various products including rockets, aircraft, automobiles, marine vessels and buildings. One common fabric structure is an orthogonal three-axis, three-dimensional fabric that includes three kinds of threads (X,Y and Z directional threads). Another is a five-axis three-dimensional fabric that includes oblique threads that extend in the lengthwise direction in addition to the perpendicular three axes. To ensure a variety of applications of a composite having a three-dimensional fabric as the frame member, it is sometimes necessary that the three-dimensional fabric have an irregular, non-rectangular cross section, such as L shape, I shape, T shape or H shape, depending on the actual usage.
A conventional three-dimensional fabric having an irregular cross section is disclosed in Japanese Unexamined Patent Publication No. 1-292162. This three-dimensional fabric includes at least two plates connected together by fabric threads. One or more of the plates includes threads that extend in three independent directions. Specifically, the longitudinal, lateral and transverse directions. This is referred to as a three-axis three dimensional fabric. At least one plate further includes two additional types of threads. That is, two types of oblique threads that extend in a direction oblique to the direction of the arrangement of the lengthwise and horizontal fabric threads and intersecting each other, thereby providing a five-axis fabric arrangement.
One such design is shown in FIG. 1. As seen therein, a three-dimensional fabric with an H-shaped cross section includes a first plate 31 as a base and four second plates 32 formed integrally and perpendicular to the plate 31. The plates 31 and 32 are linked by the transverse threads.
In producing this three-dimensional fabric, first thread guide pipes G1 and second thread guide pipes G2 are provided upright in a predetermined pattern. A layer consisting of fabric threads arranged in the X and Y directions is then laid on that portion of the bottom of the first plate 31 where the first guide pipes G1 are provided. Thereafter, a plurality of full fabric layers are woven through both sets of pipes G1 and G2. The full fabric layers include threads arranged in the X direction, Y direction and oblique directions. Subsequently, a layer consisting of threads extending in the X and Y directions is laid on top in the region of the first plate 31 where the first guide pipes G1 are provided. Next, fabric threads are inserted in the individual guide pipes G1 and G2 in a loop form so that they replace the guide pipes G1 and G2. A tack thread is inserted into each loop as a stopper. As a result, the individual layer portions are coupled by fabric threads extending in the Z direction, yielding a three-dimensional fabric with an H-shaped cross section.
The three-dimensional fabric does not have any threads which extend continuously through a bend into two perpendicularly-crossing planes. That is, none of the threads in the fabric shown in FIG. 1 which are arranged so as to be continuous to the X-Y plane and Y-Z plane. Therefore, when a stress is applied to the second plate 32 in the direction and location of arrow Q, the fabric threads in the X-Y plane of the first plate 31 carry very little of the bending stress acting on the second plate 32. In other words, the fabric threads of the X-Y plane of the first plate 31 do not effectively work to carry the loads applied to the second plate 32. Accordingly, composites using this three-dimensional fabric have the drawback of having insufficient strength.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide a three-dimensional fabric which can enhance the strength of joints when the fabric is used as a frame member of a composite which is shaped by a plurality connected plate sections, thereby improving the hardness (durability) against the tensile loads and compression loads.. Representative applications include beam members having an irregular cross section, such as L shape, I shape, or T shape.
Another independent object of the present invention to provide a method of easily producing a T-shaped join in a three-dimensional fabric.
To achieve the first object, a three-dimensional fabric embodying the present invention includes at least two plate like sections arranged in intersecting planes so as to define a bend at the intersection of the plate sections. A plurality of thread layers are woven such that they extend continuously through and between the plate sections. The portions of the thread layers within each plate section extend in planes that are perpendicular to a transverse direction that passes through the corresponding plate section. The plurality of thread layers including threads that are woven in at least two independent directions. At least one transverse thread is woven through the thread layers in the transverse direction of the corresponding plate sections to couple the thread layers together.
When a load is applied to a plate section of a composite having this three-dimensional fabric as a frame member, the threads that extend continuously from a first plate section to a second plate section effectively receive the stress acting on the junction of the plate sections. The strength of the composite is therefore enhanced.
In a preferred embodiment, the threads used in the thread layers of each plate section are woven in four different directions, which resultants in a three-dimensional fabric directions, which resultants in a three-dimensional fabric having a five-axis in every plate section. The resultant structure has better resistance to oblique stresses, compared with a composite using a perpendicular three-axis. The composite according to the present invention can therefore show sufficient strength not only against the tensile and compression loads, but also against twisting loads.
To achieve the second object, a method of forming a T-shaped joint in a three-dimensional fabric is disclosed. The method contemplates using a pair of frame members having L-shaped portions and a frame member having a flat portion. Each of the frame members is provided with a matrix of removable regulating members that extend perpendicularly from an active surfaces thereof. Threads are then woven between the regulating members of each frame member in at least two independent directions to form a thread layer having at least a two axis arrangement on each frame member. The L-shaped members being woven such that their two axis thread layer extends continuously through the bend in the L-shaped member. The thread layers together with their regulating members are then removed from their respective frames. The woven thread layers are then arranged in a substantially T-shaped relationship wherein each leg of the T has a pair of adjacent woven thread layers from different fabric pieces. Transverse threads are woven through the bend portions of the thread layers and portions of the flat fabric piece that are adjacent the bend portions. This is accomplished by replacing the associated regulating members with the transverse thread. Thereafter, transverse threads are sequentially woven through adjacent woven thread layers by replacing adjacent regulating members of the adjacent thread layers with the transverse thread to couple the thread layers.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention, together objects and advantages thereof, may best be understood by reference to the following description of the presently preferred embodiments together with the accompanying drawings in which:
FIG. 1 is an exemplary perspective view illustrating a conventional three-dimensional fabric and how its guide pipes are arranged;
FIGS. 2(a) to (d) are schematic perspective views respectively showing the arrangement of the first, the second threads and bias threads according to a first embodiment of the present invention;
FIG. 3 is a schematic perspective view of the three-dimensional fabric shown in FIG. 2;
FIG. 4 is a schematic perspective view showing a frame used during weaving of the three-dimensional fabric shown in FIG. 3;
FIGS. 5(a) to (e) are schematic diagrams illustrating a method of inserting a transverse thread;
FIGS. 6(a) and (b) are schematic diagrams showing an alternative method of inserting the transverse thread;
FIGS. 7(a) to (c) are schematic diagrams illustrating a method of inserting a transverse thread z according to a second embodiment of the invention;
FIG. 8 is a schematic perspective view of a three-dimensional fabric according to a third embodiment;
FIG. 9 is a schematic perspective view exemplifying a frame used for producing a three-dimensional fabric;
FIGS. 10(a) to (d) are schematic perspective views showing the state of arranging the first, the second threads and the bias threads, in one L-shaped fabric portion of a T-shaped joint arrangement;
FIGS. 11(a) and (b) are schematic diagrams illustrating the relationship between a thread layer woven onto a frame and pins;
FIGS. 12(a) to (c) are schematic diagrams illustrating steps in a method for coupling thread layers from independent fabric pieces into a T-shaped joint;
FIGS. 13(a) to (c) are schematic diagrams illustrating procedures of inserting a transverse thread z;
FIGS. 14(a) to (c) are schematic diagrams showing a modified method of inserting a transverse thread z;
FIGS. 15(a) to (d) are schematic diagrams showing another modified method of inserting a transverse thread z;
FIGS. 16(a) to (d) are schematic diagrams showing a further modified method of inserting a transverse thread z;
FIGS. 17(a) to (c) are schematic diagrams showing a still further modification of the method of inserting a transverse thread z;
FIGS. 18(a) to (e) are schematic perspective views of three-dimensional fabrics having different shapes; and
FIGS. 19(a) to (e) are schematic perspective views of three-dimensional fabrics having different shapes.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
First Embodiment
The first preferred embodiment of the present invention will now be described referring to FIGS. 2 through 6. In this embodiment, as shown in FIGS. 2(a) to (d) and FIG. 3, a three-dimensional fabric F is formed into an almost L shape by two plate sections 1a and 1b. The two plate sections 1a and 1b are joined at a right angle bend 2. The plate sections 1a and 1b each comprise an x thread layer consisting of a first thread x, a y thread layer consisting of a second thread y, bias thread layers respectively consisting of bias threads B1 and B2 as planar threads, and a transverse thread z arranged perpendicular to the individual layers in the transverse direction of the fabric F for linking the layers to one another.
The first thread x is arranged along the bend 2 in a plane perpendicular to the transverse direction of the plate sections 1a and 1b. The second thread y is arranged in a direction perpendicular to the first thread x in a plane parallel to the x thread layer. The bias threads B1 and B2 are arranged to be inclined at a predetermined angle (45° in this embodiment) to the first and second threads x and y in a plane parallel to the x thread layer. In other words, the three-dimensional fabric F in this embodiment is a five-axis three-dimensional fabric wherein four of the axes are coplanar. The fabrics formed by the planar four-axis arrangement are coupled to one another by the transverse thread z. The x, y and bias thread layers of the plate sections 1a and 1b are each formed integrally by a thread arranged in a zigzag form. The second thread y and the bias threads B1 and B2 are each arranged across the bend 2 so that the threads y, B1 and B2 continuously lie over the plate sections 1a and 1b.
When a load is applied in the direction of an arrow P in FIG. 3 to a composite made of the thus structured three-dimensional fabric F impregnated with a resin, a great stress acts on the bend 2 of the three-dimensional fabric F. In this case, however, the second thread y and the bias threads B1 and B2 extend in a direction crossing the bend 2 and lie over the plate sections 1a and 1b. These threads (fibers) effectively contribute to dividing of a resisting force against the stress acting on the bend 2. The strength of the composite is therefore increased. Since the three-dimensional fabric F in this embodiment has a five-axis arrangement in all planes, the amount of deformation of the composite due to the stress in an oblique direction becomes less than that of the composite of the perpendicular three-axis arranged three-dimensional fabric used as a frame member. As a result, the composite in this embodiment shows high withstandability against twisting loads as well as the tensile and compression loads.
An example of a method of producing the three-dimensional fabric F will now be explained. As shown in FIG. 4, an L-shaped frame 3 corresponding to a three-dimensional fabric in shape is used to produce the three-dimensional fabric F. A plurality of pipes 4, serving as regulating members which regulate the arrangement of the threads, are provided upright at predetermined positions on the frame 3. As shown in FIGS. 5(a) to (d), the pipes 4 are removably fitted into bores 3a formed in the frame 3. A pair of notches 4a are provided at the proximal end of each pipe 4 so that the transverse thread z can pass through each of the notches 4a.
U-shaped pins 5 are inserted in the individual bores 3a before the pipes 4 are attached to the frame 3, and supports 6 are provided between the U-shaped pins 5. The transverse threads z are then threaded through the U-shaped pins 5 and over the blocks 6. One transverse thread z is provided for each row of U-shaped pins 5. Next, the pipes are simultaneously inserted into the respective bores 3a and over the U-shaped pins 5. Thus, the transverse thread z are received by the notches 4a. However, since the blocks effectively form spaces above the recesses 3, the insertion of the pipes pushes the transverse thread into the spaces. Consequently, the transverse thread z is arranged in a zigzag fashion as shown in FIG. 5(a). Accordingly, the necessary length of the transverse thread z will vary by selecting different thickness of the supports 6.
Under such conditions, the first and second threads x and y, and the bias threads B1 and B2 are woven between the gaps of the pipes 4 on the frame 3 so that these threads are looped about the outer surfaces of the pipes 4 provided on the end portion of the frame 3. The x thread layer, the y thread layer and the bias thread layers are therefore sequentially woven in the named order. The first thread x is arranged to be woven back and forth, extending in parallel to the bend 2 of the frame 3. The second thread y is arranged to be woven back and forth in a direction that extend perpendicular to the bend 2 of the frame 3. The bias threads B1 and B2 are woven back and forth in a diagonal manner. In this embodiment, the bias threads are woven in opposite directions, crossing the first and second threads x and y at angles of ±45° respectively, yielding a pair of bias thread layers whose bias threads cross the threads x and y in the opposite directions. After the desired number of thread layers are woven, the pipes 4 are replaced with the transverse thread z, which bind the individual layers together. The actual number of layers provided will be determined in accordance with the required strength of the composite member.
The replacement of the pipes 4 with the transverse thread z is carried out as follows. The pipe 4 located at the end portion of the frame 3 is removed from the bore 3a and a thread layer 7. The U-shaped pin 5 is pulled out of the bore 3a and the thread layer 7. Then, the portion of the transverse thread z which is positioned within the U-shaped pin 5 is pulled above the thread layer 7 in a loop as shown in FIG. 5(b). The U-shaped pin 5 is removed and the loop of the transverse thread z is wrapped around the adjacent pipe 4 as shown in FIG. 5(c). This pipe 4 is then removed in the same manner as described above. Next, as shown in FIG. 5(d), part of the transverse thread z is pulled in a loop together with the U-shaped pin 5 above the thread layer 7. As a result, the previous loop of the transverse thread z is prevented from coming off, and becomes tense to tighten the thread layer 7 in the transverse direction. Likewise, the remaining pipes 4 are sequentially replaced with the transverse thread z. Therefore, as shown in FIG. 5 (e), the individual thread layers constituting the thread layer 7 are coupled to one another by the transverse thread z.
Alternatively, a selvage thread A may be put through the loop of the transverse thread z as shown in FIG. 6 (a) and (b) to prevent the loop from coming off after the replacement of the pipes 4.
Second Embodiment
Another embodiment of the method of producing a three-dimensional fabric F will now be described referring to FIG. 7(a) to (c). This embodiment differs from the above-described embodiment in the method of inserting the transverse thread z. U-shaped pins 5 are not used in this embodiment, and pipes 4 are attached to a frame 3 without the transverse thread z arranged therein. The first and second threads x and y, and bias threads B1 and B2 are arranged in the same manner as in the first embodiment. The support plates 6 are located between the pipes 4. The individual threads are woven about the pipes as previously describe. That is, they are wrapped around the pipes 4 which are provided at the end portions of the frame 3. Again, by way of example, the thread layers may be sequentially laid in an order such as an x thread layer, a y thread layer and bias thread layers. After the required number of these layers are woven (as required by design considerations to provide the desired composite strength), the resultant thread layer 7 is removed together with the pipes 4 from the frame 3. Since the supports 6 are located between the frame 3 and the thread layer 7, the pipes 4 and the thread layer 7 can easily be removed from the frame 3.
The pipes 4 are then replaced with the transverse thread z using a needle 8 having the transverse thread z put through the needle's eye. The diameter of the needle 8 is the same as the outer diameter of each pipe 4. As shown in FIG. 7(a), distal end of the needle 8 is inserted in the pipe 4 and the two are pushed through the thread layer 7. Thus, the pipe 4 is pushed out of the thread layer 7. The needle 8 follows the pipe 4 as it is removed, so that the pipe 4 is replaced with the transverse thread z. Next, the distal end of the needle 8 is inserted into the adjacent pipe 4 from a direction opposite to that of pushing out the previous pipe 4. The same operation is repeated as was described in the previous procedure. Thus, the next pipe 4 is replaced with the transverse thread z. The remaining pipes 4 are sequentially replaced with the transverse threads z in the same manner. As a result, the individual layers constituting the thread layer 7 are linked to one another by the transverse thread z as shown in FIG. 7 (c). Unlike the previously described embodiment, U-shaped pins 5 and the transverse thread z do not need to be set when the pipes 4 are attached to the frame 3. Thus, in the method of this embodiment, the preparation for the weaving is simplified and the U-shaped pins 5 can be eliminated. This method can therefore reduce the number of elements necessary to produce the three-dimensional fabric F.
Third Embodiment
The third embodiment will now be explained referring to FIGS. 8 through 13. As shown in FIG. 8, a three-dimensional fabric F according to this embodiment is formed by a combination of a pair of L-shaped fabric pieces 9a and 9b, and a flat fabric piece 10. In effect, this results in a T-shaped structure having three plate sections 1a, 1b and 1c connected with one another at a junction (bend) 2. As shown in FIG. 10 (a) to (d), each of the fabric pieces 9a, 9b and 10 (only the fabric piece 9a is exemplified in FIG. 10) includes an x thread layer consisting of a first thread x arranged generally in parallel with the bend 2 of the plate sections 1a, 1b and 1c in a plane perpendicular to the transverse direction, a y thread layer consisting of a second thread y arranged in a direction perpendicular to the first thread x in a plane parallel to the x thread layer, bias thread layers respectively consisting of bias threads B1 and B2 arranged to be inclined at a predetermined angle (45° in this embodiment) to the first and second threads x and y in a plane parallel to the x thread layer, and a transverse thread z arranged orthogonal to the individual thread layers in the transverse direction of the three-dimensional fabric F for coupling the layers together.
Thus, as in the previous embodiment, the three-dimensional fabric F in this embodiment is a five-axis, three-dimensional fabric where fabrics having a planar four-axis arrangement are coupled to one another by the transverse thread z. The x and y thread layers and bias thread layers of the individual fabric pieces 9a, 9b and 10 are each formed integrally by a thread arranged in a zigzag fashion. In the case of the L-shaped fabric pieces 9a and 9b, for example, the first and second threads x and y, and the bias threads B1 and B2 are arranged respectively as shown in FIG. 10 (a) to (d). The second thread y and the bias threads B1 and B2 are each arranged across a bend 11 of the fabric pieces 9a and 9b so that the threads y, B1 and B2 continuously lie over their two planes which are located perpendicular to each other.
If a load is applied in the direction of an arrow Pa to a composite made of the three-dimensional fabric F impregnated with a resin, the second thread y and the bias threads B1 and B2 share the resisting force against the stress acting on the bend 2. In the third embodiment as well as in the previous embodiments, therefore, the amount of deformation of the composite due to the stress in an oblique direction becomes less than that of the composite of the perpendicular three-axis, three-dimensional fabric used as a frame member. As a result, the composite in this embodiment shows high withstandability against the twisting load as well as the tensile and compression loads.
An example of a method of producing this three-dimensional fabric F will be described below. Three frames are used to produce the three-dimensional fabric F. The frames are designed to have shapes corresponding to the shapes of a pair of L-shaped portions and a single flat plate section acquired by dividing the T-shaped portion of the three-dimensional fabric. More specifically, two frames 3 of an L shape similar to the frames 3 used in the previous embodiment and one frame 12 of a flat shape as shown in FIG. 9 are used. Many pins 13 serving as regulating members are provided upright at predetermined intervals on each of the frames 3 and 12.
With supports 6 located between the pins 13 as in the first embodiment, threads x and y and bias threads B1 and B2 are so arranged such that an x thread layer, a y thread layer and bias thread layers can be sequentially woven on each of the frames 3 and 12.
The threads x and y and the bias threads B1 and B2 are arranged on each L-shaped frame 3 in the same manner as in the previous embodiment. The first thread x to be arranged on the frame 12 woven back and forth in rows that extend substantially in parallel to the width direction of the frame 12. The second thread y is so arranged to be woven back and forth in the lengthwise direction of the frame 12. The bias threads B are arranged in a zigzag form so as to form an angle of 45° to both threads x and y, yielding a pair of bias thread layers whose bias threads have been arranged to cross the threads x and y in the opposite directions. The individual thread layers are sequentially woven on each of the frames 3 and 12 with the actual number of layers being determined in accordance with the demanded fabric strength. Thus, a thread layer 7 is produced.
Next, as shown in FIG. 11 (a) and (b), the thread layers 7 are removed together with the pins 13 from the frames 3 and 12 (the illustration given only for the frame 3). The supports 6 present between each frame 3 and the thread layer 7 at this time facilitate the removal of the pins 13 and thread layer 7 from the frame 3. Then, the two L-shaped thread layers 7 removed from the frames 3 and one flat thread layer 7 removed from the frame 12 are arranged in a substantially T-shaped manner and combined to form the three-dimensional fabric F shown in FIG. 12(c).
Before combining the three thread layers 7, the pins 13 inserted into the bends of the L-shaped thread layers 7 are replaced with the transverse threads z. Further the pins 13 in the flat thread layer 7 that are positioned adjacent the bends of the L-shaped thread layers 7 are replaced with the transverse threads z. As a result, parts of the individual thread layers 7 are coupled by the transverse threads z, as shown in FIG. 12(b). Next, the pins 13 inserted into that portion of one L-shaped thread layer 7 which faces the other L-shaped thread layer 7 are pushed into the mating portion of the adjacent (latter) thread layer 7 to drive out the pins 13 therefrom. This couples the L-shaped thread layers 7 together. Subsequently, the connected thread layers 7 and the flat thread layer 7 are arranged in such a way that their associated pins 13 face one another. Then, both L-shaped thread layers 7 and the flat thread layer 7 are connected together by driving out those pins 13 of either the L-shaped thread layers 7 or the flat thread layer 7 with the pins 13 of the adjacent section.
Next, a needle 8 is inserted in an end face of one of the pins and is pushed through the thread layers 7 so as to drive the pin 13 out of the thread layers 7. Thus, a loop of the transverse thread z is inserted through the gap left by the pin 13 as shown in FIG. 13(a). A selvage thread A is then inserted into the loop portion, the needle 8 is pulled up. As a result, the loop portion is tightened while it is prevented from coming out by the selvage thread A as shown in FIG. 13(b).
Thereafter, the same operation is repeated to sequentially replace the remaining pins 13 with the transverse thread z. Consequently, the individual thread layers constituting the thread layers 7 are connected together by the transverse threads z as shown in FIG. 13(c), yielding a three-dimensional fabric F. Since a gap 14 is formed in that portion where the bends of both L-shaped thread layers 7 correspond to the flat thread layer 7, a filler can be filled in the gap 14 as needed.
The present invention is not limited to the above-described embodiments, but may be modified in various other manners within the scope and spirit of the invention. For instance, instead of using the method of replacing the pipe 4 with the transverse thread z in the second embodiment, two needles 8 may be used to insert two transverse threads z in the same gap made by driving out the pipe 4, as shown in FIG. 14 (a) to (c). This method can connect the thread layers 7 tighter by the transverse threads z than that of the second and third embodiments.
Also a needle 8 with a hole in the tip may be used as shown in FIG. 15(a) to (d). In this case the needle 8 may be inserted from one thread layer 7 into the gap from which the pipe 4 has been removed to put a loop of the transverse thread z in the gap. This loop portion may be pulled through the previously formed loop portion by a hook 15, to provide a loop stopper. This operation can then be repeated for the remaining pipes 4.
Further, a hook 15 may be used as shown in FIG. 16(a) to (d). This hook 15 is used to drive out the pipe 4 from one thread layer 7 and hook the transverse thread z lying on the opposite side. As the hook 15 is pulled back, the transverse thread z is inserted in a loop into the gap made by removing the pipe 4 therefrom. The loop portion is put through the previously-formed loop portion, and this operation is repeated for the other pipes 4, providing loop stoppers.
Furthermore, a needle 8 with a hole in the tip may be used as shown in FIG. 17(a) to (c). This needle 8 may be inserted from one thread layer 7 into the gap from which the pipe 4 has been removed to put the transverse thread z in a loop in the gap, with a selvage thread A then put through the loop portion to provide a loop stopper.
The pipes 4 used in the second embodiment and the above modifications may be replaced with pins.
The above-described different methods may be used to replace the regulating members with the transverse threads z in the three-dimensional fabric producing method according to the third embodiment as well.
The inclination angle of the bias threads B1 and B2 to the first and second threads x and y may be set to other than 45°. Each of the plate sections 1a, 1b and 1c of the three-dimensional fabric F may be designed to have a three-axis arrangement instead of a five-axis arrangement by eliminating the bias threads B1 and B2. The bias threads B1 and B2, constituting a pair of bias thread layers, may be arranged at an angle of 60° to the second thread y, with the first thread x unused, thereby providing a four-axis arrangement. While each of the threads x and y and the bias threads B1 and B2, constituting the respective thread layers, consists of a single thread in the described embodiments, they may consist of a plurality of threads.
The three-dimensional fabric is not limited to have an L shape, but may be formed into a channel shape, a U shape or a box type as shown in FIG. 18(a), (b) and (e), respectively. The three dimensional fabric may also be designed to have partially-cut box shapes as shown in FIG. 18(c) and (d). Those three-dimensional fabrics F can be produced using frames having corresponding shapes with many pins or pipes attached thereto, in the same manner as done in the case of the three-dimensional fabric with an L shape.
Meanwhile, in the method of producing a three-dimensional fabric according to the third embodiment, before the individual thread layers 7 are arranged to correspond to the shape of the three-dimensional fabric, the regulating members which are not located to mate with those of the other thread layers as well as part of the regulating members located to have mating regulating members of the other thread layers may be replaced with the transverse threads z to couple part of the thread layers with the threads z. The shape of the three-dimensional fabric F is not limited to a T shape, but this method may be used to produce three-dimensional fabrics F with an I shape or the like, which have a bend formed by connecting a plurality of plate sections into a T shape as shown in FIG. 19 (a) to (e), for example. Such a three-dimensional fabric F can be produced using frames having shapes acquired by cutting the fabric along the alternate two short dash and one long line, with many pins or pipes attached to the frames, in the same manner as in the case of the above-described three-dimensional fabric F with a T shape. | A three-dimensional fabric is disclosed that is appropriate for use in composite materials having various beam type shapes that are formed from a plurality of intersecting plate sections. A plurality of thread layers are woven such that they extend continuously through and between a pair of adjacent plate sections. The thread layers respectively include threads that are woven in at least two independent planar directions. The thread layers are bound together by transverse threads. When a load is applied to a plate section of a composite having this three-dimensional fabric as a frame member, the threads that extend continuously from a first plate section to a second plate section effectively receive the stress acting on the junction of the plate sections. The strength of the composite is therefore enhanced. | 3 |
This is a division of application Ser. No. 770,328 filed on Aug. 28, 1985, now U.S. Pat. No. 4,624,958 which is a division of application Ser. No. 484,803 filed on Apr. 14, 1983, now U.S. Pat. No. 4,546,113.
BACKGROUND OF THE INVENTION
The present invention is concerned with certain diamidines and a bis-imidazoline having antiprotozoal activity, and their use in the control of trypanosomiasis and/or babesiosis in mammals, particularly in cattle.
Trypanosomiasis is a disease of man and animals caused by flagellate blood borne protozoan parasites. The disease is encountered mainly in Africa, where it is transmitted by the Tse Tse fly. Animal typanosomiasis caused by Trypanosoma congolense and T. vivax, is considered to be the limiting factor for livestock production in most of the African Continent. Although trypanosomiasis can be fatal to man, its devastating effect on meat producing animals has indirectly caused much more human suffering due to protein starvation. Babesiosis is another hemo-protozoan disease of livestock and is economically important in the tropical and subtropical regions of the world.
Previously reported diamidines having antiprotozoal activity include ##STR2## wherein Z is: --NH--N═N-- (diminazene, see The Merck Index, 9th Ed., monograph No. 3258);
--CH═CH-- (stilbamidine, loc. cit., monograph No. 8597; Ashley et al. [A], J. Chem. Soc., pp. 103-116, 942);
--CH═CH--CH═CH-- (Ashley et al. [A]).
--O(CH 2 ) P O--, where p=1 to 10 (Ashley et al. [A]; when p=5, pentamidine, loc. cit., monograph No. 6912); or
--O-- (phenamidine, loc. cit., monograph No. 6994); and ##STR3## wherein in Y is O, S, NH, NCH 3 or CH 2 (Dann et al. [A], where Ann. vol. 749, pp. 68-89, 1971; Dann, U.S. Pat. Nos. 3,652,591 and 3,689,506).
On the other hand, compounds failing to protect (cure) mice against a protozoal infection include those compounds of the formula (I) wherein Z is --CO--, --CHOH--, --CH 2 CO--, --CH═CHCO--, --NHCO--, --SO 2 --, --NHSO 2 --, --S--S--, --N═N--, --NHNH--, --N═N(O)--, --CH 2 --, --S--, --CH 2 NH--, --NHCONH--, --OCH 2 OCH 2 O--, --CH 2 SCH 2 --, --CH 2 NHCH 2 --, --OCH 2 (p-C 6 H 4 )CH 2 O-- or --CH 2 O(p-C 6 H 4 )OCH 2 --; in spite of the fact that the compounds having the last seven values of Z did show an early and favorable effect on the level of trypanosomes in the peripheral blood stream (Ashley et al. [A]; Ashley et al. [B], J. Chem. Soc., pp. 3089-3093, 1957). Furthermore, replacement of --O(CH 2 ) 4 O-- in (I) with an olefinic variant, --OCH 2 CH═CHCH 2 O--, leads to considerable less activity against T. rhodesiense and inactivity against T. congolense (Ashley et al. [C], J. Chem. Soc., pp. 1668-1671, 1957); substitution of the bridging group in diminazene with a methyl group, i.e., Z=--N(CH 3 )N═N--, reduces activity by about 75% (Ashley et al. [B]); and the m, m'-isomers of the compounds (I) wherein Z is --O(CH 2 ) 3 O-- or --O(CH 2 ) 5 O-- are about half as active as the p, p'-isomers.
Among the diamidines reported to have antiprotozoal activity are a number of compounds having the formula (I) wherein Z is represented by one of the following 5-membered heterocyclic groups: ##STR4## where Q is O, S, NH or N(CH 3 ); ##STR5## where Q' is S, NH or CH 2 ; ##STR6## (Das et al. [A], J. Med. Chem. Vol. 20, pp. 531-536, 1977; Das et al. [B], ibid., Vol. 20, pp. 1219-1221, 1977; Das et al. [C], ibid., Vol. 23, pp. 578-581, 1980; Dann et al. [B], Ann. pp. 160-194, 1975). For a similar compound (I), wherein Z is ##STR7## reports concerning activity are conflicting. Thus, against T. rhodesiense infections in mice, Das et al. [C] reports no more than a minor increase in mean survival time, at a dose of 40 mg/kg; while earlier Dann et al. [B] reported minimum curative dose of 1-10 mg/kg for the same compound against the same microorganism.
It has also been previously noted by Berg (J. Chem. Soc., pp. 5097-5101, 1961) that the compound of the formula (I) wherein Z is --NHCONH-- is lacking in activity, although the corresponding meta isomer: ##STR8## showed considerable activity. Berg further noted that replacement of the --NHCONH-- group in (III) with --NHC(═NH)NH--, --NHC(═NCH 3 )NH-- or --NHCSNH-- led to lowered activity.
The bis-imidazoline compound of the formula ##STR9## presently discovered to have antiprotozoal activity, has been previously reported to have antifungal activity (Anne et al., Antimicrobial Agents and Chemotherapy, vol. 18, pp. 231-239, 1980), and to inhibit oncornaviral DNA polymerase (De Clercq et at., J. Med. Chem., Vol. 23, pp. 787-795, 1980). Neither Anne et al. nor DeClercq et al. describe compound (IV) per se, nor do they provide a method of preparation therefor. For this reason, a detailed preparation method for this compound is included below.
SUMMARY OF THE INVENTION
The present invention encompasses compounds of the formula ##STR10## wherein X is --CH 2 CH═CH--, --CH 2 C(CH 3 )═CH--, --NHC(═NH)NH--, ##STR11## n is 0, 1 or 2; m is 0 or 1;
R is (C 1 -C 3 )alkyl, 2-hydroxyethyl, 2,3-dihydroxypropyl, benzyl or 2-, 3- or 4-picolyl; with the provisos that when R is 4-picolyl, m is 1; and when R is methyl and m is 1, n is other than O;
and the pharmaceutically acceptable acid addition salts thereof. Such salts include, but are not limited to, those formed with HCl, H 2 SO 4 , H 3 PO 4 , propionic acid, succinic acid, maleic acid, citric acid, methanesulfonic acid, isethionic acid, p-toluenesulfonic acid and aceturic acid. The preferred salts, because of their more consistent biological activity, are those with HCl.
It is clear from the above background of the invention that the present art is highly unpredictable in character. Present studies have further proven that view to be correct, in that we are now able to extensively add to the list of compounds of the formula (I) which are lacking in antiprotozoal activity. For example, those compounds wherein Z is --C(CH 3 )═CHCH 2 --, --CH═C(C 6 H 5 )CH 2 --, --CH═C(CO 2 CH 3 )CH 2 --, --N═C(NHCH 3 )NH-- or ##STR12## where R a is --CH 2 CH═CH 2 or CH 3 , when tested in mice against T. congolense or B. rodhaini by the method detailed below, show no activity against either microorganism at a dose of 50 mg/kg. In spite of these facts, it has now been discovered that the compounds of the formula (V) possess valuable antiprotozoal activity, in particular, in vivo activity against Trypanosome congolense and/or Babesia rodhaini, as determined in laboratory induced infections in mice, reflecting general utility in the treatment of trypanosomiasis and/or babesiosis in mammals, particularly in cattle. The activity of the present p-substituted compounds is particularly surprising in view of the teaching of Berg (cited above) and the further fact that m-isomers of the present compounds show no useful activity against either of the above microorganisms (vide post).
The present invention also encompasses a pharmaceutical cmmposition for use in the treatment of a susceptible protozoan infection in a mammal, comprising an antiprotozoal compound of the formula (V) and a pharmaceutically inert carrier; and a method of treating an infection in a mammal caused by a susceptible protozoan, which comprises administering an antiprotozoal amount of a compound of the formula (V).
The present invention further encompasses that same treatment method, but with the compound of the formula (IV), above, or a pharmaceutically-acceptable salt thereof; and a sterile pharmaceutical composition suitable for parenteral administration to a mammal which is infected with a susceptible protozoan, said composition comprising an antiprotozoal effective amount of a compound of the formula (IV), at a concentration of at least 1% (w/v), and a pharmaceutically inert carrier.
DETAILED DESCRIPTION OF THE INVENTION
The bis-amidine compounds (V) of the present invention are readily prepared from a corresponding dinitrile of the formula ##STR13## wherein X is as defined above; via an intermediate dicarboximidate ester of the formula ##STR14## wherein X is as defined above and R is (C 1 -C 5 ) alkyl or (C 2 -C 5 )alkoxyalkyl. Preferred values of R are methyl, ethyl and 2-methoxyethyl.
The first stage, (VI)→(VII), is carried out by reacting the dinitrile (VI) with at least 2 equivalents of an alcohol (ROH, where R is as defined above) in the presence of at least 2 equivalents of a strong, anhydrous acid (e.g., HCl, H 2 SO 4 or sulfonic acid such as methanesulfonic acid, isethionic acid or p-toluenesulfonic acid), under anhydrous conditions in a reaction-inert solvent, conveniently in an excess of the alcohol, ROH, optionally diluted with a further reaction-inert solvent such as chloroform. Preferred alcohols (methanol, ethanol, 2-methoxyethanol) correspond to the preferred groups R, as specified above. Temperature is not critical, the range -20° to 50° C. being fully satisfactory. Ambient temperature is preferred, avoiding costs associated with cooling or heating. The preferred acid is dry HCl conveniently introduced in excess by perfusing the alcoholic solvent at -20° to 0° C. prior to reaction with the dinitrile. The intermediate dicarboximidate ester (VII) is readily isolated from the reaction mixture, usually in the form of an addition salt with the acid used in the process. Said isolation is accomplished by standard methods of concentration, and/or addition of a non-solvent or of a further excess of the acid, as necessary to obtain a recoverable solid.
As used herein, the expression "reaction-inert solvent" refers to any solvent which does not react with reactants, intermediates or product in a manner which adversely affects the yield of the desired product.
The second stage, (VII)→(V), is carried out by reacting the dicarboximidate ester (VII), usually in the form of an acid addition salt, with excess ammonia (at least four equivalents, to form the bis-amidine, plus at least one equivalent for each equivalent of acid associated with the addition salt). Temperature is not critical; again, the range 0°-50° C. being fully satisfactory, with ambient temperatures preferred. The reaction is usually carried out in anhydrous reaction-inert solvent, alcohols such as those used in the above first stage being particularly well-suited. In this case, it will be noted that the alcohol need not correspond to the value of R in the starting material, since even although a different alcohol may interact with the starting material (by ester exchange), there will be no adverse effect on yield. The diamidine product (V) is isolated, most conveniently in the form of the same acid addition salt as that introduced into the present stage, by the same standard methods detailed above for the isolation of intermediate ester (VII). If an alternative salt of (V) is desired, it is preferable to first convert the isolated salt to the free base form, a conversion which is conveniently done by neutralization of the acid addition salt in water, with recovery of free base by filtration or extraction into a water immiscible solvent. The free base is then contacted with the appropriate acid in a reaction-inert solvent. Those salts which do not precipitate directly are isolated by concentration and/or by addition of a non-solvent.
When the final product contains an optional sulfone or sulfoxide group and that group is not already present in the starting dinitrile, it can be introduced by the oxidation of a corresponding thioether derivative. An oxidizing agent particularly well-suited to the present purpose is 30% H 2 O 2 , with substantially 1 equivalent used to form the sulfoxide and at least 2 equivalents used to form the sulfone. Either oxidation is generally carried out in the presence of a reaction-inert solvent (e.g., methanol). Temperature is not critical, the range 0°-50° C. being fully satisfactory; ambient temperatures are preferred.
The dinitriles (VI) required as starting materials for synthesis of the present diamidine compounds are readily prepared from known compounds (available commercially or prepared according to literature methods). Preparations 1-50 detailed below provide extensive exemplification of methods for the preparation of said dinitriles.
The utility of the compounds (IV) and (V) in the treatment of trypanosomiasis and/or babesiosis is demonstrated by their in vivo activity against Trypanosome congolense and Babesia rodhaini infections in mice. Groups of mice (usually 10 in number) are infected, usually intraperitoneally, with a multiple of the 100% lethal dose of the microorganism. The ability of a given subcutaneous dose of the test compound to prevent death over a 4 week period is then determined. Activity is expressed as % protection, i.e., the proportion of the group of lethally infected mice which survive at the given dosage. Because they show at least 80% protection at a subcutaneous dose of 50 mg/kg, against both Trypanosome congolense and Babesia rodhaini, most highly preferred compounds of the formula (V) are those wherein X is --CH 2 CH═CH 2 , ##STR15## Additional preferred compounds, because they show at least 90% protection against Trypanosome congolense at a dose no higher than 50 mg/kg, are the three compounds of the formula (V) wherein X is --NHC(═NH)NH--, or ##STR16## with R as 4-picolyl; although it is further noted that these two compounds, (like the compound wherein X is ##STR17## show 0% protection against Babesia rodhaini. Further preferred compounds, because they show at least 90% protection against Babesia rodhaini at a dose no higher than 50 mg/kg, are the four compounds of the formula (V) wherein X is --CH 2 C(CH 3 )═CH--, ##STR18## Of the latter compounds, the third is more preferred, also showing 40% protection against Trypanosome congolense at 50 mg/kg. It is further noted that the first of these four compounds shows 10% protection against Trypanosome congolense at 50 mg/kg, while the second and fourth (like compounds of the formula (V) wherein X is ##STR19## where R is 2-picolyl or 3-picolyl) show 0% protection against Trypanosome congolense at 50 mg/kg. The compound of the formula (IV) is also a preferred compound, in that it shows 100% protection against Babesia rodhaini at a dose of 6.25 mg/kg (although it shows 0% protection against Trypanosome congolense even at 100 mg/kg )
By way of contrast, known 1,3-di(m-amidinophenyl)guanidine of Berg (cited above) showed no activity against Trypanosome congolense or Babesia rodhaini (at 50 mg/kg or 25 mg/kg, respectively); and the further m-disubstituted amidine, 1,3-di(m-amidinophenyl)propene (isomeric with one of the present most highly preferred compounds) showed no activity against Trypanosome congolense at 50 mg/kg, and although showing 33% protection against Babesia rodhaini at 25 mg/kg, was toxic at this dose
In treating natural infections in mammals due to a susceptible protozoan, the mammal is dosed, preferable parenterally (e.g., subcutaneously, intramuscularly or intraperitoneally) with 1-100 mg of the active compound (in single or divided doses) per kilogram of body weight of the mammal.
The compounds of the formulae (IV) and (V) are formulated in sterile form for parenteral administration (injection) according to methods well known in the pharmaceutical art, employing such standard excipients, buffers, solvents, suspending agents and preservatives as are commonly employed for such parenteral dosage forms. These formulations can be solutions or suspensions; in preconstituted liquid form, or as dry powders for reconstitution shortly before injection. The concentration of drug in vehicle will generally be relatively high (e.g., 5-20%), certainly at least 1% w/v, in order to minimize the volume of injection.
The present invention is illustrated by the following examples. However, it should be understood that the invention is not limited to the specific details of these examples. Unless otherwise specified, all operations were carried out at ambient temperature; all temperatures are in degrees centigrade; stripping of all solvents was carried out at reduced pressure; all tlc (thin layer chromatography) was carried out on commercial silica gel plates containing an ultra violet sensitive detector, with the eluant specified in parentheses; all solution drying was over MgSO 4 ; and all solvent ratios are by volume. The abbreviations DMF, THF and DMSO refer, respectively, to dimethylformamide, tetrahydrofuran and dimethylsulfoxide.
EXAMPLE 1
Diethyl p,p'-(1,3-Diphenylpropene)dicarboximidate Dihydrochloride
1,3-Di(p-cyanophenyl)propene (11.9 g, 0.049 mole) was taken into 640 ml 15:1 CHCl 3 :absolute ethanol, cooled to -10° to 0° and perfused with HCl gas for 65 minutes, then allowed to stand at room temperature for 40 hours and finally stripped to yield title product as a white solid; 15.5 g; ir(KBr) 3.45, 6.25, 6.90, 7.25, 7.35 and 9.25 microns.
EXAMPLE 2
1,3-Di(p-amidinophenyl)propene Dihydrochloride
Absolute ethanol (350 ml) was saturated with NH 3 at 0°-5° by perfusing with NH gas for 25 minutes. Title product of the preceding Example (15.5 g, 0.038 mole) was added, the mixture was allowed to warm to room temperature and stirred for 4 days. Crystallization was induced by cooling to 0°-5° C. for 2 hours. After granulating for 1 day at room temperature, title product was recovered by filtration with acetone wash: 7.2 g; m.p. 314°-318°; tlc (2:1:1 butanol:H 2 O:CH 3 CO 2 H) Rf 0.34.
Analysis: Calculated: C, 55.34; H, 6.02; N, 15.18; Cl - , 19.21. Found: C, 55.10; H, 5.98; N, 15.21; Cl - , 19.06.
To obtain a second crop, the filtrate was stripped to a yellow foam which was triturated with acetone, stirred with 50 ml 2N HCl initially added dropwise) and filtered with acetone wash: 3.3 g; m.p. 314°-318°.
EXAMPLE 3
Diethyl p,p'-(2-Methyl-1,3-diphenylpropene)dicarboximidate Dihydrochloride
1,3-Di(p-cyanophenyl)-2-methylpropene (800 mg) was converted to title product by the method of Example 1. After stripping, the resulting foam was triturated with acetone: 1.2 g; ir(KBr) 3.0, 3.40, 6.25, 6.95, 7.25, 7.45 and 9.45 microns.
EXAMPLE 4
2-Methyl-1,3-di(p-amidinophenyl)propene Dihydrochloride
Title product of the preceding Example (1.2 g) was converted to present title product by the method of Example 2. After 4 days at room temperature, the reaction mixture was stripped to yield title product as an oil which solidified on trituration with acetone: 766 mg; tlc (2:1:1 butanol:H 2 O:CH 3 CO 2 H) Rf 0.6; ir(KBr) 3.05, 3.25, 6.06, 6.25, 6.50 and 6.75 microns.
EXAMPLE 5
Di(2-methoxyethyl) p,p'-(1,3-Diphenylguanidine)dicarboximidate Dihydrochloride
2-Methoxyethanol (35 ml) was cooled in an acetoneice bath and purged with dry HCl for 20 minutes. 1,3-Di(p-cyanophenyl)guanidine (500 mg) was added and the mixture warmed to room temperature and stirred 20 hours. The reaction mixture was stripped of excess HCl, poured into 300 ml ether, granulated and title product recovered by filtration; ir(KBr) 2.92, 3.48, 6.00, 6.21, 6.95, 8.00, 8.32, 8.80 and 9.10 microns. The entire product was used in the next step.
EXAMPLE 6
1,3-Di(p-amidinophenyl)guanidine Dihydrochloride
The entire title product from the preceding Example was taken into absolute ethanol (50 ml), cooled to 0°-5° C., and the solution purged with NH for 15 minutes. After stirring for 60 hours at room temperature, the reaction mixture was stripped to solids, which were slurried in 5 ml methanol and cooled to 0°-5° C. The cold slurry was purged with dry HCl, initially forming a solution from which title product crystallized: 595 mg; m.p. 325°-330°; ms 261, 244, 236; high resolution ms 278, 261, 244 (no oxygen); tlc (2:1:1 butanol:H 2 O:CH 3 CO 2 H) Rf 0.05.
EXAMPLE 7
Di(2-methoxyethyl) p,p'-(1,3-Diphenylpyrrole)dicarboximidate Dihydrochloride
By the method of Example 5, 1,3-di(p-cyanophenyl)pyrrole (600 mg) was converted to present title product: 974 mg; ir(KBr) 3.00, 3.45, 5.90, 6.25, 6.90, 7.40, 7.85, 8.35 and 9.45.
EXAMPLE 8
1,3-Di(p-amidinophenyl)pyrrole Dihydrochloride
Title product of the preceding Example (974 mg) was converted to present title product by the method of Example 2, it being unnecessary to cool the reaction mixture to induce precipitation of the product. At the end of the reaction period, the reaction mixture was filtrated and the filtrate reserved. The filter cake was repulped for 10 minutes in 8 ml 2N HCl and refiltered with acetone wash to yield a first crop of title product: 200 mg; ms 303, 286, 269; ir(KBr) shows amidine band at 6.00 microns; tlc (2:1:1 butanol:H 2 O:CH 3 CO 2 H) Rf 0.27.
Analysis: Calculated: C, 54.84; H, 5.38; N, 17.76; Cl - 17 98. Found: C, 55.24; H, 5.62; N, 17.44; Cl - 16.71.
A second crop was obtained by stripping the reserved filtrate to solids which were then further processed as above: 160 mg.
EXAMPLE 9
Di(2-methoxyethyl) p,p'-(1,4-Diphenylimidazole)dicarboximidate Dihydrochloride
By the method of Example 5, 1,4-di(p-cyanophenyl)imidazole (436 mg) was converted to present title product: 721 mg; ir(KBr) 3.00, 3.50, 6.10-6.25, 6.90, 7.15, 7.85, 8.70, 8.85, 9.20 and 9.35 microns.
EXAMPLE 10
1,4-Di(p-amidinophenyl)imidazole Dihydrochloride
By the method of Example 8, title product of the preceding Example (721 mg) was converted to present title product. The crude product which was isolated directly from the reaction mixture (330 mg) was slurried in 30 ml ethanol, purged with dry HCl, cooled and refiltered to yield purified title product: 239 mg; m.p. 359-361° (dec.); tlc (2:1:1 butanol:H 2 O:CH 3 CO 2 H) rf 0.26.
A second crop (75 mg) was obtained by concentration of the ethanol mother liquor.
EXAMPLE 11
Di(2-methoxyethyl) p,p'-(2,5-Diphenyltetrazole)dicarboximidate Dihydrochloride
By the method of Example 5, 2,5-di(p-cyanophenyl)tetrazole (400 mg) was converted to present title product: 666 mg (91%); ir(KBr) 2.90, 3.45, 6.10, 6.85, 7.15, 7.90, 8.50, 8.90, 9.30 and 9.85 (doublet)microns.
EXAMPLE 12
2,5-Di(p-amidinophenyl)tetrazole Dihydrochloride
By the method of Example 8, title product of the preceding Example (660 mg) was converted to present title product. The crude product isolated directly from the reaction mixture was repulped sequentially in ethyl acetate, 2N HCl and acetone to yield purified title product: 284 mg; tlc (2:1:1 butanol:H 2 O:CH 3 CO 2 H) Rf 0.14; ms 261, 244, 116.
EXAMPLE 13
Di(2. methoxyethyl) p,p'-(1,4-Diphenyl-2-methylimidazole)dicarboximidate Dihydrochloride
By the method of Example 5, 1,4-di(p-cyanophenyl)-2-methylimidazole (350 mg, 0.0012 mole) was converted to present title product: 611 mg; ir(KBr) 2.82, 3.42, 6.10, 6.20, 6.95, 7.38 and 9.00 microns.
EXAMPLE 14
1,4-Di(p-amidinophenyl)-2-methylimidazole Dihydrochloride
By the method of Example 4, title product of the preceding Example (611 mg) was converted to present title product. The reaction mixture, which was clarified prior to stripping, gave crude product as a yellow foam. The latter was triturated with acetone and then a combination of acetone and 2N HCl, and finally filtered with acetone wash to yield title product: 378 mg; pnmr/DMSO-d 6 /delta 2.85 (s, 3H, CH 3 ), 8.0-8.65 (m, 9H, aromatic), 9.45-10.1 (bd. t, 8H, protonated amidine groups)ppm.
EXAMPLE 15
Di(2-methoxyethyl) p,p'-(1,4-diphenyl-2-benzylimidazole)dicarboximidate Dihydrochloride
By the method of Example 5, 1,4-di(p-cyanophenyl)-2-benzylimidazole (240 mg) was converted to present title product: 370 mg; ir(KBr) 2.94, 3.40, 6.05, 6.15 and 7.35 microns.
EXAMPLE 16
1,4-Di(p-amidinophenyl)-2-benzylimidazole Dihydrochloride
By the method of Example 14, title product of the preceding Example (370 mg) was converted to present title product: 225 mg; ir(KBr) no CN band, C═N band at 6.00 microns; tlc (2:1:1 butanol:H 2 O:CH 3 CO 2 H) Rf 0.39. Title product (195 mg) was further purified by dissolving in 15 ml methanol, briefly purging with dry HCl, stripping, triturating with cold 2N HCl, and filtering with 2N HCl and finally acetone wash: 116 mg.
EXAMPLE 17
Di(2-methoxyethyl) p,p'[1,4-Diphenyl-2-(2-picolyl)imidazole]dicarboximidate Trihydrochloride
By the method of Example 5, 1,4-di(p-cyanophenyl)-2-(2-picolyl)imidazole hydrochloride (580 mg) was converted to present title product: 930 mg; ir(KBr) 2.90, 3.44, 6.20, 6.85, 7.15, 7.35 and 8.32 microns.
EXAMPLE 18
1,4-Di(p-amidinophenyl)-2-(2-picolyl)imidazole Trihydrochloride
By the procedure of Example 4, title product of the preceding Example (925 mg) was converted to present title product. The initially isolated, crude oil was combined with acetone, diluted dropwise with 2N HCl and then with methanol. Since oily material remained, the whole was restripped, the residue was treated with 5 ml CH 3 OH, and solids (160 mg) recovered by filtration. The filtrate was purged with HCl gas for 2 minutes and then diluted with 50 ml acetone to precipitate title product, which was recovered by filtration with acetone wash: 393 mg; m.p. 215° (dec.); ir(KBr) no CN band, includes C═N band at 6.00 microns; tlc (2:1:1 butanol:H 2 O:CH 3 CO 2 H) Rf 0.10.
EXAMPLE 19
Di(2-methoxyethyl) p,p'(1,4-Diphenyl-2-methylthioimidazole)dicarboximidate Dihydrochloride
By the method of Example 5, 1,4-di(p-cyanophenyl)-2-methylthioimidazole (340 mg) was converted to present title product: 456 mg; ir(KBr) 2.91, 3.44, 6.20, 6.85, 7.15, 7.35 and 8.32 microns.
EXAMPLE 20
1,4-Di(p-amidinophenyl)-2-methylthioimidazole Dihydrochloride
By the procedure of Example 4, title product of the preceding Example (456 mg) was converted to present title product. Following trituration with acetone, the product was further triturated with a mixture of acetone and 2N HCl and recovered by filtration with acetone wash: 248 mg; pnmr(CDCl 3 ) includes singlet at 2.7 ppm (SCH 3 ); ir(KBr) no CN band, includes C═N band at 6.00 microns; ms includes 333 (m-17) and 316 (m-34); tlc (2:1:1 butanol:H 2 O:CH 3 CO 2 H) Rf 0.25.
EXAMPLE 21
1,4-Di(p-amidinophenyl)-2-methanesulfonylimidazole Dihydrochloride
Title product of the preceding Example (225 mg) was dissolved in 10 ml CH 3 OH and cooled to 0°-5° C. Excess 30% H 2 O 2 (50 drops, greater than 2 equivalents) was added and the mixture warmed to room temperature, stirred 60 hours, and finally stripped to an oil which was solidified by trituration with methanol to yield title product: 221 mg; tlc (2:1:1 butanol:H 2 O:CH 3 CO 2 H) Rf 0.15.
By restricting the amount of H 2 O 2 to 1 equivalent, the corresponding sulfoxide, 1,4-di(p-amidinophenyl)-2-methanesulfinylimidazole dihydrochloride, is obtained.
EXAMPLE 22
Di(2-methoxyethyl)p,p'-(1,4-Diphenyl-2-propylthioimidazole)dicarboximidate Dihydrochloride
By the method of Example 5, 1,4-di(p-cyanophenyl)-2-propylthioimidazole (500 mg) was converted to present title product; ir(KBr) 2.95, 3.40, 6.20, 6.80, 7.30, 8.80 and 9.10 microns. The entire batch of product was used in the next step.
EXAMPLE 23
1,4-Di(p-amidinophenyl-2-propylthioimidazole Dihydrochloride
By the method of Example 4, title product of the preceding Example (entire batch) was converted to present title product. Prior to stripping, the reaction mixture was treated with activated carbon. The crude residue, after stripping, was taken up in 5 ml CH 3 OH, the solution purged for 10 minutes with dry HCl, and title product precipitated by dilution with acetone: 381 mg; ms 362, 345, 302, 232, 219; tlc (2:1:1 butanol:H 2 O:CH 3 CO 2 H) Rf 0.50.
EXAMPLE 24
Di(2-methoxyethyl) p,p'-[1,4-Diphenyl-2-(2-hydroxyethylthio)imidazole]dicarboximidate Dihydrochloride
By the method of Example 5, 1,4-di(p-cyanophenyl)-2-(2-hydroxyethylthio)imidazole (500 mg) was converted to present title product: 817 mg; ir(KBr) 2.90, 3.40, 6.25, 6.95 and 9.35.
EXAMPLE 25
1,4-Di(p-amidinophenyl)-2-(2-hydroxyethylthio)imidazole Dihydrochloride
By the method of Example 6, title product of the preceding Example (817 mg) was converted to present title product, which was precipitated from the methanol/HCl by dilution with acetone: 377 mg; m.p. >250°; tlc (2:1:1 butanol:H 2 O:CH 3 CO 2 H) Rf 0.42.
EXAMPLE 26
Di(2-methoxyethyl) p,p'-[1,4-Diphenyl-2-(2,3-dihydroxypropylthio)imidazole]dicarboximidate Dihydrochloride
By the method of Example 5, 1,4-di(p-cyanophenyl)-2-(2,3-dihydroxypropylthio)imidazole (331 mg) was converted to present title product; irKBr) 2.90, 3.40, 6.25, 6.85, 7.35 and 9.00. The entire batch was used in the next step.
EXAMPLE 27
1,4-Di(p-amidinophenyl)-2-(2,3-dihydroxypropylthio)imidazole Trihydrochloride
By the procedure of Example 6, title product of the preceding Example (the entire batch) was converted to present title product: 296 mg; ms 267, 252, 209; tlc (2:1:1 butanol:H 2 O:CH 3 CO 2 H) Rf 0.25.
EXAMPLE 28
Di(2-methoxyethyl) p,p'-[1,4-Diphenyl-2-(3-picolylthio)imidazole]dicarboximidate Trihydrochloride
By the procedure of Example 5, 1,4-Di(p-cyanophenyl)-2-(3-picolylthio)imidazole (0.48 g) was converted to present title product: 0.78 g, ir(KBr) 2.90, 3.40, 6.25, 6.95, 7.45 and 9.10.
EXAMPLE 29
1,4-Di(p-amidinophenyl)-2-(3-picolylthio)imidazole Trihydrochloride
By the method of Example 4, title product of the preceding Example (0.78 g) was converted to present title product. The initially formed oil was taken up in 2 ml of 2N HCl and crystallized by slowly adding 10 ml of acetone to the stirred solution: 0.37 g; ms 393 (m-2NH 3 ); ir(KBr) no CN band, C═N band at 6.00 microns; tlc (2:1:1 butanol:H 2 O:CH 3 CO 2 H) Rf 0.14.
EXAMPLE 30
Di-(2-methoxyethyl) p,p'[1,4-Diphenyl-2-(4-picolylthio)imidazole]dicarboximidate Trihydrochloride
By the method of Example 5, 1,4-di(p-cyanophenyl)-2-(4-picolylthio)imidazole (500 mg) was converted to present title product, ir(KBr) 2.95, 3.40, 6.30, 6.70, 6.95 and 7.90 microns. The entire batch of product was used in the next step.
EXAMPLE 31
1,4-Di(p-amidinophenyl)-2-(4-picolylthio)imidazole Trihydrochloride
By the method of Example 6, the entire batch of title product from the preceding Example was converted to present title product: 500 mg; m.p. 230°-240°; ms 395, 301, 243; tlc (2:1:1 butanol:H 2 O:CH 3 CO 2 H) Rf 0.08. A second crop (128 mg) was obtained from mother liquor by addition of acetone.
EXAMPLE 32
Di-(2-methoxyethyl p,p'[1,4-Diphenyl-2-(2-picolylthio)imidazole]dicarboximidate Trihydrochloride
By the method of Example 5, 1,4-di(p-cyanophenyl)-2-(2-picolylthio)imidazole (500 mg) was converted to present title product; ir(KBr) 2.90, 3.40, 6.30, 6.85, 7.15, 7.35 and 9.20 microns. The entire batch of product was used in the next step.
EXAMPLE 33
1,4-Di(p-amidinophenyl)-2-(2-picolylthio)imidazole Trihydrochloride
By the procedure of Example 25, the entire batch of title product of the preceding Example was converted to present title product: 729 mg; ms 393, 360, 259, 243; tlc (2:1:1 butanol:H 2 O:CH 3 CO 2 H) Rf 0.17.
EXAMPLE 34
Di(2-methoxyethyl) p,p'-(1,4-Diphenyl-2-benzylthioimidazole Dihydrochloride
By the method of Example 5, 1,4-di(p-cyanophenyl)-2-(benzylthio)imidazole was converted to present title product: 300 mg; ir(KBr) 2.90, 3.40, 6.30, 6.85, 7.35 and 7.80 microns.
EXAMPLE 35
1,4-Di(p-amidinophenyl)-2-(benzylthio)imidazole Dihydrochloride
By the method of Example 6, title product of the preceding Example (300 mg) was converted to present title product. Since the initially formed oil did not crystallize from the cold CH 3 OH-HCl solution, it was restripped and the residue crystallized by trituration with a mixture of 2N HCl and ethyl acetate: 163 mg; tlc (2:1:1 butanol:H 2 O:CH 3 CO 2 H) Rf 0.50.
EXAMPLE 36
2-[4-(2-Imidazolidinyl)phenyl]-6-(2-imidazolidinyl)indole Dihydrochloride
2-(p-Cyanophenyl)-6-cyanoindole (3.83 g) was slurried in 60 ml ethylenediamine, and the mixture sparged with H 2 S. An exotherm was noted, with a solution resulting. After 8 minutes sparging, product began to precipitate. The mixture was allowed to cool slowly back to room temperature, stirred for an additional 2 hours and poured into 175 ml 6N NaOH. After stirring 15 minutes, crude product was recovered by filtration with a small amount of 6N NaOH and then water wash. Dried product was dissolved in 1 liter CH 3 OH, treated with activated carbon, filtered and the filtrate acidified by sparging with excess dry HCl over a 3 minute period, precipitating title product. After granulating 10 minutes, title product was recovered by filtration with methanol and then acetone wash: 5.11 g; m.p. greater than 360°; tlc (2:1:1 butanol:H 2 O:CH 3 CO 2 H) Rf 0.06; ms 329, 300, 233.
Analysis: Calculated for C 20 H 19 N 5 .2HCl.2H 2 O: C, 54.79; H, 5.70; N, 15.98; Cl - , 16.21. Found: C, 54.98; H, 5.74; N, 16.11; Cl - , 15.93.
PREPARATION 1
Methyl p-Cyanobenzoylacetate
Dimethyl carbonate (126 g, 1.4 moles) was added dropwise to a slurry of NaH (50% in mineral oil, 13.44 g, 0.28 mole) slurried in 280 ml of dry dioxane. The reaction mixture was warmed to 80°-85° and p-cyanoacetophenone (40.7 g, 0.28 mole) in 140 ml dioxane added dropwise (at about 3/4 addition, mechanical loss due to foaming occurred; such losses are avoided by slower addition, e.g., over 1 hour). After addition was complete, heating at 80° was continued for 2 hours and crude product recovered by hot filtration. The cake was distributed between dilute CH 3 CO 2 H and ether. The ether layer was separated; washed in sequence with H 2 O, saturated NaHCO 3 , H 2 O and brine; dried; and stripped to yield title product: 39 g, (68.6%); m.p. 93°-98°; tlc (4:1 toluene:ethyl acetate) Rf 0.58. Recrystallization of 0.5 g from 2-propanol gave 0.403 g; m.p. 96°-99°.
PREPARATION 2
Methyl 3-(p-cyanophenyl)-2-(p-cyanobenzoyl)propionate
Methyl p-cyanobenzoylacetate 17.77 g, 0.087 mole) and p-cyanobenzyl bromide (17.16 g, 0.087 mole) were combined in 525 ml DMF under N 2 . K 2 CO 3 (12.1 g, 0.087 mole) was added, the slurry stirred 1.5 hours and finally poured into a mixture of 2.5 liters H 2 O and 0.5 liter ethyl acetate. The organic layer was separated, washed with fresh H 2 O and then brine, stripped to dryness, and the residue slurried in ether to yield title product: 14.83 g (53.6%); m.p. 154°-157°; tlc (4:1 toluene:ethyl acetate) Rf 0.44.
PREPARATION 3
1,3-Di(p-cyanophenyl)-1-propanone
Title product of the preceding Preparation (5.80 g, 0.018 mole) was refluxed under N 2 in 140 ml 1:1 concentrated HCl:THF for 1.25 hours. The reaction mixture was cooled and title product recovered by filtration: 3.35-3.54 g (71-75%); m.p. 149°-152° C.; tlc (4:1 toluene:ethyl acetate) Rf 0.47.
PREPARATION 4
1,3-Di(p-cyanophenyl)-1-propanol
Title product of the preceding preparation (1.04 g, 0.004 mole) was slurried in 200 ml anhydrous C 2 H 5 OH. NaBH 4 (0.155 g, 0.004 mole) was added. After 5 minutes, a solution resulted. After 30 minutes, the reaction mixture was stripped to an oil, taken up in ethyl acetate, washed with H 2 O and then brine, dried and stripped to yield title product: 1.03 g; m.p. 110°-112°.
PREPARATION 5
1,3-Di(p-cyanophenyl)propene
Using a Dean-Stark trap, title product of the preceding Preparation (262 mg, 1 mmole), p-toluenesulfonic acid (270 mg, 1.42 mmole) and 25 ml toluene were combined and refluxed for 3 hours. The reaction mixture was stripped to low volume; diluted with ethyl acetate; washed in sequence with 5% KOH, H 2 O and brine; dried; and stripped to yield 260 mg of crude product. Chromatography on silica gel with toluene as eluant, collecting the less polar component, gave purified title product: 150 mg; m.p. 98°-105°.
PREPARATION 6
1,3-Di(p-cyanophenyl)acetone
To dry N-methylpyrrolidone was added Na 2 Fe(CO) 4 (25 g, 0.065 mole) and then p-cyanobenzyl bromide (12.7 g, 0.065 mole). A mild exotherm was noted. After stirring 1 hour, more of the bromide (19.0 g, 0.097 mole) was added and stirring continued for 21 hours. The reaction mixture was then poured into 1.8 liters of ether, stirred 1 hour and filtered. The filtrate was stripped to 200 ml, added slowly to 700 ml 2N HCl, cooled and crude product recovered by filtration. The partially dried cake (13.3 g) was taken up in 800 ml hot CH 3 OH and filtered. The filtrate was boiled down to 200 ml, cooled, and purified title product recovered by filtration: 4.64 g; m.p. 149°-150°; tlc (4:1 toluene:ethyl acetate) Rf 0.41.
PREPARATION 7
1,3-Di(p-cyanophenyl)isopropanol
By the method of Preparation 4, title product of the preceding preparation (5.2 g, 0.02 mole) was converted to present title product: 5.03-5.18 g (95.9-98.7%); m.p. 157°-160°.
PREPARATION 8
1,3-Di(p-cyanophenyl)isopropyl Mesylate
Title product of the preceding Preparation (1.0 g, 0.0038 mole) and methanesulfonyl chloride (0.94 g, 0.0082 mole) were combined in 16 ml pyridine and stirred under N 2 for 4 hours. The reaction mixture was then diluted with 150 ml H 2 O, granulated and filtered (washing with H 2 O, 2N HCl and finally fresh H 2 O) to yield title product: 1.19 g (91.7%); m.p. 140°-143°; tlc (4:1 toluene:ethyl acetate) Rf 0.37.
PREPARATION 9
1,3-Di(p-cyanophenyl)propene
Title product of the preceding Preparation (9.0 g), in a small flask, was melted under N 2 by immersion in an oil bath at 200° for 5 minutes. The melt was cooled, taken up in ethyl acetate, washed in sequence with saturated NaHCO 3 , H 2 O and brine, dried, treated with activated carbon, stripped and chromatographed on silica gel with toluene as eluant to yield title product, 4.4 g; m.p. 99°-107°.
PREPARATION 10
2-Methyl-1,3-di(p-cyanophenyl)-2-propanol
Title product of Preparation 6 (2.6 g, 0.01 mole) in 100 ml THF, cooled to 5°, was reacted with methylmagnesium chloride (5 ml of 2.8N in ether, 0.014 mole). After 1 hour, the reaction mixture was added to saturated NH 4 Cl and extracted with ethyl acetate. The extract was washed with H 2 O and then brine, stripped to solids (2.64 g) and triturated with hot toluene to yield title product: 1.48 g; m.p. 147°-148° C.; tlc (4:1 toluene: ethyl acetate) Rf 0.30.
PREPARATION 11
2-Methyl-1,3-di(p-cyanophenyl)propene
By the method of Preparation 5, title product of the preceding Preparation (1.12 g, 0.004 mole) was converted to present title product: 1.24 g crude; 944 mg after chromatography; oil; ms 258, 243, 140; tlc (4:1 toluene:ethyl acetate) Rf 0.7.
PREPARATION 12
1,3-Di(p-cyanophenyl)guanidine
Cyanogen bromide (3.18 g, 0.03 mole) and p-cyanoaniline (7.08 g, 0.06 mole) were combined in 30 ml absolute ethanol and refluxed 16 hours. The reaction mixture was then cooled and diluted with 170 ml ether. The resulting slurry was granulated 0.5 hour, filtered with 2N NaOH wash and the cake dried (6.04 g). The cake was repulped in 300 ml ether, filtered, repulped in ethyl acetate and again filtered. The ether filtrate was stripped and the residue recrystallized from 2-propanol to yield title product: 0.55 g; m.p. 195°-200°; ir(KBr) strong CN signal; ms 261, 144, 118; tlc (ethyl acetate) Rf 0.48. The ethyl acetate filtrate was stripped and the residue chromatographed on silica gel with ethyl acetate as eluant and tlc monitoring, to yield additional title product: 1.32 g; m.p. 196°-200° C.; ms 261, 144, 118.
PREPARATION 13
N-(p-Bromophenyl)-p-cyanophenacylamine
p-Cyanophenacyl bromide (29.8 g, 0.138 mole) and p-bromoaniline (47.13 g, 0.266 mole) were combined with 53.2 g of absolute ethanol and stirred 16 hours. The solution was then diluted with ether and the resulting slurry filtered. The filter cake was repulped in 500 ml ether, filtered, repulped in 400 ml acetone and again filtered to yield title product: 17.14 g (40.9%); m.p. 154°-157°.
PREPARATION 14
Dimethyl 1-(p-Bromophenyl)-4-(p-cyanophenyl)pyrrole-2,3-dicarboxylate
Title product of the preceding Preparation (9.45 g, 0.030 mole) and dimethyl acetylenedicarboxylate (8.52 g, 0.060 mole) were combined with 30 ml CH 3 OH, and the slurry refluxed for 4 hours. The reaction mixture was cooled in an ice-water bath. The resulting solids were recovered by filtration and recrystallized from 2-propanol to yield title product: 6.46 g; m.p. 178°-180°.
PREPARATION 15
1-(p-Bromophenyl)- 4-(p-cyanophenyl)pyrrole-2,3-dicarboxylic Acid
Title product of the preceding Preparation (7.62 g, 0.0173 mole) and LiI (23.3 g, 0.173 mole) were combined in 150 ml DMF. NaCN (1.70 g, 0.0346 mole) was added portionwise, as the temperature rose to 41° C. The reaction mixture was heated at 120° C. for 16 hours, then cooled and filtered. The filtrate was reserved and the filter cake was taken up in 200 ml of warm H 2 O. The resulting solution was cooled to room temperature, acidified to pH 1.4 with 2N HCl and title product recovered by filtration: 2.58 g; m.p. 222°-224°; ms 412/410. The reserved filtrate was carefully acidified to pH 1.4 with 2N HCl (trapping HCN with a 6N NaOH trap) to provide additional title product; 4.03 g; m.p. 217°-221°; ms 412/410; tlc (4:1 toluene ethyl acetate) Rf 0.0.
PREPARATION 16
1,3-Di(p-cyanophenyl)pyrrole
Title product of the preceding Preparation (3.5 g, 0.0085 mole) and CuCN (3.05 g, 0.034 mole) were combined with quinoline (30 ml) and the mixture refluxed 4.5 hours, then cooled, poured into stirring ethyl acetate and filtered. The filtrate was washed with 2N HCl, water and brine, dried, treated with activated carbon and stripped to dryness. The resulting residue was slurried in ether and filtered to yield title product: 1.29 g; m.p. 234°-240°; tlc (4:1 toluene:ethyl acetate) Rf 0.50; ms 269, 242, 140.
PREPARATION 17
N-(p-Iodophenyl)-p-cyanophenacylamine
p-Cyanophenacyl iodide (18.0 g, 0.08 mole) was combined with p-iodoaniline (35.2 g, 0.16 mole) in 32.1 g of absolute ethanol and stirred 16 hours. Precipitated title product was recovered by filtration and repulped in 400 ml ether: 42.4 g; m.p. 160°-165°; ms 362, 232, 219.
PREPARATION 18
1-(p-Bromophenyl-2-mercapto-4-(p-cyanophenyl)imidazole
Title product of Preparation 13 (1.49 g, 0.048 mole), concentrated HCl (0.46 g, 0.048 mole), KSCN (0.46 g, 0.047 mole) and 31 ml 95% ethanol were combined and refluxed 1.25 hours. The reaction mixture was cooled and poured into 50 ml H 2 O containing 0.5 ml concentrated NH 4 OH. The resulting slurry was granulated 10 minutes and filtered. The filter cake was sucked dry for 10 minutes, then repulped in ether to provide title product: 1.38 g; m.p. 307°-311°; ms 356, 276, 218; tlc (4:1 toluene:ethyl acetate) Rf 0.40.
PREPARATION 19
1-(p-Bromophenyl)-4-(p-cyanophenyl)imidazole
Title product of the preceding Preparation (773 mg, 2.05 mmoles) was slurried in 37 ml CH 3 CO 2 H with cooling to 0°-5°. NaNO 3 (73 mg, 0.105 mmole) in a mixture of 0.73 ml concentrated HNO 3 and 2.2 ml H 2 O was added and the reaction mixture than warmed to room temperature. After 30 minutes, when dissolution was almost complete, crystallization of product began. After stirring a further 45 minutes, the slurry was poured into ice-water, granulated and filtered. The wet filter cake was repulped in 100 ml 1:1 H 2 O:concentrated NH 4 OH, refiltered and water washed to yield title product: 474 mg; m.p. 178°-185°; tlc (4:1 toluene:ethyl acetate). Rf 0.27.
PREPARATION 20
1,4-Di(p-cyanophenyl)imidazole
Title product of the preceding Preparation (400 mg, 1.23 mmoles) and CuCN (414 mg, 4.92 mmoles) were combined in 4 ml DMF and the mixture refluxed 9.5 hours, cooled and poured into 24 ml H 2 O containing 8 g of NaCN. The resulting slurry was filtered and the dried filter cake repulped in acetone and then in ether yielding 312 mg of solids. Chromatography on silica gel with ethyl acetate as eluant and recovering the less polar component gave purified title product: 164 mg; m.p. 258°-263°; tlc (20:1 CHCl 3 :CH 3 OH) Rf 0.32.
PREPARATION 21
p-Cyanobenzaldehyde Benzenesulfonylhydrazone
Benzenesulfonyl hydrazine (20.5 g, 0.12 mole) was dissolved by warming in 110 ml absolute ethanol. p-Cyanobenzaldehyde (15.6 g, 0.12 mole) was separately dissolved in 50 ml of hot ethanol and added to the hydrazine solution. The resulting slurry was refluxed 0.5 hour, cooled and filtered to yield 28.1 g; m.p. 209°-213°. Recrystallization from CH 3 CN gave purified title product: 23.7 g; m.p. 210°-213°.
PREPARATION 22
2,5-Di(p-cyanophenyl)tetrazole
Title product of the preceding Preparation (1.55 g, 0.005 mole) was dissolved in 30 ml pyridine and cooled to -5°. A room temperature solution of p-cyanoaniline (0.59 g, 0.005 ml) in a mixture of 1.3 ml concentrated HCl and 13 ml 9:4 H 2 O:ethanol was added, the mixture was recooled to 0°, and NaNO 2 (345 mg, 0.005 mole) in 2 ml H 2 O was added dropwise over 15 minutes. After stirring an additional 45 minutes at -5° to -10°, the reaction mixture was poured into CHCl 3 , washed with H 2 O and then brine, dried, treated with activated carbon, and stripped to solids. The latter were triturated 3× with hexane, and repulped in ether and then acetone to yield title product: 576 mg; m.p. 216° (dec.); tlc (4:1 toluene:ethyl acetate) Rf 0.63.
PREPARATION 23
1,4-Di(p-cyanophenyl)-2 -methylimidazole
Title product of Preparation 20 (1.3 g, 0.0048 mole) was stirred with 200 ml dry THF at -78° under N 2 . t-Butyl lithium (5.8 ml of 1M in pentane, 0.0058 mole) was added dropwise over 3 minutes. After 27 minutes at -78°, methyl iodide (3.4 g, 0.024 mole) in 15 ml THF was added dropwise over 3 minutes. After 2 hours at -78°, additional methyl iodide (1.7 g, 0.012 mole) and then t-butyl lithium (6.6 ml, 0.0066 mole) were added and stirring continued for a few minutes. The reaction was quenched into 1.2 liters H 2 O and extracted with ethyl acetate. The organic layer was washed 2× with fresh H 2 O and then brine, dried, treated with activated carbon, and stripped to a foam, 1.04 g. The foam was chromatographed on 50 g silica gel, eluting with ethyl acetate: 350 mg; m.p. 212°-220°.
PREPARATION 24
1,4-Di(p-cyanophenyl)-2-(alpha-hydroxybenzyl)imidazole
Title product of Preparation 20 (1.5 g, 0.0056 mole) was combined with 200 ml dry THF and stirred under N 2 at -78°. t-Butyl lithium (4.6 ml of 1.33M in pentane, 0.0062 mole) was added dropwise over 2 minutes, followed after 10 minutes by the dropwise addition of benzaldehyde (1.8 g, 0.0167 mole) in 10 ml THF. After stirring 1.5 hours, the reaction mixture was poured slowly into 500 ml of ice and water, and extracted with ethyl acetate. The extract was washed with H 2 O and then brine, dried, treated with activated carbon, stripped to wet solids and triturated with acetone to yield title product: 623 mg; m.p. 217°-222°; tlc (20:1 CHCl 3 :CH 3 CH) Rf 0.39. A second crop was obtained from the acetone mother liquor: 141 mg; m.p. 218°-224°.
PREPARATION 25
1,4-Di(p-cyanophenyl)- 2-(alpha-chlorobenzyl)imidazole
Title product of the preceding Preparation (1 g, 0.0027 mole) was dissolved in 100 ml THF and stirred under N 2 . SOCl 2 (1 ml, 1.58 g, 0.0133 mole) was added and reaction stirred 1.25 hours, then refluxed 1.5 hours, cooled and stripped to a foam. The foam was repulped in cold ether to yield title product: 780 mg; tlc (4:1 toluene:ethyl acetate) Rf 0.19.
PREPARATION 26
1,4-Di(p-cyanophenyl)-2-benzylimidazole
Title product of the preceding Preparation (780 mg, 0.002 mole), tributyltin hydride (1.16 g, 0.004 mole) and a few crystals of azobisisobutyronitrile were combined under N 2 in 80 ml of toluene and the mixture refluxed 1.5 hours, then stripped to an oil and distributed between 50 ml each hexane and CH 3 CN. The CH 3 CN layer was separated, washed 4× with fresh hexane and stripped to a foam which was chromatographed on 40 g silica gel, eluting with 4:1 toluene:ethyl acetate and monitoring by tlc. Clean product fractions were combined and stripped to yield title product: 280 mg; m.p. 168°-188°; ms 360; ir(KBr) includes 4.5 microns CN peak; tlc (4:1 toluene:ethyl acetate) Rf 0.30.
PREPARATION 27
1,4-Di(p-cyanophenyl)-2-(alpha-hydroxy-2-picolyl)imidazole
By the method of Preparation 24, title product of Preparation 20 (7.5 g, 0.028 mole) was converted to present title product: 3.3 g; m.p. 167°-175° C.; ir(KBr) includes CN band at 4.5 microns; ms 377; tlc (20:1 CHCl 3 : CH 3 OH) Rf 0.42.
PREPARATION 28
1,4-Di(p-cyanophenyl)-2-(alpha-chloro-2-picolyl)imidazole Hydrochloride
Title product of the preceding Preparation (1.5 g, 0.004 mole) was dissolved in 100 ml dry THF and cooled to 0°-5° C. SOCl 2 (1.4 g, 0.012 mole) was added dropwise. After stirring 0.5 hour at 0° C., the reaction was stripped and the residue repulped in ether to yield title product: 1.4 g; m.p. 140° (dec.); ms 397/395; tlc (20:1 CHCl 3 :CH 3 OH) Rf 0.62.
PREPARATION 29
1,4-Di(p-cyanophenyl)-2-(2-picolyl)imidazole Hydrochloride
By the method of Preparation 26, title product of the preceding Preparation (1.4 g, 0.0032 mole) was converted to present title product; using 20:1 CHCl 3 : CH 3 OH as eluant in the chromatography, and triturating the final product with 20:1 ether:ethyl acetate: 620 mg; m.p. 185°-194°; ir(KBr) includes CN band at 4.5 microns; ms 361.
PREPARATION 30
1-(p-Bromophenyl)-2-methylthio-4-(p-cyanophenyl)imidazole
Title product of Preparation 18 (3.36 g, 0.094 mole) and then methyl iodide (0.6 ml, 0.094 mole) were added to 107 ml of 90% ethanol containing 534 mg NaOH. The mixture was refluxed 4 hours, cooled to 0°-5° and title product recovered by filtration: 2.5 g (71%); m.p. 188°-190°; ms 372/370, 298/296, 182, 171, 169; tlc (4:1 toluene:ethyl acetate) Rf 0.60.
PREPARATION 31
1,4-Di(p-cyanophenyl)-2-methylthioimidazole
By the method of Preparation 16, title product of the preceding Preparation (2.49 g, 0.0067 mole) was converted to present title product: 420 mg; m.p. 209°-219° ms 316, 283, 243, 200, 182.
PREPARATION 32
1-(p-Iodophenyl)-2-mercapto-4-(p-cyanophenyl)imidazole
By the method of Preparation 18, title product of Preparation 17 (15.0 g, 0.041 mole) was converted to present title product: 7.43 g (44.5%); m.p. 285°-290°; ms 403, 371, 276.
PREPARATION 33
1-p-Iodophenyl)-2-propylthio-4-(p-cyanophenyl) imidazole
Title product of the preceding Preparation (4.03 g, 0.01 mole) and 1-bromopropane (3.68 g, 0.03 mole) were combined in 413 ml 90% ethanol containing NaOH (0.44 g, 0.011 mole) and stirred 5.5 hours. The reaction mixture was then filtered and the filtrate stripped. The resulting residue was repeatedly triturated with hexane and distributed between H 2 O and ethyl acetate. The organic layer was separated, washed with H 2 O and then brine, dried, stripped to an oil, and crystallized by trituration with isopropyl ether to yield title product: 3.06 g; m.p. 110°-115°; ms 445, 405, 344, 276.
PREPARATION 34
1,4-Di(p-cyanophenyl)-2-propylthioimidazole
Title product of the preceding Preparation (3.12 g, 0.007 mole) and CuCN (2.51 g, 0.028 mole) were combined in 30 ml DMF and heated in an oil bath at 155° for 1 hour. The reaction mixture was cooled, poured into 400 ml saturated KCN, and the precipitated title product granulated and recovered by filtration: 2.28 g; m.p. 117°-122°; ms 344, 302.
PREPARATION 35
1-(p-Iodophenyl)-2-(2-hydroxyethylthio)-4-(p-cyanophenyl)imidazole
By the method of Preparation 33, a like quantity of title product of Preparation 32 and ethylene bromohydrin (2.1 g, 0.017 mole) were converted to present title product: 2.92 g (65.3%); m.p. 148°-172°; ms 447, 403, 217; tlc (1:1 toluene:ethyl acetate) Rf 0.45.
PREPARATION 36
1,4-Di(p-cyanophenyl)-2-(2-hydroxyethylthio)imidazole
By the method of Preparation 34, title product of the preceding Preparation (2.79 g, 0.0062 mole) was converted to present title product: 2.06 g. The initially isolated product was slurried in ethyl acetate to yield a first crop of title product: 257 mg; m.p. greater than 300°; tlc (1:1 toluene:ethyl acetate) Rf 0.36; ms 346, 315, 301, 242. The ethyl acetate filtrate was chromatographed on silica gel with ethyl acetate as eluant to yield additional title product (501 mg) having identical physical properties.
PREPARATION 37
1-(p-Iodophenyl)-2-(2,3-dihydroxypropylthio)-4-(p-cyanophenyl)imidazole
By the method of Preparation 33, title product of Preparation 32 (4.5 g, 0.011 mole) and 3-chloro-1,2-propandiol (1.48 g, 0.013 mole) were converted to present title product. After stripping the reaction mixture, the residue was simply repulped in water: 517 g; m.p. 160°-174°; ms 477, 446, 403; tlc (1:1 toluene:ethyl acetate) Rf 0.20.
PREPARATION 38
1,4-Di(p-cyanophenyl)-2-(2,3-dihydroxypropylthio)imidazole
By the method of Preparation 34, title product of the preceding Preparation (5.0 g, 0.0105 mole) was converted to present title product. The product initially isolated was further pruified by stirring with 200 ml acetone, removing 1.28 g of insoluble material, and stripping the filtrate to 2 g of solids. The latter were redissolved in acetone and chromatographed on silica gel with ethyl acetate as eluant to yield purified title product: 368 mg; m.p. 190°-195°; tlc (1:1 toluene: ethyl acetate) Rf 0.14.
PREPARATION 39
1-(p-Bromophenyl)-2-(3-picolylthio)-4-(p-cyanophenyl)imidazole
NaOH (0.96 g, 0.024 mole) was dissolved in 98 ml 98% ethanol. Title product of Preparation 18 (3.0 g, 0.0084 mole) was added, followed by 3-picolyl chloride hydrochloride (1.61 g, 0.0092 mole). After stirring for 10 minutes, just as there was almost complete solution, heavy precipitation began. After 1 hour, title product was recovered by filtration, with water repulp: 3.03 g; m.p. 177°-178°; ms 447, 298, 259; tlc (1:1 toluene:ethyl acetate) Rf 0.4.
PREPARATION 40
1,4-Di(p-cyanophenyl)-2-(3-picolylthio)imidazole
By the method of Preparation 34, title product of the preceding Preparation (3.0 g, 0.0067 mole) was converted to present title product: 2.2 g, which was further purified by chromatography on 100 g silica gel using CHCl 3 as eluant: 0.87 g; m.p. 218°-225°; ms 393, 360; tlc (1:1 toluene:ethyl acetate) Rf 0.23.
PREPARATION 41
1-(p -Iodophenyl)-2-(4-picolylthio)-4-(p-cyanophenyl)imidazole
Title product of Preparation 32 (4.03 g, 0.01 mole) and then 4-picolyl chloride hydrochloride (2.55 g, 0.014 mole) were added with stirring to 413 ml 90% ethanol containing NaOH (1.12 g, 0.028 mole). After stirring 4 hours, the reaction mixture was filtered and the filtrate evaporated to dryness in vacuo. The residue was repulped in ether, taken up in ethyl acetate, washed with water and then brine, dried, treated with activated carbon and restripped to yield title product: 2.96 g (59.9%); m.p. 155°-162°; ms 494, 401, 344, 293, 275, 259.
PREPARATION 42
1,4-(p-Cyanophenyl)-2-(4-picolylthio)imidazole
By the method of Preparetion 34, title product of the preceding Preparation (2.34 g, 0.0047 mole) was converted to present title product: 1.02 g; m.p. 170°-174°; ms 393, 360, 301, 259, 243.
PREPARATION 43
1-(p-Iodophenyl)-2-(2-picolylthio)-4-(p-cyanophenyl)imidazole
By the method of Preparation 41, a like quantity of title product of Preparation 32 and 2-picolyl chloride hydrochloride (2.13 g, 0.012 mole) were converted to present title product. After stripping the reaction mixture to dryness and taking up in ethyl acetate and water, a first crop of title product, 897 mg, was recovered by filtration. The ethyl acetate layer in the filtrate was separated, washed with brine, dried and stripped. The residue was repulped in 2-propanol and then chromatographed on silica gel, with ethyl acetate as eluant. The less polar product fractions were combined and stripped to yield a second crop of the product: 714 mg; m.p. 180°-184°; tlc (1:1 toluene: ethyl acetate) Rf 0.53; ms 494, 259.
PREPARATION 44
1,4-Di(p-cyanophenyl)-2-(2-picolylthio)imidazole
By the method of Preparation 34, title product of the preceding Preparation (1.5 g, 0.003 mole) was converted to present title product: 1.36 g, further purified by dissolving in 200 ml of acetone, treating with activated carbon and restripping: 1.05 g; m.p. 164°-170°; ms 393, 360, 307, 270; tlc (1:1 toluene: ethyl acetate) Rf 0.43.
PREPARATION 45
1-(p-Bromophenyl)-2-benzylthio-4-(p-cyanophenyl)imidazole
By the method of Preparation 30, title product of Preparation 18 was converted to present title product.
PREPARATION 46
1,4-Di(p-cyanophenyl)-2-(benzylthio)imidazole
By the method of Preparation 34, title product of the preceding Preparation was converted to present title product, initially obtained as gummy solids. The latter were taken up in acetone, filtered and the filtrate chromatographed on silica gel to yield purified title product: 766 mg; m.p. 168°-172° C.; ms 392, 360, 258.
PREPARATION 47
4-Cyano-2-nitrotoluene
With stirring, concentrated H 2 SO 4 (205 ml) was cooled to 5° C. Keeping the temperature below 20° C., concentrated HNO 3 (85 ml) was added dropwise. Keeping the temperature below 40° C., p-tolunitrile (96 ml) was then added dropwise. After stirring 10 minutes, the reaction mixture was quenched onto 3 kilograms ice, granulated and filtered to yield title product: 120.5 g; m.p. 102°-104°.
PREPARATION 48
1-(p-Cyanophenyl)-2-(o-nitro-p-cyanophenyl)ethanol
Title product of the preceding Preparation (122.4 g, 0.755 mole) and p-cyanobenzaldehyde (100.0 g, 0.755 mole) were dissolved in 882 ml DMSO. NaOCH 3 (6.125 g, 5 mole) was added and the mixture stirred 4 hours, then quenched into 6 liters of ice and water, granulated 1 hour and title product recovered by filtration: 201.3 g; m.p. 147°-153°.
PREPARATION 49
p-Cyano-o-nitrobenzyl p-Cyanophenyl Ketone
Title product of the preceding Preparation (100.7 g, 0.343 mole) in 2.5 liters acetone at 5° was oxidized with CrO 3 in pyridine (132 ml of 0.343 M) added dropwise over 20 minutes. The reaction mixture was stripped, the residue repulped in water at 70° to yield title product: 93.5 g. The latter was further purified by dissolution in 650 ml warm CH 3 CN, treatment with activated carbon, evaporation to 250 ml, cooling and filtration: 69.9 g; m.p. 188°-190°.
PREPARATION 50
2-(p-Cyanophenyl)-6-cyanoindole
Title product of the preceding Preparation (28.5 g, 0.097 mole) was combined with 700 ml CH 3 CO 2 H and stirred at 0°-5° C. while zinc powder (64.0 g, 0.097 mole) was added portionwise. The mixture was then refluxed 45 minutes and filtered hot. The mixture was reduced in volume by stripping, cooled and crude product recovered by filtration. The latter was slurried for 0.5 hour in 5% NaHCO 3 , recovered by filtration, taken up in acetone and the mixture filtered and the cake washed with acetone until the wash was free of yellow color. The combined filtrate and wash were stripped to yield purified title product: 20.7 g; m.p. 270°-275°. | Diamidines of the formula ##STR1## wherein X is a propylene, isobutylene, guanidine, pyrrole, tetrazole, imidazole or substituted imidazole group; and 2-[4-(2-imidazolinyl)phenyl]-6-(2-imidazolinyl)indole, are useful in the treatment of certain protozoal infections in mammals, particularly in cattle. | 2 |
FIELD OF THE INVENTION
[0001] The field of the invention relates to techniques for tubular expansion and sealing in open hole with attachment techniques to an existing tubular.
BACKGROUND OF THE INVENTION
[0002] Various techniques have been developed to expand liners and attach them to existing casing already in the wellbore. Some of these techniques involve running a liner with a wide bell at the bottom where the expansion equipment is located and then driving the swage up the liner and out the top and along the way setting external seals to the surrounding casing as the swage makes an exit. One such process is shown in U.S. Pat. No. 6,470,966. The extensive list of prior art included in that patent is representative of the state of the art in downhole tubular expansion techniques that include attachment to an existing tubular. Other patents show the use of swages that include a series of retractable rollers that can be radially extended downhole to initiate a tubular expansion such as of a casing patch as for example is illustrated in U.S. Pat. No. 6,668,930. Some devices swage in a top to bottom direction as illustrated in U.S. Pat. No. 6,705,395.
[0003] What is needed and addressed by the present invention are refinements to the previous techniques that improve performance, mitigate risk and save time to reduce the cost to the operator. Techniques involving expansion in stages coupled with cementing in between are envisioned. An adjustable swage to expand on location removes the need for oversized bells to house the expansion equipment as done in some techniques. Techniques using cement or just sealing externally in open hole are envisioned. Composite materials facilitate subsequent drill out while improved shoe configuration improves circulation when tripping into the hole. The shoe and/or liner can be rotationally locked to work the string for delivery downhole. These and other advantages will become more apparent to one skilled in the art from a review of the description of the preferred embodiments and the associated drawings, while recognizing that the full scope of the invention is given by the claims.
SUMMARY OF THE INVENTION
[0004] An expansion and cementing assembly is run into the well as the expandable liner is made up. A work string is tagged into the expansion assembly and run to depth. Pressure drives the swage to initially expand and move uphole with the attached work string until the liner is expanded above the location of the subsequent cement placement. The assembly is then lowered to engage the guide/float shoe to perform the cementing step. The swage assembly is then released from the guide/float shoe and the balance of the expansion is performed without further expansion against the recently placed cement. The expansion assembly can start at the guide/float shoe or higher, in which case expansion can occur initially in a downhole direction and later be completed in an uphole direction. Variations without cementing are also contemplated.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] FIG. 1 is a view of a wellbore that has been cased with an open hole segment below;
[0006] FIG. 2 is the view of FIG. 1 showing a liner with a float shoe inserted into the open hole segment through the casing;
[0007] FIG. 3 is the view of FIG. 2 with the swage assembly being run in;
[0008] FIG. 4 is the view of FIG. 3 with the circulation established through the swage assembly and the float shoe as the liner is run in;
[0009] FIG. 5 is the view of FIG. 4 with the swage assembly expanded but not yet driven;
[0010] FIG. 6 is the view of FIG. 5 with the swage assembly released from the supporting string and being driven down to the float shoe;
[0011] FIG. 7 is the view of FIG. 6 with the circulation re-established after the swage assembly engages the float shoe;
[0012] FIG. 8 is the view of FIG. 7 with the support string releasing the liner and being advanced further into the liner using additional stands added above;
[0013] FIG. 9 is the view of FIG. 8 with the swage assembly again latched to the supporting string and cement pumped through the float shoe to fill the annulus around the already expanded liner;
[0014] FIG. 10 is the view of FIG. 9 with the swage assembly now driven up to complete the expansion of the liner top into the casing;
[0015] FIG. 11 is the view of FIG. 10 with the swage assembly out of the fully expanded liner and the liner hanger to the surrounding casing engaged;
[0016] FIG. 12 is a view similar to FIG. 1 to illustrate an alternative method;
[0017] FIG. 13 is the view of FIG. 12 with the liner in the well showing a swage assembly connected to the float shoe;
[0018] FIG. 14 is the view of FIG. 13 with the work string run in to engage the swage assembly;
[0019] FIG. 15 is the view of FIG. 14 with the circulation established as the liner is run into the open hole;
[0020] FIG. 16 is the view of FIG. 15 with the swage assembly extended in the liner;
[0021] FIG. 17 is the view of FIG. 16 with the swage assembly pressure released from the float shoe and ready to move uphole;
[0022] FIG. 18 is the view of FIG. 17 with the swage assembly driven uphole;
[0023] FIG. 19 is the view of FIG. 18 with the swage assembly again engaged to the float show after initial expansion;
[0024] FIG. 20 is the view of FIG. 19 with the annulus around the expanded portion of the liner being cemented;
[0025] FIG. 21 is the view of FIG. 20 with the swage assembly driven up to complete the expansion above the cemented zone and engage the hanger on the liner to the casing;
[0026] FIG. 22 is the view of FIG. 21 with the swage assembly removed from the liner;
[0027] FIG. 23 is another view of FIG. 1 for an alternative embodiment without cementing the liner;
[0028] FIG. 24 is the view of FIG. 23 with the liner in the hole and suspended from the surface with an open hole packer outside the liner;
[0029] FIG. 25 is the view of FIG. 24 with the string latched into the swage assembly that is supported at the float shoe;
[0030] FIG. 26 is the view of FIG. 25 with the circulation established for running in the liner;
[0031] FIG. 27 is the view of FIG. 26 with the swage assembly expanded;
[0032] FIG. 28 is the view of FIG. 27 with the swage assembly released to move uphole from the float shoe;
[0033] FIG. 29 is the view of FIG. 28 with the liner expanded and the open hole packer set;
[0034] FIG. 30 is the view of FIG. 29 with the swage expanding the hanger on the liner into contact with the casing; and
[0035] FIG. 31 is the view of FIG. 30 with the swage assembly out of the liner and the float shoe ready to be drilled out or retrieved to the surface.
[0036] FIG. 32 shows an open hole that can be under reamed with respect to the cased hole above;
[0037] FIG. 33 shows a liner inserted and expanded to hang off the casing above with options to seal it with cement or external packers or both or neither;
[0038] FIG. 34 shows an under reamed open hole below the already expanded and hung off liner;
[0039] FIG. 35 shows a production string through the expanded liner and hung off the casing where the production string can be cemented or not as needed;
[0040] FIG. 36 shows a casing patch application using expansion;
[0041] FIG. 37 shows an open hole patch using expansion;
[0042] FIG. 38 shows an open hole patch in an under reamed hole;
[0043] FIG. 39 shows an under reamed open hole below a cased hole;
[0044] FIG. 40 is the view of FIG. 39 with a liner inserted and expanded to create a lower bell in the under reamed portion of the well;
[0045] FIG. 41 is the view of FIG. 40 with the shoe drilled out of the bottom of the expanded liner and further showing a variety of sizes of new hole to be drilled deeper;
[0046] FIG. 42 is the view of FIG. 41 with a production string run in and hung off the casing and optionally cemented;
[0047] FIG. 43 is the view of FIG. 41 with a second liner hung off from the bell of the liner above and optionally externally sealed with cement or/and one or more packers pr neither;
[0048] FIG. 44 is the view of FIG. 43 with the lower liner expanded in two dimensions to create a lower bell;
[0049] FIG. 45 is the view of FIG. 44 with the length of the liner below the liner lap expanded to allow for high setting a subsequent liner in the event of a hole collapse;
[0050] FIG. 46 shows a sequence of liners allowing the sidetrack exit while maintaining bore size;
[0051] FIG. 47 shows a cased hole with a bell on the lower end of the casing that can be there for run in or created with expansion of a subsequent liner and an under reamed open hole below;
[0052] FIG. 48 is the view of FIG. 45 with a liner run in and hung off in the casing bell and optionally sealed with cement or/and one or more external packers or neither;
[0053] FIG. 49 shows a casing with a lower bell and an upper liner hung from the bell with an open hole below the size of the expanded liner or under reamed; and
[0054] FIG. 50 is the view of FIG. 47 with a production liner inserted through the expanded liner above it and the production liner hung from above the bell in the casing;
[0055] FIG. 51 shows a cased hole with a bell on the lower end of the casing that can be there for run in or created with expansion of a subsequent liner and an under reamed open hole below.
[0056] FIG. 52 is the view of FIG. 51 with a liner run in and hung off in the casing bell with a second casing bell positioned at the bottom that can be created upon expansion of the liner or created with expansion of a subsequent liner and is optionally sealed with cement and/or one or more external packers or neither.
[0057] FIG. 53 is the view of FIG. 52 with the shoe drilled out and the open hole below under reamed to accommodate a subsequent liner.
[0058] FIG. 54 is the view of FIG. 53 with an additional liner shown run in and hung off as the one above it and as subsequent liners can also be installed.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0059] FIG. 1 shows casing 10 in a wellbore 12 that extends from the surface 14 . The open hole portion 16 has a pilot hole 18 at the lower end. A rig 19 is illustrated schematically at the surface 14 . In FIG. 2 a liner 20 is supported from the rig 19 and extends into the open hole 16 . Liner 20 has a hanger/packer 22 on the outside that will eventually support the liner 20 and seal it to the casing 10 . A sealed latch assembly 24 is located inside the float shoe 26 . Float shoe 26 has a spring loaded one way valve 28 as well as a bottom exit 30 as well as side exits 32 . The side exits promote well conditioning during circulation when running in the liner 20 . The float shoe 26 allows flow in the liner 20 to exit but prevents reverse flow such as cement later pumped through the liner 20 and into the surrounding annulus 34 . The float shoe 26 can also be made of a soft composite material or other similar materials that promote rapid drill out after the cementing is completed.
[0060] FIG. 3 shows the insertion of an assembly 36 that comprises from the bottom up a latch component 38 designed to seal and latch to component 24 when brought into contact with it. Further uphole is a piston assembly 40 designed to selectively change the size of the adjustable swage 42 such as is illustrated in U.S. Pat. No. 7,128,146, for example. Further up is an uphole oriented swab cup 44 and a disconnect 46 . A section of pipe 50 spaces the lower swab cup 44 from an oppositely oriented upper swab cup 48 . Further up is a running tool 52 shown gripping the interior of the liner 20 and finally an annular debris barrier 54 is designed to keep debris from getting into the liner 20 as it is circulated when being run into the well 12 .
[0061] FIG. 4 shows a run in string 56 starting to be assembled above the debris barrier 54 and the liner 20 now supported through the string 56 off of rig 19 as it is delivered deeper into the wellbore with circulation through the assembly 36 represented by arrow 58 and return flow represented by arrow 60 . In this view it is easy to see the function of the debris barrier 54 . The valve 28 responds to delivered pressure from the surface 14 to open and let the flow out through the lateral shoe passages 32 to allow for a secondary flow path in case the bottom is plugged when resting on bottom.
[0062] In FIG. 5 a plug or dart or some other obstructing device 62 is dropped or pumped until landed to seal off passage 64 . Then with passage 64 closed at its lower end and pressurized the pressure 66 acts on piston assembly 40 as indicated by arrows 66 . The swage assembly 42 grows in radial dimension to create an initial bump out 68 in the liner 20 .
[0063] In FIG. 6 the pressure in passage 64 has been further increased to cause a separation between components 46 so that the applied pressure in passage 64 now can enter space 70 as indicated by arrows 72 . That pressure acts on lower swab cup 44 that looks uphole while the liner 20 which is gripped by running tool 52 and is supported off of string 56 from rig 19 remains immobile despite uphole pressure on upper swab cup 48 which is downhole oriented. Arrows 66 indicate that pressure on the piston assembly 40 continues to keep the swage assembly 42 at an enlarged dimension as it travels toward the float shoe 26 until components 38 and 24 re-latch and seal as shown in FIG. 7 .
[0064] In FIG. 7 components 38 and 24 have latched and a pressure buildup has popped a disc internal to dart 62 so that circulation can be established with the bulk of the liner 20 below the casing 10 already expanded. Arrows 72 and 74 represent circulation flow through passages 32 and 36 in the float shoe 26 .
[0065] FIG. 8 shows that circulation has stopped and the float shoe 28 is resting on bottom in the pilot hole 18 . The string 56 is being added to at the surface 14 to again bring together the connection 46 so that cementing around the already expanded portion of the liner 20 can take place.
[0066] In FIG. 9 the connection 46 is brought together in a sealing relationship and cement 76 is delivered into annulus 34 to the top 77 of the expanded portion of liner 20 . The cement 76 goes down passage 64 and through the one way valve 28 in the float shoe 26 to the annulus 34 . A wiper plug or dart 78 wipes passage 64 clear of the cement 76 . Optionally some cement 76 can be pumped above plug 78 to ease subsequent drill out as shown in FIG. 10 .
[0067] In FIG. 10 with wiper plug 78 remaining landed a buildup of pressure in passage 64 builds an uphole pressure on sealed latch 24 which has a downhole oriented swab cup 80 whose presence results in an uphole force represented by arrow 82 to drive the assembly 36 uphole to finish the expansion of the liner 20 into a sealed relationship with the casing 10 . The swage assembly 42 remains at maximum dimension because the piston assembly 40 is pressurized at this time as the movement uphole of the 36 continues.
[0068] FIG. 11 shows the expansion of the liner 20 to be complete and the hanger/packer 24 set to the casing 10 as a result of the conclusion of the expansion. It should be noted that the uphole oriented expansion of FIG. 10 does not occur against cement 76 already in annulus 34 . Rather, expansion continues once the extended swage assembly 42 reaches the location 77 which marked the end of expansion. The assembly 36 can now come all the way out of the liner 20 . The shoe 26 can now be drilled out and more hole can be drilled.
[0069] FIG. 12 begins another embodiment for a well with casing 100 and an open hole portion 102 terminating in a pilot hole 104 . In FIG. 13 a liner string 106 is supported from a rig 108 . At the bottom of the liner 106 is a float shoe 110 with a one way valve 112 and lateral exits 114 . The float shoe 110 has a seat 116 for landing a plug as will be later described. A latch assembly 118 releasably holds the swage assembly 120 and the piston assembly 122 that controls the dimension of the swage assembly 120 to the float shoe 110 . Above the piston assembly 122 is one portion 124 of a latch assembly. Outside the liner 106 is a hanger/packer 126 .
[0070] FIG. 14 shows a string 128 with another portion 130 of a connection that will seal and connect to portion 124 . Alternatively, the running string 128 could deliver the piston assembly 122 and the swage assembly 120 with a latch below that engages the float shoe 110 . This engagement can be with a type HRD running tool sold by Baker Oil Tools or an equivalent.
[0071] FIG. 15 shows the liner 106 lowered to the pilot hole 104 and circulation through string 128 out ports 112 and 114 and up through the annulus 133 as represented by arrows 132 and 134 as such lowering is taking place. A debris barrier 136 is at the top of liner 106 for the reason explained before. String 128 supports the liner 106 near its lower end using latch assembly 118 .
[0072] FIG. 16 shows that circulation has stopped and a plug 138 has been landed on seat 116 to allow pressure built up in string 128 to reach the piston assembly 122 so that its movement causes the swage assembly 120 move out to a larger dimension putting a bump out 142 in liner 106 . Further pressure buildup as shown in FIG. 17 releases the latch connection 118 to the float shoe 110 .
[0073] FIG. 18 shows pressure buildup against the plug 138 increasing the volume of chamber 144 as the swage assembly 120 continues to hold its enlarged dimension by virtue of continuous pressure on the piston assembly 122 schematically represented by arrow 140 . The uphole expansion is allowed to continue to a point below the bottom of the casing 100 but leaves the liner 106 expanded over substantially its entire length.
[0074] FIG. 19 shows the string 128 lowered so that latch 118 is back inside float shoe 110 and secured and a follow on pressure buildup blows a passage through the plug 138 so that the assembly is ready for cementing as shown in FIG. 20 . In FIG. 20 cement 145 is delivered through passages 112 and 114 at a pressure that keeps the piston assembly 122 ports closed. After cement 145 is delivered to annulus 133 up to location 146 on the liner 106 representing where expansion stopped, a wiper plug 148 is landed on the now opened plug 138 . Optionally some cement 145 can be pumped above plug 148 to ease subsequent drill out as shown in FIG. 20 .
[0075] Once again pressure is built up from the FIG. 20 position to cause latch 118 to release and to allow the swage assembly 120 held extended by piston assembly 122 that is now under pressure to be driven up through the already expanded portion to location 146 and then further up to the top of the liner 106 . The swage assembly 120 can optionally have a backup seal like a swab cup 150 shown in FIG. 20 so that it can keep a seal while driven up to the location 146 where expansion will continue until the hanger/packer 126 is against the casing 100 , as shown in FIG. 21 , and for continued movement until the entire liner 106 is expanded and all the expansion equipment is removed as shown in FIG. 22 . At that point the float shoe 110 can be milled out.
[0076] FIG. 23 starts an embodiment that tracks the previous embodiment only without cementing and instead using an open hole packer to seal the annulus around the expanded liner. As before a casing 200 is above an open hole 202 that is drilled or 204 if it is under-reamed. A rig 206 is at the surface 208 . As shown in FIG. 24 , the liner string 210 has a hanger/packer 212 for eventual support and sealing contact with the casing 200 and one or more external open hole packers 214 such as for example FORMpac® or REPacker® sold by Baker Oil Tools. At the lower end of the liner 210 is a float shoe 216 with a one way valve 218 and side outlets 220 and a lower port 220 A. A latch assembly 222 is latched into the float shoe 216 for ultimate support of the liner 210 as will be explained below. Going uphole there is an adjustable swage assembly 224 with a piston operating assembly 226 and a connector profile 228 . FIG. 25 illustrates a running string 230 with a connector 232 at its lower end adapted to contact connector profile 228 for a supporting and sealed connection to allow running in the liner 210 to the pilot hole 234 as shown in FIG. 26 . As stated before for an alternative, the assembly that is above the float shoe 216 can be run into the liner 210 after the liner is assembled in the wellbore 202 or 204 . In FIG. 26 , string 230 is used to lower liner 210 while circulation represented by arrows 236 and 238 flowing through lateral outlets 220 and lower port 220 A facilitate the advancement of the liner 210 . A debris barrier 240 prevents debris from entering the liner 210 during circulation as it is advanced into the wellbore.
[0077] In FIG. 27 a plug 242 is landed to allow pressure buildup in the string that is represented by arrow 244 , This pressure actuates the piston assembly 226 to increase the size of the swage assembly 224 and to create a bump out 246 in the liner 210 . As shown in FIG. 28 further pressure increase and set down weight releases the latch assembly 222 so that the swage assembly 224 start being powered uphole with pressure and/or overpull. An optional seal such as a swab cup 248 could be used with the swage assembly 224 in the event that the swage assembly itself will not sufficiently seal against the liner it is trying to expand as better illustrated in FIG. 29 . Also in FIG. 29 the swage assembly is moved up the substantial length of the liner 210 with the result being that the open hole packer 214 is sealed against the open hole 202 . Multiple open hole packers can be run. Because there is no cementing in this embodiment, the swage assembly can be driven continuously until the hanger/packer is set against the casing 200 as shown in FIG. 30 . The expansion equipment is removed as shown in FIG. 31 out the top of the liner 210 and the float shoe 216 can be milled out.
[0078] The remaining FIGS. focus on some applications of the techniques described above. FIG. 32 shows a parent casing 300 and more hole drilled that can include under reaming as represented by 301 or simply an extension of the hole that is the size of the parent casing 300 as represented by the dashed line in FIG. 32 . This view was previously illustrated in other FIGS. discussed earlier.
[0079] FIG. 33 is a split view indication that liner 302 is hung off the casing 300 using a hanger/packer 320 . At the lower end is a shoe 303 . The view is split showing that liner 302 is sealed with cement 304 on the left or with an external packer or seal 305 on the right as an alternative. As another alternative the cement 304 and seal 305 can be used together. There can be one or more seals 305 employed. The packer 305 can seal either to the smaller or larger bore such as 301 depending on how the hole is drilled and which sealing device is used.
[0080] FIG. 34 shows the liner 302 expanded and hung off the parent casing 300 and the shoe 303 drilled out with the annulus around the liner 302 isolated. More hole 310 is drilled which could be a straight bore or an under reamed bore as actually shown.
[0081] FIG. 35 shows a second liner 311 through the expanded liner 302 and hung off the parent casing 300 . Although the liner 311 is shown cemented, it could also be in open hole without cement and it could be slotted. Alternatively it could be hung off liner 302 but hanging off the casing 300 allows a larger inside diameter for liner 311 . Additionally, the hanging of liner 311 from casing 300 allows for subsequent flow to be isolated from the expanded liner 302 which might have not have the required pressure capacity or corrosion resistance. The extension bore if under reamed allows lower circulation pressure when cementing the production liner 311 . The staging of the liners 302 and 311 allows different mud weights to be used to account for differing formation properties so as to avoid mud loss or formation damage during drilling and subsequent running of the string 311 .
[0082] FIG. 36 shows a casing patch application where the casing 400 has a break or a crack or is otherwise damaged 401 and a section of tubular 402 can be inserted into position and expanded by the techniques described above so that pair of straddling seals 403 are disposed on opposed sides of the break 401 . Alternatively, longer continuous seals can be expanded to cover the damaged sections in place of straddling. Alternatively, the tubular 402 can be expanded into the inside wall of the casing 400 without seals such as 403 and simple expansion results in a tight seal that can be metal to metal.
[0083] FIG. 37 illustrates an open hole patch application where additional hole 411 has been drilled past the casing 410 and in the open hole region there is a fluid loss zone, water or other undesirable fluid is being produced into the wellbore, and/or sloughing formation. The tubular patch 412 can be run in and expanded in the manner shown before with the use of external packers 413 to straddle the zone where the losses or unwanted inflow or sloughing is occurring. Alternatively, longer continuous seals can be expanded to cover the damaged sections in place of straddling. It should be noted that there may be a reduction in the drift diameter in the patch 412 as compared to the drift diameter of the casing 420 which will restrict the passage of bit and drill string assemblies, possibly leading to a smaller open hold being drilled below the open hole patch. However, FIG. 38 is the same view as FIG. 37 with the drilled hole 411 having been under reamed in the troublesome zone so that after expansion of the patch 412 to engage the seals 413 the drift diameter of the patch is at least as large as the drift diameter in the casing 420 and maintains the bit passage diameter for continuous drilling of the hole further.
[0084] FIG. 39 starts another sequence of views with a cased hole 430 and an under reamed open hole 431 below it. In FIG. 40 a liner 432 has been inserted and expanded to two diameters or possibly more diameters depending on the cone capabilities. The smaller diameter is in casing 433 and the larger diameter is in the under reamed open hole 431 below. As covered before, a shoe 434 can be run if cement 435 is the option selected or if the alternative of external packers 436 is used. In either even the shoe provides a seat as a part of the expansion process previously discussed. The inside dimension of the liner 437 in the open hole is at least as large as its inside diameter inside the casing 433 . In FIG. 41 the shoe 434 is drilled out and additional hole 438 is drilled with a possible variation of the degree of under reaming which accounts for the dashed and solid line in the FIG. The innermost dashed line 439 represents the hole that would be made with the largest bit to fit through the top of the liner 432 while the next series of dashed lines represent under reaming to get the inside dimension of the lower end 437 of the same liner that had previously been expanded into an under reamed portion of the well above. The solid line represents a continuation of the bore size above. FIG. 42 shows another tubular 440 which can be the production string inserted and optionally cemented with cement 441 although it could be left in open hole without cement. Essentially what will pass through the top 432 of the liner above can be used. Again the lower bore size depends on formation conditions and whether cementing is to be done. In FIG. 42 the hole is under reamed to be about the size of the expanded portion 437 of the liner above. The string 440 is hung and/or sealed off inside the casing 442 but could optionally be hung off the bell portion 437 of the upper liner. The latter is illustrated in FIG. 43 where the second liner 446 is expanded and hung and/or sealed off at 445 to the already expanded liner above and in the enlarged bell portion. The string 446 can be cemented 448 or sealed with external packers 447 . At the top, it can be hung from the bell of the previously expanded liner above using a hanger/packer 445 . Note that there is no reduction in drift size as between the smallest dimension of the liner above 432 and the expanded dimension of the string 446 . This is due to the lower string 446 being hung off in the bell of the liner above at hanger/packer 445 .
[0085] In FIG. 44 the upper and lower liners are expanded to two or more different dimensions. The lower liner is hung with hanger packer 452 in the bell of the liner above it. The lower portion 453 of the lower liner is flared out so that the choke points for flow are at the hanging areas of both liners and in each case there is no reduction of drift regardless how many strings are run and sequentially hung from the string above. Here again the option of cementing 455 or using an external packer or packers 454 is also illustrated. The process can be repeated to add additional expandable liners until depth is reached. Open hole production can be another option.
[0086] FIG. 45 shows a progression of FIG. 44 where the second liner 456 has been drilled out and the open hole 457 has been under reamed to accommodate another expandable liner. The third liner 458 is shown off bottom due to a collapse of the open hole 459 . Alternatively, the liner could become stuck in the open hole for a variety of reasons including differential sticking and fill. Although the third liner 458 did not reach its targeted depth, it is still able to be expanded in two or more dimensions, maintaining flexibility for further wellbore construction. The extended recess section length of the previous liner 456 accommodates the length that the third liner 458 is set high by means of a longer liner lap. It can therefore be seen that the extended recess diameter section of the previous liner increases the flexibility of operations and mitigates risk beyond that of a shorter recess length. If a shorter recess length were present in the second liner 456 , then the third liner 458 would not have been able to be expanded without restricting the pass through diameter.
[0087] FIG. 46 is a further embodiment of the operational flexibility and risk mitigation provided by the extended recess diameter length. A third liner 460 has been installed into the wellbore below a second expandable liner 461 . The third liner 460 is shown in a no longer useable form as collapsed. Alternatively, the third liner could be leaking, not fully expanded, or otherwise damaged. Alternatively, the open hole below an undamaged third liner 460 could render the third liner unusable if for example the open hole stopped producing hydrocarbons, started producing water, or opened up for fluid losses. The sidetrack technique is then employed above the third liner 460 milling a window out of the side of the second liner 461 in a section that has been expanded to the recess diameter. After the window is milled the open hole section is further drilled and under reamed as required to accommodate running in a fourth liner 463 out of the window. The fourth liner is expanded in two or more dimensions and a hanger packer 462 is hung and/or sealed off in the recess diameter section of the second liner 461 . The section of the fourth liner 463 outside of the milled window in the second liner 461 is able to be expanded to the recess diameter. Open hole isolation for the fourth liner 463 is accomplished with cement 464 and/or the use of open hole packer or packers 465 . The bottom of the fourth liner 463 has been drilled out for further wellbore construction. All of the operational flexibility and risk mitigation provided by the two or more dimension expansion of the fourth liner and the recess resulting can be utilized in further wellbore construction such as: several additional Monobore liners are able to be run, ability to perform additional sidetracks, ability to set subsequent liners off of bottom, and running production strings of pipe to produce reservoirs without reducing the size of these production strings due to restricted pass through.
[0088] FIG. 47 shows and upper casing 470 that has a bell at the lower end either in the condition installed or due to expansion into it of the first liner to be hung. In FIG. 45 there is no liner in the hole but the FIG. is intended to be schematic of both ways a bell can be formed. FIG. 48 shows a liner 473 hung with hanger/packer 472 in the bell of casing 470 . Again the shoe is used to expand the string 473 and to facilitate cementing 476 or use of an external packer or packers 475 or both or neither if production will occur from open hole. FIG. 49 shows the shoe 474 drilled out and the hole 477 extended to the diameter of the expanded liner above. It can be under reamed to make it even larger should the formation characteristics and the cement delivery pressure be an issue. Running clearance could also be an issue that would warrant under reaming for running in of the liner 478 shown in FIG. 50 . The production liner 478 can be cemented 479 or it can be in open hole without cement or sealed with external packers. The string 478 is hung off the smaller dimension of the casing above the bell where the upper liner is supported. As a result of two dimension expansion of the upper liner with the upper end in the bell of the casing and the upper wellbore under reamed, the resulting internal dimension to depth is not reduced and the use of the upper liner for staged completion of the well does not narrow the size of the production liner 478 which is dictated by the casing size where the production liner 478 is shown to be supported in FIG. 50 .
[0089] FIGS. 51-54 show a progression of the wellbore construction concepts shown in FIGS. 47-50 in which the subsequent liner also contains a bell for the sake of being able to repeat the process multiple times without restriction of pass through. FIG. 51 shows and upper casing 480 that has a bell 481 at the lower end either in the condition installed or due to expansion into it of the first liner to be hung. In FIG. 51 there is no liner in the hole but the FIG. is intended to be schematic of both ways a bell can be formed. FIG. 52 shows a liner 483 hung with hanger/packer 482 in the bell 481 of casing 480 . Again the shoe 484 is used to expand the string 483 and to facilitate cementing 486 or use of an external packer or packers 485 or both or neither. FIG. 52 shows a bell section at the bottom of the liner 483 that is created either as a part of the process of expansion of this string or upon the installation of subsequent liner. FIG. 53 shows the shoe 484 drilled out and the hole 487 drilled out and under reamed as above. FIG. 54 shows the installation of a second liner 489 hung with a hanger/packer 488 in the bell of the previous liner. Zonal isolation is shown to be performed either with cement 492 , one or more open hole packers 490 , or both or neither. The second liner 489 contains a bell section 491 as the previous liner that can be used to hang off subsequent liners without restricting the wellbore.
[0090] Those skilled in the art will appreciate that the various embodiments offer many advantages that include improved circulation from the lateral ports in the float shoe and a fast drill out from using soft materials for the float shoe. There is an ability to transmit torque through the liner string as it is being advanced right down to the float shoe. Using an adjustable swage removes the need for a bell portion in the liner assembly reducing surge/swab effects. The liner is substantially expanded prior to cementing making for a smaller volume to cement with shorter pump times and earlier compressive strength. The balance of the expansion to tie the liner to the casing is not done against cement. The adjustable swage also allows removal through the liner at any time should the full expansion of the liner become impossible for some reason.
[0091] The above description is illustrative of the preferred embodiment and many modifications may be made by those skilled in the art without departing from the invention whose scope is to be determined from the literal and equivalent scope of the claims below. | An expansion assembly is run into the well as the expandable liner is made up. A work string is tagged into the expansion assembly and run to depth. Pressure drives the swage to initially expand and move uphole with the attached work string until the liner is expanded to set at least one external packer. The balance of the expansion in the uphole direction is continued until the string is expanded into sealing support of a higher string in the wellbore and the variable swage comes out of the hole with the work string. A shoe is milled out and the process can be repeated. | 4 |
BACKGROUND OF THE INVENTION
The present invention relates to a method and apparatus for forming a thin film by a CVD method and a method of manufacturing a semiconductor device comprising the step of forming a thin film by a CVD method.
With progress in the degree of integration of a DRAM, it is of high importance to decrease the thickness of a capacitor insulating film. In the case of using the conventional material for forming a capacitor insulating film, the capacitor insulating film must be formed very thin in order to obtain a sufficient electrostatic capacitance. Therefore, it is proposed in recent years to use a material having a high dielectric constant such as BaSrTi oxide (hereinafter referred to as “BSTO”) for forming a capacitor insulating film.
In forming a BSTO thin film on a semiconductor substrate by a CVD method, it is ideal to use as a Ba source and a Sr source materials having a high vapor pressure and gaseous at room temperature. However, such a Ba source and a Sr source are unknown. Therefore, materials solid at room temperature and sublimated to form a gaseous phase when heated to a predetermined temperature are used as the Ba source and Sr source, said materials including, for example, bis(2,2,6,6-tetramethyl-3,5-heptanedionate)barium (hereinafter referred to as “Ba(THD) 2 ”), and bis(2,2,6,6-tetramethyl-3,5-heptanedionate)strontium (hereinafter referred to as “Sr(THD) 2 ”). Also, bis(2,2,6,6-tetramethyl-3,5-heptanedionate)titanium oxide (hereinafter referred to as “TiO(THD) 2 ”) was used as a Ti source. Incidentally, TiO(THD) 2 is solid at room temperature and sublimated when heated.
FIG. 1 schematically shows a conventional CVD apparatus used for forming a BSTO thin film. In the conventional method, a solid Ba(THD) 2 16 housed in a container 7 is heated by a heater 25 to 215° C. so as to be sublimated to generate a Ba(THD) 2 gas. A nitrogen gas is supplied as a carrier gas from a nitrogen gas supply source 14 into the container 7 . The flow rate of the nitrogen gas into the container 7 is controlled by a mass flow controller 22 . It follows that the Ba(THD) 2 gas and the nitrogen gas within the container 7 are supplied together into a chamber 1 through a valve 6 .
A Sr(THD) 2 gas and a TiO(THD) 2 gas are also supplied similarly into the chamber 1 . To be more specific, a solid Sr(THD) 2 17 housed in a container 20 and a solid TiO(THD) 2 18 housed in a container 19 are heated to 215° C. and 130° C., respectively, so as to generate a Sr(THD) 2 gas and a TiO(THD) 2 gas. Also, a nitrogen gas is supplied from a nitrogen gas source 14 into the containers 20 and 19 through mass flow controllers 21 , 23 , respectively. Naturally, the Sr(THD) 2 gas and the TiO(THD) 2 gas are supplied together with the nitrogen gas from the containers 20 and 19 into the chamber 1 through valves. Further, an oxygen gas is supplied from an oxygen gas supply source 15 into the chamber 1 through a mass flow controller 24 .
The Ba(THD) 2 gas, Sr(THD) 2 gas, TiO(THD) 2 gas, oxygen gas and nitrogen gas are mixed within the chamber 1 to form a gas stream 5 within the chamber 1 . The gas pressure within the chamber 1 is monitored by a pressure gauge 13 and controlled at about 10 Torr by a conductance valve 12 for pressure control.
A wafer 2 and a susceptor 8 within the chamber 1 are heated to about 600° C. by the light emitted from a lamp 3 and transmitted through the quartz wall of the chamber 1 . As a result, the mixed gas within the chamber 1 is partially decomposed, and the decomposed materials carry out reactions. The reaction product is deposited on the wafer 2 to form a BSTO thin film.
A stagnant layer 4 through which a gas does not flow is formed in the vicinity of the surface of the wafer 2 during formation of the BSTO thin film. The mixed gas forming the gas stream 5 is partly supplied into the stagnant layer 4 . The mixed gas supplied into the stagnant layer 4 is diffused within the stagnant layer 4 so as to reach the wafer surface. As a result, the raw material gas components contained in the mixed gas are decomposed so as to bring about deposition of BSTO.
As described above, the stagnant layer 4 contributes to the deposition of BSTO. Therefore, in order to form a BSTO thin film of a uniform thickness, it is necessary to control highly accurately the thickness, etc. of the stagnant layer 4 and, thus, to make the deposition rate uniform.
However, the thickness of the stagnant layer 4 tends to be affected by the gas stream 5 . Also, it is very difficult to keep the gas stream 5 constant and uniform, leading to a non-uniform supply of the raw material gas components onto the wafer surface and to non-uniform deposition rate. It follows that it is difficult to form a BSTO thin film of a uniform thickness.
It should also be noted that the amount of the raw material gas components supplied from the gas stream 5 into the stagnant layer 4 is dependent in general on the partial pressure of the raw material gas components contained in the mixed gas forming the gas stream 5 . Under the conditions described above, the amount of the raw material gas components supplied into the stagnant layer 4 is only several percent of the raw material gas components contained in the mixed gas forming the gas stream 5 . In other words, the amount of the raw material gas components which are decomposed and consumed for the formation of the BSTO thin film is only several percent of all the raw material gas components supplied to the chamber 1 . Naturally, a major portion of the raw material gas components supplied to the chamber 1 is not decomposed so as to be discharged to the outside of the apparatus through a main valve 9 , a conductance valve 12 for the pressure control, a pipe 11 and a pump 10 , leading to a markedly high manufacturing cost of a semiconductor device including a BSTO thin film.
It should also be noted that the Ba(THD) 2 gas, Sr(THD) 2 gas and TiO(THD) 2 gas used in the conventional method are prepared by sublimation of the solid raw materials 16 to 18 . This makes it necessary to heat the pipe, valve, etc. connected to the chamber 1 so as to prevent the Ba(THD) 2 gas, etc. from being solidified. However, the valve, etc. used in the CVD apparatus tends to bring about deterioration of the driving section when the valve is exposed to high temperatures. It follows that the valve, etc. must be renewed frequently.
In order to suppress the deterioration, it is necessary to set the heating temperature of the pipe, valve, etc. at a low level. If the heating temperature is lowered, however, the flow rate of the raw material gas components must be maintained at a low level in order to prevent the raw material gas components from being solidified.
BRIEF SUMMARY OF THE INVENTION
An object of the present invention is to provide a method and apparatus for forming a thin film and a method of manufacturing a semiconductor device wherein a film of a uniform thickness can be formed.
Another object is to provide a method and apparatus for forming a thin film and a method of manufacturing a semiconductor device wherein a thin film can be formed at a low cost.
Still another object of the present invention is to provide a method and apparatus for forming a thin film and a method of manufacturing a semiconductor device wherein a thin film can be formed under higher temperature conditions without renewing frequently the constituent members of the apparatus.
According to an aspect of the present invention, there is provided a method of forming a thin film on a substrate surface by a CVD method, comprising the steps of arranging a substrate such that one main surface of the substrate is exposed to a closed space, and decomposing by heating a raw material gas filling the closed space so as to form a thin film containing at least one element constituting the raw material gas on the main surface of the substrate, the raw material gas containing a gas component generated by heating a material, which is solid or liquid at room temperature, arranged within the closed space.
According to another aspect of the present invention, there is provided a method of manufacturing a semiconductor device, comprising the step of forming a thin film on a semiconductor substrate by a CVD method, the step including the sub-steps of arranging a semiconductor substrate such that one main surface of the substrate is exposed to a closed space, and decomposing by heating a raw material gas filling the closed space so as to form a thin film containing at least one element constituting the raw material gas on the main surface of the semiconductor substrate, the raw material gas containing a gas component generated by heating a material, which is solid or liquid at room temperature, arranged within the closed space.
Further, according to still another aspect of the present invention, there is provided an apparatus for forming a thin film on a substrate surface by a CVD method, comprising a substrate holding means for holding a substrate, a reaction vessel forming a closed space to which one main surface of the substrate is exposed, a material holding means arranged inside the reaction vessel for holding a solid or liquid material, and a heating means mounted on the side of the other main surface of the substrate for heating the substrate.
Additional objects and advantages of the invention will be set forth in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. The objects and advantages of the invention may be realized and obtained by means of the instrumentalities and combinations particularly pointed out hereinafter.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate presently preferred embodiments of the invention, and together with the general description given above and the detailed description of the preferred embodiments given below, serve to explain the principles of t e invention.
FIG. 1 schematically shows a conventional CVD apparatus;
FIG. 2 schematically shows a thin film forming apparatus according to first and third embodiments of the present invention; and
FIGS. 3A and 3B schematically show thin film forming apparatuses according to second and fourth embodiments, respectively, of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Let us describe the present invention more in detail with reference to the accompanying drawings.
Specifically, FIG. 2 schematically shows a thin film forming apparatus according to first and third embodiments of the present invention.
In the first embodiment of the present invention, the apparatus shown in FIG. 2 is used for film formation in which a part of the raw material gas components is generated from a solid material. As shown in the drawing, the apparatus includes a reaction furnace 31 . A front chamber 39 is connected to the reaction furnace 31 via a gate valve 38 . A substrate 32 such as a semiconductor wafer is supplied from the front chamber 39 into the reaction furnace 31 .
Arranged within the reaction furnace 31 are a susceptor 36 , a heater 37 and a reaction vessel 33 . The wafer 32 transferred from the front chamber 39 into the reaction furnace 31 is supported by the susceptor 36 , and the wafer 32 is heated by the heater 37 via the susceptor 36 . The reaction vessel 33 is movable relative to the susceptor 36 . Where, for example, the wafer 32 is disposed on the susceptor 36 , the reaction vessel 33 is moved to a position away from the susceptor 36 . On the other hand, the reaction vessel 33 is moved for the film forming operation such that the peripheral portion of the reaction vessel 33 is brought into contact with the susceptor 36 so as to form a closed space 51 .
A container 50 acting as a material holding means for holding a material generating a reactant gas, i.e., raw gas component is arranged inside the reaction vessel 33 . The material holding means is not particularly limited as far as the material holding means is capable of holding the material generating the reactant gas and is shaped to permit the generated reactant gas to be diffused within the closed space 51 . The reactant gas generating material used in this embodiment is solid at room temperature and generates a gas when heated to a predetermined temperature. It follows that a plate-like body can be used in this embodiment as the material holding means.
An oxygen gas supply source 52 and a nitrogen gas supply source 53 are connected to the reaction furnace 31 . A mass flow controller 34 and a valve 35 are mounted to the pipe connecting the oxygen gas supply source 52 to the reaction furnace 31 . Likewise, a mass flow controller 46 and a valve 45 are mounted to the pipe connecting the nitrogen gas supply source 53 to the reaction furnace 31 .
A pipe 41 is connected at one end to the reaction furnace 31 and at the other end to a pump 40 . Further, a pressure gauge 44 , a valve 43 and a conductance valve 42 are mounted to the pipe 44 in the order mentioned when viewed from the reaction furnace 31 .
The apparatus shown in FIG. 2 is used for forming, for example, a BSTO thin film. In forming a BSTO thin film, the pressure within the front chamber 39 housing the semiconductor wafer 32 is reduced to 10 −2 Torr or less. Then, the gate valve 38 is opened to transfer the wafer 32 from the front chamber 39 into the reaction furnace 31 having the inner pressure reduced in advance to 10 −2 Torr or less. The wafer 32 transferred into the reaction furnace 31 is disposed on the susceptor 36 . In this step, the reaction vessel 33 is positioned away from the susceptor 36 , and the temperature within the reaction furnace 31 is set at 300° C. or less. Also, the pump 40 is driven, and the valve 43 is opened so as to reduce in advance the inner pressure of the reaction furnace 31 to 10 −2 Torr or less, as described above.
Then, the gate valve 38 is closed, and the valve 35 is opened to introduce an oxygen gas into the reaction furnace 31 . In this step, the discharge power is controlled by the conductance valve 42 on the basis of the indication of the pressure gauge 44 so as to control the pressure within the reaction furnace 31 at 10 Torr.
Further, the reaction vessel 33 is moved to bring the periphery of the reaction vessel 33 into contact with the susceptor 36 so as to form the closed space 51 . Under this condition, a nitrogen gas, which is an inert gas, is introduced into the reaction furnace 31 in place of the oxygen gas. To be more specific, the flow rate of the oxygen gas is lowered by using the mass flow controller 34 and, at the same time, the valve 45 is opened so as to supply a nitrogen gas from the nitrogen gas supply source 53 into the reaction furnace 31 . The pressure within the reaction furnace 31 is maintained at 10 Torr by increasing the flow rate of the nitrogen gas by using the mass flow controller 46 in accordance with decrease in the oxygen gas flow rate. By the particular operation, the oxygen gas in the space within the reaction furnace 31 and outside the reaction chamber 33 is replaced by the nitrogen gas. On the other hand, the closed space 51 remains to be filled with the oxygen gas.
In the next step, the susceptor 36 is heated by the heater 37 to elevate the wafer temperature to about 600° C. In this step, solid materials 47 to 49 consisting of, for example, TiO(THD) 2 , Ba(THD) 2 and Sr(THD) 2 , respectively, which act as raw material gas sources, are arranged within the container 50 . When the wafer 32 is heated, these solid materials 47 to 49 are heated to 300° C. or more by, for example, the heat radiation from the wafer 32 , with the result that a TiO(THD) 2 gas, a Ba(THD) 2 gas and a Sr(THD) 2 gas are generated from these solid materials 47 , 48 and 49 , respectively.
These TiO(THD) 2 gas, Ba(THD) 2 gas and Sr(THD) 2 gas scarcely form a gas stream and are diffused uniformly within the closed space 51 . It follows that a region producing a function equal to that produced by the stagnant layer formed in the conventional method is formed over the entire region of the closed space 51 . The TiO(THD) 2 gas, Ba(THD) 2 gas, Sr(THD) 2 gas and oxygen gas within the closed space 51 are uniformly mixed and, then, decomposed on the wafer 32 so as to deposit BSTO on the wafer 32 .
The wafer 32 was kept heated for one minute, followed by lowering the wafer temperature. At the same time, the reaction vessel 33 was moved away from the susceptor 36 so as to purge the gas within the closed space 51 .
The BSTO thin film thus formed was found to have a uniform thickness of ±2%. In the first embodiment of the present invention, the raw material gas components do not form a gas stream and are diffused uniformly within the closed space 51 , leading to the high uniformity in the thickness of the resultant BSTO thin film. In other words, if the raw material gas stream is non-uniform, the deposition rate is rendered nonuniform, resulting in failure to form a thin film of a uniform thickness.
It should also be noted that, in the first embodiment of the present invention, the raw material gas components are supplied to the stagnant layer at a high efficiency, compared with the conventional method. As a result, such a high film forming rate as about 200 Å/min was obtained in the first embodiment of the present invention.
Also, in the first embodiment of the present invention, all the raw material gas components were utilized for forming a stagnant layer, making it possible to form a BSTO thin film at a low cost, compared with the conventional method.
Also, in the first embodiment of the present invention, the solid materials 47 to 49 providing the sources of the raw material gas components are sublimated within the closed space 51 . In other words, the sublimation is carried out within the stagnant layer, making it unnecessary to heat the pipe, valve, etc. unlike the case where the evaporation is carried out at a position remote from a position where the stagnant layer is formed. Naturally, the valve, etc. are prevented from being deteriorated.
In the embodiment described above, a BSTO thin film was formed under the conditions of 10 Torr and 600° C. However, the BSTO thin film formation can be carried out under the pressure of 1 mTorr to 200 Torr and the temperature of 300° C. to 700° C. Also, the thin film formed by the method of the present invention is not limited to a BSTO film. Specifically, the method described above is applicable to formation of a thin film using a material which is solid in the vicinity of room temperature as a raw material gas source.
Let us describe a second embodiment of the present invention with reference to FIGS. 3A and 3B. A thin film forming apparatus differing from that used in the first embodiment is used in the second embodiment.
As shown in FIG. 3A, the thin film forming apparatus shown in FIG. 3A comprises a reaction chamber 55 . A waiting chamber 56 is positioned adjacent to the reaction chamber 55 with a shutter 57 interposed therebetween. If the shutter 57 is opened, the reaction chamber 55 is allowed to communicate with the waiting chamber 56 , as shown in FIG. 3B. A front chamber 39 is connected to the waiting chamber 56 via a gate valve 38 . In the apparatus shown in FIG. 3A, a substrate 32 such as a semiconductor wafer is transferred from the front chamber 39 into the waiting chamber 56 and, then, into the reaction chamber 55 .
A reaction vessel 33 supported by a shaft 58 is arranged within the waiting chamber 56 . In the second embodiment, the inner diameter of the reaction vessel 33 is smaller than the diameter of the wafer 32 such that a closed space 51 is defined by the reaction vessel 33 and the wafer 32 . Also, the reaction vessel 33 can be moved into the reaction chamber 55 by opening the shutter 57 and moving the shaft 58 upward, as shown in FIG. 3 B.
An oxygen gas supply source 52 is connected to the waiting chamber 56 . A mass flow controller 34 and a valve 35 are mounted to the pipe connecting the oxygen gas supply source 52 to the reaction chamber 31 . Also, a pipe 41 - 1 is connected at one end to the waiting chamber 56 and to a pump 40 - 1 at the other end. Further, a pressure gauge 44 - 1 , a valve 43 - 1 and a conductance valve 42 - 1 are mounted to the pipe 41 - 1 in the order mentioned as viewed from the waiting chamber 56 .
A plurality of containers 50 are mounted within the reaction vessel 33 as holding means for holding the reactant gas generating material. The holding means is not particularly limited as far as the holding means is shaped to hold the reactant gas generating material and to diffuse the generated gas into the reaction vessel 33 . The reactant gas generating material used in this embodiment is not particularly limited as far as the material is solid at room temperature and generates a gas when heated to temperatures higher than a predetermined temperature. Naturally, the reactant gas generating means used in this embodiment may be in the form of a plate.
Each of the containers 50 is mounted to a shaft 61 . It is possible for the shaft 61 to be capable of moving, for example, each of these containers 50 in a vertical direction.
A nitrogen gas supply source 53 is connected to the reaction chamber 55 . A mass flow controller 46 and a valve 45 are mounted to the pipe connecting the nitrogen gas supply source 53 to the reaction chamber 55 . Also, a pipe 41 - 2 is connected at one end to the reaction chamber 55 and to a pump 40 - 2 at the other end. Further, a pressure gauge 44 - 2 , a valve 43 - 2 and a conductance valve 42 - 2 are mounted to the pipe 41 - 2 in the order mentioned as viewed from the reaction chamber 55 . It should be noted that a ceiling plate 60 of the reaction chamber 55 is formed of a material having a relatively high heat conductivity, with the result that the heat generated from a heater 37 can be conducted into the reaction chamber 55 .
Let us describe how to form, for example, a BSTO thin film by the film forming method using the apparatus shown in FIG. 3 A. In the first step, the front chamber 39 housing the semiconductor wafer 32 is evacuated by a pump (not shown) to a vacuum of 10 −2 Torr or less. In this step, the pump 40 - 1 is driven and the valve 43 - 1 is opened so as to maintain the pressure within the waiting chamber 56 at a level equal to the inner pressure of the front chamber 39 . Then, the gate valve 38 is opened so as to transfer the wafer 32 from the front chamber 39 into the waiting chamber 56 . After transfer of the wafer 32 into the waiting chamber 56 , the gate valve 38 is closed while maintaining the wafer 32 at a position remote from the reaction chamber 33 by a mechanism (not shown).
In the next step, the valve 35 is opened so as to introduce an oxygen gas into the waiting chamber 56 . In this step, the pressure within the waiting chamber 56 is adjusted at 10 Torr by operating the conductance valve 42 - 1 based on the indication of the pressure gauge 44 - 1 so as to control the exhausting power. Then, the wafer 32 is disposed on the reaction vessel 33 so as to form the closed chamber 51 . It should be noted that solid materials 47 to 49 of TiO(THD) 2 , Ba(THD) 2 and Sr(THD) 2 are housed in advance in the containers 50 arranged within the reaction vessel 33 .
Then, a nitrogen gas is supplied into the reaction chamber 55 at a flow rate of 1 slm, and the pressure within the reaction chamber 55 is set at 10 Torr by operating the conductance valve 42 - 2 based on the indication of the pressure gauge 44 - 2 so as to control the exhausting power. After the valves 35 and 43 - 1 are closed, the shutter 57 is opened as shown in FIG. 3 B. As a result, a gas in the reaction chamber 55 and the waiting chamber 56 is substituted by a nitrogen gas. It should be noted that the closed space 51 is left filled with an oxygen gas in this step.
In the next step, the reaction vessel 33 is moved upward by the shaft 58 so as to permit the wafer 32 to approach the ceiling plate 60 . The ceiling plate 60 is heated in advance to 900° C. by the heater 37 . Therefore, the wafer 32 is heated by the heat radiation from the ceiling plate 60 . It should also be noted that the solid materials 47 to 49 of TiO(THD) 2 , Ba(THD) 2 and Sr(THD) 2 are also heated in accordance with the temperature elevation of the wafer 32 . As a result, a TiO(THD) 2 gas, a Ba(THD) 2 gas and a Sr(THD) 2 gas are generated from these solid materials 47 to 49 , respectively.
The temperatures of the wafer 32 and the solid materials 47 to 49 are dependent on the distances from the heat source. Naturally, the temperatures of the solid materials 47 to 49 are somewhat lower than the temperature of the wafer 32 . In this embodiment, the distance between the ceiling plate 60 and the wafer 32 is controlled to set the wafer temperature at about 600° C. It should be noted that the solid material 47 generates a raw material gas component at a temperature lower than the temperatures at which the solid materials 48 and 49 generate raw material gas components. The distances of the solid materials 47 to 49 from the ceiling plate 60 are determined in view of the raw material gas generating temperatures noted above. To be more specific, the solid materials 48 and 49 are positioned closer to the heat source than the solid material 47 so as to set the temperature of the solid materials 48 and 49 at about 300° C. On the other hand, the solid material 47 is positioned to set the temperature thereof at about 200° C.
The TiO(THD) 2 gas, the Ba(THD) 2 gas and the Sr(THD) 2 gas thus generated scarcely form a gas stream and is diffused uniformly within the closed space 51 . In other words, a region performing the function equal to that performed by the stagnant layer in the conventional method is formed in the entire region of the closed space 51 .
The TiO(THD) 2 gas, the Ba(THD) 2 gas, the Sr(THD) 2 gas, and the oxygen gas within the closed space are mixed uniformly and, then, decomposed on the wafer 32 so as to deposit a BSTO film on the wafer 32 .
The BSTO deposition was continued for one minute, followed by moving the reaction vessel 33 downward so as to lower the wafer temperature. Then, the shutter 57 was closed, and the wafer 32 was arranged at a position away from the reaction vessel 33 by using a mechanism (not shown). At the same time, the pump 40 - 1 was driven so as to purge the gas within the closed space 51 , followed by taking the wafer 32 out of the apparatus.
The second embodiment described above also produces effects similar to those described previously in conjunction with the first embodiment. What should also be noted is that, in the second embodiment, the concentrations of the raw material gas components within the closed space can be controlled by controlling the distances between the solid materials 47 to 49 and the heater 37 , making it possible to control highly accurately the composition of the BSTO thin film.
Incidentally, the nitrogen gas can be supplied into the closed space 51 through an axial bore formed in the shaft 58 . Also, the film forming conditions can be changed in various fashions as in the first embodiment described previously.
Let us describe a third embodiment of the present invention. Third embodiment is substantially equal to the first embodiment, except that TEOS, which is liquid at room temperature, was used in place of the solid materials 47 to 49 and the wafer 32 was heated to 700° C. in the film forming step. In the third embodiment, a silicon oxide film having a uniformity of ±2% was formed at such a high film forming rate as about 1000 Å/min.
Let us describe a fourth embodiment of the present invention. The fourth embodiment is substantially equal to the second embodiment, except that TEOS, which is liquid at room temperature, was used in place of the solid materials 47 to 49 , and the wafer 32 was heated to 700° C. in the film forming step. In the fourth embodiment, a silicon oxide film having a uniformity of ±2% was formed at such a high film forming rate as about 1000 Å/min. Also, the fourth embodiment was advantageous over the third embodiment in that TEOS was poured easily into the container 50 .
In each of the first to fourth embodiments described above, the film thickness was controlled by controlling the film forming time. However, it is also possible to control the film thickness by controlling the supply amounts of the raw material gas components. Specifically, the amounts of the raw materials such as the oxygen gas, the solid materials 47 to 49 , etc. required for forming a thin film of a desired thickness are calculated in advance. Also, the amounts of the raw materials such as the oxygen gas, the solid materials 47 to 49 , etc. within the closed space 51 are made equal to the calculated amounts so as to permit these raw materials to be consumed completely in a single film formation. Under the particular condition, the film thickness reaches saturation in a certain time, making it possible to form a thin film of a desired thickness without relying on the film forming time.
As described above, a thin film is formed within a closed space in the present invention, and the raw material gas components are diffused uniformly within the closed space without forming a gas stream. It follows that the present invention makes it possible to form a thin film of a uniform thickness. What should also be noted is that the present invention permits supplying the raw material gas components to the stagnant layer at a higher efficiency than in the conventional method, leading to an improved film forming rate. Further, in the present invention, all the raw material gas components are utilized for formation of a stagnant layer. It follows that the present invention makes it possible to form a thin film at a low cost, compared with the conventional method. Still further, the sources of the raw material gas components are evaporated within a closed space in the present invention. To be more specific, the evaporation is carried out within the stagnant layer in the present invention. This makes it unnecessary to heat the pipe, valve, etc. in the present invention, unlike the prior art in which the evaporating position is apart from the forming position of the stagnant layer. Naturally, deterioration of the valve, etc. can be prevented in the present invention.
Additional advantages and modifications will readily occur to those skilled in the art. Therefore, the invention in its broader aspects is not limited to the specific details and representative embodiments shown and described herein. Accordingly, various modifications may be made without departing from the spirit or scope of the general inventive concept as defined by the appended claims and their equivalents. | Disclosed is a method of forming a thin film on a substrate surface by a CVD method, including the steps of arranging a substrate such that one main surface of the substrate is exposed to a closed space, and decomposing by heating a raw material gas filling the closed space so as to form a thin film containing at least one element constituting the raw material gas on the main surface of the substrate, the raw material gas containing a gas component generated by heating a material, which is solid or liquid at room temperature, arranged within the closed space. | 2 |
BACKGROUND OF THE INVENTION
This invention is directed to new and improved antiviral, antitumor immune system enhancing nucleosides and nucleotides.
The immune system is an inherently complex system that serves its host by providing natural resistance and recovery against both pathogens of an external source as well as aberrant "self" cells, i.e. tumor growth. It provides both "natural", i.e. inborn and unchanging, or "acquired", i.e. adaptive immune response.
For the most part the immune system is innocuous to "self." The immune system is able, in most instances, to recognize "self," its host, and differentiate between "self" and non-self. That is the immune system is "self tolerant." In certain instances, however, the immune system does attack its host as if it was foreign resulting in autoimmunity or autoimmune disease or hypersensitivity expressed in the form of allergies, certain forms of kidney disease and the like.
While for the most part an effective and active immune system confers biological advantages for the host, modern medicine has sought in certain instances to repress the immune system because of autoimmunity hypersensitivity in graft or organ transplant and in other instances stimulate the immune system by immunization. It is therefore advantageous in certain intances to attempt to stimulate the immune system against pathogen or tumor attack and other instances to repress the immune system when it becomes self destructive to the host or for organ transplant or the like.
While most molecular entities either synthetic or natural which are known to stimulate the immune system are large molecules such as interferon, poly I:C or large messenger proteins, certain small molecules have also been shown to modulate the immune system as well. Of the small molecular entities the nucleoside 3-deaza-adenosine has been indicated in U.S. Pat. No. 4,309,419 to Walberg, et al., which issued Jan. 5, 1982, as being an inhibitor of the immune response. Other nucleosides, most notably 8-bromoguanosine, 8-mercaptoguanosine and 7-methyl-8-oxoguanosine have been noted as showing stimulation of the immune system.
Certain components of the immune system are cellular in nature while others are humoral, that is they exist free in serum or other body fluids. Adaptive immunity is based upon special properties of lymphocytes. The lymphocyte populations are generally divided between T lymphocytes commonly called T cells and B lymphocytes commonly called B cells. The T lymphocytes undergo a maturation processing in the thymus whereas the B lymphocytes are continuously generated in the bone marrow and are responsible for the production of antibodies. The lymphocytes freely circulate in the blood and from blood gain access to the tissues from which they are collected and recycled back via the lymph systems including the lymph glands and spleen.
Components of the cellular immune mechanisms include macrophages (hereinafter also refered to as MAC's), polymorphonuclear leucocytes commonly called PMN, mast cells and other cellular or molecular entities such as interferon and the like. Further, complements which are a series of proteins present in the serum can be activated by other immune components or directly by pathogens such as bacteria or the like.
Natural killer cells, hereinafter also identified as NK cells, constitute a group of cells which are concerned with natural immunity. These are lymphoid cells which are generally found in at least the young of all mammallian species and can be readily elicited in older animals. They generally exert a selective cytotoxicity against a range of target cells mostly malignant tumor cells.
The B cells produce antibody. Antibodies are a group of proteins of various classes including IgG, IgM, IgA, IgD, IgE. Not all specific antibody classes are present in different animal species. Generally the higher up on the evolutionary chain of animals the more antibody species present with warm blooded mammals generally having a full contingent of the different antibody species. The immune system is capable of modifying certain regions on the antibody proteins allowing the antibody protein to bind with specific antigens of various origins. These include pathogens, parts of pathogens such as cellular wall polysaccharide molecules, large protein or the like, as well as other foreign debris such as pollen and even in autoimmune diseases portions of the host itself. Some antibody production by the B cells is independent of the T cells while other antibody production is T cell dependent.
There are several groups of T cells including helper T cells which stimulate other T cells and B cells for the production of antibody, supressor T cells which modulate the immune response to keep it from overwhelming the host, cytotoxic T cells (CTL's) which are very important against pathogens especially viral pathogens and delayed hypersensitive T cells which are important in attracting and activating a variety of other cells, including the macrophages.
The immune system is important in protecting the host against a variety of pathogens including bacteria, viruses, protozoa, parasitic worms such as flukes, tapeworms and round worms, fungi, and tumor cells of the host which become parasitic on the host. The antiviral activity of the immune system is generally associated with the T cells whereas the natural antitumor ability of the host resides with the macrophages, the natural killer cells, certain non-T and non-B myeloid cells and with certain portions of the complement system.
As is evident, the immune system is a very complex system which is extremely important to the host for protection of the host against outside pathogens as well as against internal aberrant cells. Catastrophic effects to the host can result when pathogens, tumors or the like overwhelm the immune system of the host. It has even been suggested that tumors may have the ability to depress or subvert the hosts immune system. This is supported by the recognition of clinicians that viral and bacteria infections can be a major contributor to the deaths among tumor patients.
In view of the above it is evident that there is a need for new and improved antiviral and antitumor immune enhancing agents.
SUMMARY OF THE INVENTION
The present invention relates to a novel class of nucleosides and nucleotides of the thiazolo[4,5-d]pyrimidine ring system.
In accordance with the invention, disclosed are compounds of the formula: ##STR4## wherein R 1 and R 2 individually are H or C 1 -C 18 acyl and R 3 is H, C 1 -C 18 acyl or ##STR5## or R 1 is H and together R 2 and R 3 are ##STR6## and X is =O or =S: Y is --OH, --SH, --NH 2 or halogen: and Z is H, --NH 2 , --OH or halogen, wherein halogen is Cl or Br: or a pharmaceutically acceptable salt thereof.
These compounds are useful as immune system enhancers and have certain immune system properties including modulation, mitogenicity, augmentation and/or potentiation or they are intermediates for compounds which have these properties. The compounds have been shown to express effects on at least the natural killer, macrophages and lymphocyte cells of the immune system of a host. Because of these properties they are useful as antiviral and antitumor agents or as intermediates for antiviral and antitumor agents. They can be used to treat an affected host by serving as the active ingredients of suitable pharmaceutical compositions.
In accordance with the invention, compounds of the above referenced structure are utilized to treat viral diseases in mammals by administering to the mammal a therapeutically effective amount of the compounds.
Further in accordance with the invention, compounds of the above referenced structure are utilized to treat tumors in mammals by administering to the mammal a therapeutically effective amount of the compounds.
Additionally in accordance with the invention, compounds of the above referenced structure are utilized to stimulate the immune system of a mammalian host by administering to the mammalian host a therapeutically effective amount of the compounds.
Additionally in accordance with the invention, 5-amino-3-β-D-ribofuranosylthiazolo[4,5-d]pyrimidin-2,7(6H)-dione is utilized to enhance natural killer immune cells in a host by administering to the host a therapeutically effective amount of 5-amino-3-β-D-ribofuranosylthiazolo[4,5-d]pyrimidin-2,7(6H)-dione as the active component in a pharmaceutical composition.
Additionally in accordance with the invention, 5-amino-3-β-D-ribofuranosylthiazolo[4,5-d]pyrimidin-2,7(6H)-dione is utilized to enhance macrophage cells in a host by administering to the host a therapeutically effective amount of 5-amino-3-β-D-ribofuranosylthiazolo[4,5-d]pyrimidin-2,7(6H)-dione as the active component in a pharmaceutical composition.
Additionally in accordance with the invention, 5-amino-3-β-D-ribofuranosylthiazolo[4,5-d]pyrimidin-2,7(6H)-dione is utilized to enhance lymphocyte cells in a host by administering to the host a therapeutically effective amount of 5-amino-3-β-D-ribofuranosylthiazolo[4,5-d]pyrimidin-2,7(6H)-dione as the active component in a pharmaceutical composition.
Additionally in accordance with the invention a therapeutical pharmaceutical composition is disclosed which contains as its active ingredient a therapeutically effective amount of 5-amino-3-β-D-ribofuranosylthiazolo[4,5-d]pyrimidin-2,7(6H)-dione.
Additionally in accordance with the invention a prophylactic pharmaceutical composition is disclosed which contains as its active ingredient a prophylatically effective amount of 5-amino-3-β-D-ribofuranosylthiazolo[4,5-d]pyrimidin-2,7(6H)-dione. In addition the prophylatic composition can include a further antiviral agent as a further active ingredient.
Since as antitumor agents the compounds of the invention stimulate various natural immune system responses, the compounds of the invention would be useful against a broad spectrum of tumors including but not necessary limited to carcinomas, sarcomas and leukemias. Included in such a class are mammary, colon, bladder, lung, prostate, stomach and pancreas carcinomas and lymphoblastic and myeloid leukemias.
The method of treating tumors is effective in bringing about regression, palliation, inhibition of growth and remission of tumors.
DETAILED DESCRIPTION OF THE INVENTION
The synthesis of the guanosine analog, 5-amino-3-β-D-ribofuranosylthiazolo[4,5-d]pyrimidine-2,7(6H)-dione, can be effected by the direct glycosylation of the preformed guanine base analog. (Scheme I). Thus, 5-aminothiazolo[4,5-d]pyrimidine-2,7(3H,6H)-dione (4), prepared in five steps from the commercially available diaminopyrimidinone by the method of Baker and Chatfield, J. Chem. Soc. (C), 2478 (1970), was glycosylated by trimethylsilylation using hexamethyldisilazane followed by treatment with 1-0-acetyl-2,3,5-tri-0-benzoyl-D-ribofuranose (5) in the presence of trimethylsilyl trifluoro-methanesulfonate as a catalyst. The major product, 5-amino-3-(2,3,5-tri-0-benzoyl-β-D-ribofuranosyl)thiazolo[4,5-d]pyrimidine-2,7(6H)-dione (6) was isolated.
Treatment of 6 with sodium methoxide in methanol gave the deprotected guanosine analog, 5-amino-3-β-D-ribofuranosylthiazolo[4,5-d]pyrimidine-2,7(6H)-dione (7). When 7 was deaminated with excess nitrous acid the xanthosine analog, 3-β-D-ribofuranosylthiazolo[4,5-d]pyrimidine-2,5,7(4H,6H)-trione (8) was produced. Replacement of the 5-amino group of compound 6 by a hydrogen atom was accomplished by treatment of 6 with t-butyl nitrite in tetrahydrofuran to yield 3-(2,3,5-tri-0-benzoyl-β-D-ribofuranosyl)thiazolo[4,5-d]pyrimidine-2,7(6H)-dione (9). Deprotection of 9 using sodium methoxide in methanol or methanolic ammonia provided the inosine analog, 3-β-D-ribofuranosylthiazolo[4,5-d]-pyrimidine-2,7(6H)-dione (10).
The guanosine analog, 7, was phosphorylated and the 5'-monophosphate (11) was obtained. The 3',5'-cyclic monophosphate derivative, 12, was then prepared from 11.
The preparation of the analogous 8-mercapto compound in the thiazolo[4,5-d]pyrimidine system is depicted in Scheme II starting with 5-amino-2-chlorothiazolo[4,5-d]pyrimidin-7(6H)-one (13). Compound 13 was reacted with NaSH in ethylene glycol at 110° to provide the 2-thioxo heterocycle, 14. Glycosylation of 14 by the same procedure as that used to prepare the 2-oxo compound, 6, (except that some heating was required to ensure that any S-glycoside formed would be converted to the more thermodynamically stable N-glycoside) resulted in the formation of 5-amino-2-thioxo-3-(2,3,5-tri-0-benzoyl-β-D-ribofuranosyl)thiazolo[4,5-d]pyrimidin-7(6H)-one (15). Treatment of 15 with sodium methoxide in methanol yielded the 8-mercapto-guanosine analog, 5-amino-2-thioxo-3-β-D-ribofuranosylthiazolo[4,5-d]pyrimidin-7(6H)-one (16).
Various related derivatives in the guanosine analog series were also prepared. The 6-thioguanosine analog was prepared by two routes starting from 6 (Scheme III). In one approach, 6 was treated with the mild chlorinating agent dimethyl(chloromethylene)ammonium chloride (generated in situ from thionyl chloride and DMF), and provided 5-amino-7-chloro-3-(2,3,5-tri-0-benzoyl-β-D-ribofuranosyl)thiazolo[4,5-d]pyrimidin-2-one (17). Reaction of 17 with thiourea in refluxing ethanol gave the protected thio-guanosine analog, 5-amino-7(6H)-thioxo-3-(2,3,5-tri-0-benzoyl-β-D-ribofuranosyl)thiazolo[4,5-d]pyrimidin-2-one (18). Compound 18 was also prepared directly from 6 by reaction with P 2 S 5 in pyridine. Deprotection of 18 was accomplished either with sodium methoxide in methanol or with methanolic ammonia and the 6-thioguanosine analog, 5-amino-7(6H)-thioxo-3-β-D-ribofuranosylthiazolo[4,5,-d]pyrimidin-2-one (19) was isolated as the crystalline monohydrate. The chloro function at position 7 was also nucleophilically substituted by azide using sodium azide in dry DMF which subsequently ring closed onto N-6 to form the new tricyclic ring compound, 5-amino-7-(2,3,5-tri-0-benzoyl-β-D-ribofuranosyl)tetrazolo[1,5-c]thiazolo[4,5-d]pyrimidin-2-one (20).
In an effort to study the thiazolo[4,5-d]pyrimidine ring system with respect to the order of nucleophilic substitution at the 2,5, and 7 positions and possibly use this information to synthesize the adenosine analog, chlorinatation of the readily available 2-chlorothiazolo[4,5,-d]pyrimidine-5,7(4H,6H)-dione (21) using refluxing POCl 3 and N,N-dimethylaniline (Scheme IV) was effected. The desired 2,5,7-trichloro-thiazolo[4,5,-d]pyrimidine (22) was obtained along with a small amount of 5,7-dichloro-2-(N-methyl-anilino)thiazolo[4,5-d]pyrimidine (23). The trichloro compound, 22, was carefully hydrolyzed in 1N NaOH at 60° C. in order to obtain the mono-oxo derivative, 5,7-dichloro-thiazolo[4,5-d]pyrimidin-2(3H)-one (24), the structure of which was verified by single crystal X-ray analysis. Reaction of 24 with 1,2,3,5-tri-O-acetyl-D-ribofuranose (25) under fusion glycosylation conditions produced 5,7-dichloro-3-(2,3,5-tri-O-acetyl-β-D-ribofuranosyl)thiazolo[4,5-d]pyrimidin-2-one (26). Attempts to use 26 for further modification to obtain the adenosine analog were unsuccessful due to the labile nature of the thiazole ring toward nucleophilic ring-opening.
This was circumvented by the synthesis of the adenosine analog from its preformed heterocycle in the same manner as that used to obtain the guanosine analog. The known 2,7-diaminothiazolo[4,5-d]pyrimidine (27) served as the starting material (Scheme V). Treatment of 27 with nitrous acid under conditions similar to those used to prepare 13 provided 7-amino-2-chlorothiazolo[4,5-d]pyrimidine (28). The structure of compound 28 was verified by single-crystal X-ray analysis.
Treatment of 28 with NaSH in DMF at 0° C. yielded the 2-mercapto derivative, 7-aminothiazolo[4,5-d]pyrimidine-2(3H)-thione (29). The conversion of the 2-thioxo function in 29 to a 2-oxo function was accomplished using cold alkaline hydrogen peroxide to yield 7-aminothiazolo[4,5-d]pyrimidin-2(3H)-one (30). Reaction of 30 with the benzoyl-protected sugar, 5, under the same glycosylation conditions (at room temperature) as used to produce the blocked guanosine analog, 6, resulted in the formation of the unexpected blocked 4-ribofuranosyl isomer, 7-amino-4-(2,3,5-tri-O-benzoyl-β-D-ribofuranosyl)-thiazolo[4,5-d]pyrimidin-2(3H)-one (31), as the only isomer detected and isolated. If, however, the same reaction was carried out at elevated temperature (80° C.), the predominant product obtained was the desired 3-ribofuranosyl isomer, 7-amino-3-(2,3,5-tri-O-benzoyl-β-D-ribofuranosyl)-thiazolo[4,5-d]pyrimidin-2(3H)-one (32). Both isomers, 31 and 32, were deprotected using sodium methoxide in dry methanol to obtain 7-amino-4-β-D-ribofuranosylthiazolo[4,5-d]pyrimidin-2(3H)-one (33) and 7-amino-3-β-D-ribofuranosylthiazolo[4,5-d]pyrimidin-2(3H)-one (34), respectively.
For the compounds of the invention, pharmaceutically acceptable acid addition salts of the basic moiety can be selected from, but not necessarily limited to, the group consisting of hydrochloride, hydrobromide, hydroiodide, citrate, sulfate, substituted sulfate, phosphate, carbonate, bicarbonate and formate. Pharmaceutically acceptable salts of the phosphate moiety can be selected from, but not necessarily limited to, the group consisting of alkali and alkaline earths, e.g. sodium, potassium, calcium, magnesium, lithium: ammonium and substituted ammonium trialkylammonium, dialkylammonium, alkylammonium, e.g. triethylammonium, trimethylammonium, diethylammonium, octylammonium, cetyltrimethylammonium and cetylpyridium.
The hydroxyl groups on the glycon and heterocycle and the amino groups of the heterocycle can be blocked with groups such as, but not necessarily limited to, acyl, isopropylidene and dimethylaminomethylene. The acyl group can be selected from a group consisting of C 1 -C 18 straight chain, brached chain, substituted, unsaturated, saturated or aromatic acid such as, but not necessarily limited to acetic, trifluoroacetic, propionic, n-butyric, isobutyric, valeric, caproic, pelargonic, enanthic, caprylic, lactic, acrylic, propargylic, palmitic, benzoic, phthalic, salicylic, cinnamic and naphthoic acids.
Melting points were taken on a Thomas-Hoover capillary melting point apparatus or on a Haake-Buchler digital melting point apparatus and are uncorrected. Nuclear magnetic resonance ( 1 H NMR) spectra were determined at 300.1 MHz with an IBM NR300AF spectrometer. The chemical shifts are expressed in δ values (parts per million) relative to tetramethylsilane as internal standard. Ultra violet spectra (UV: sh=shoulder) were recorded on a Beckman DU-50 spectrophotometer. Elemental analyses were performed by Robertson Laboratory, Madison, N.J. Evaporations were carried out under reduced pressure with the bath temperature below 40° C. Thin layer chromatography (TLC) was run on silica gel 60 F-254 plates (EM Reagents). E. Merck silica gel (230-400 mesh) was used for flash column chromatography.
EXAMPLE 1
5-amino-3-(2,3,5-tri-O-benzoyl-β-D-ribofuranosyl)thiazolo[4,5-d]pyrimidine-2,7(6H)-dione (6)
A mixture of dry 5-aminothiazolo[4,5-d]pyrimidine-2,7(3H,6H)-dione 4 (5.5 g, 30 mmol), hexamethyldisilazane (HMDS, 100 mL), ammonium sulfate (15 mg) and pyridine (10 mL) was heated under reflux for 4 h with the exclusion of moisture. Excess HMDS was removed by distillation to provide the syrupy bis-silyl derivative. The bis-silyl intermediate was dissolved in dry acetonitrile (300 mL) and 1-O-acetyl-2,3,5-tri-O-benzoyl-D-ribofuranose (5: 15.1 g, 30 mmol) was added followed by trimethylsilyl trifluoromethanesufonate (9.3 mL, 42 mmol). The clear reaction mixture was stirred at ambient temperature for 16 h. The solvent was evaporated to dryness and the residual syrup was dissolved in EtOAc (600 mL). The solution was washed with 5% NaHCO 3 solution (2×150 mL), and the dried (Na 2 SO 4 ) organic layer was evaporated. The residual syrup was triturated with ether to yield 18.1 g (96%). The resulting foam was purified on a silica gel column by Prep LC techniques using CHCl 3 --MeOH (9:1, v/v) as the solvent. Recrystallization of the residue from EtOH gave 5-amino-3-(2,3,5-tri-O-benzoyl-β-D-ribofuranosyl)thiazolo[4,5-d]pyrimidin-2,7(6H)-dione (6) as colorless cyrstals: yield 14.5 g, 77%: mp 248°-250° C.: UV λ max (pH 1) 215 sh nm (ε28000), 219 (28000), 224 sh (27600), 301 (8500): UV λ max (pH 7) 215 sh nm (ε28900), 222 (29500), 301 (10600): UV λ max (pH 11) 218 nm (ε27800), 273 (6900): Anal. Calcd. for C 31 H 2 N 4 O 9 S: C, 59.23: H, 3.85: N, 8.91: S, 5.10. Found: C, 59.26: H, 3.89: N, 8.93: S, 5.23.
EXAMPLE 2
5-Amino-3-β-D-ribofuranosylthiazolo[4,5-d]pyrimidine-2,7(6H)-dione (7)
A solution of 6 (0.75 g, 1 mmol) in methanol (75 mL) was adjusted to pH 9 with NaOCH 3 and stirred at room temperature for 16 h. The reaction mixture was evaporated to dryness and the residue was triturated with ether (2×75 mL). The ether insoluble solid was dissolved in water (15 mL) and acidified with acetic acid whereupon the crude product precipitated. Crystallization of this material from water gave a colorless powder: yield 0.31 g, 78%: mp 238° C. (decomp.): UV λ max (pH 1) 215 nm (ε2280), 245 (6900), 301 (8400): UV λ max (pH 7) 215 nm (ε22100), 245 (6900), 301 (8000): UV λ max (pH 11) 245 nm (ε5700), 291 (6000). NMR (DMSO-d 6 ) δ5.79 (1H, d, J=5.32 Hz, C 1 , H), 6.90 (2H, s, NH 2 ), 11.12 (1H, s, NH), and other sugar protons. Anal. Calcd. for C 10 H 12 N 4 O 6 S.H 2 O: C, 35.92: H, 4.22: N, 16.76: S, 9.59. Found: C, 35.82: H, 4.02: N, 16.92: S, 9.66.
EXAMPLE 3
3-β-D-Ribofuranosylthiazolo[4,5-d]pyrimidine-2,5,7(4H,6H)-trione (8)
To a suspension of 7 (0.76 g, 2.4 mmol) in glacial acetic acid (150 mL) was added dropwise a solution of sodium nitrite (1.5 g, 21.7 mmol) in water (15 mL) with stirring. After 30 min the suspension became clear and stirring was continued at room temperature overnight. The white solid which had separated was filtered, washed with cold water and dried. Recrystallization from hot water gave fine colorless crystals of 8: yield 0.3 g, 40%: mp 250° C. dec.: UV λ max (pH 1) 293 nm (ε5500): UV λ max (pH 7) 212 nm (ε14200), 301 (6100): UV λ max (pH 11) 204 nm (ε21900), 301 (5600). Anal. Calcd. for C 10 H 11 N 3 O 7 S: C, 37.86: H, 3.49: N, 13.24: S, 10.10. Found: C, 37.81: H, 3.42: N, 13.01: S, 10.01.
EXAMPLE 4
3-(2,3,5-Tri-O-benzoyl-β-D-Ribofuranosyl)thiazolo[4,5-d]pyrimidine-2,7(6H)-dione (9)
To a solution of 6 (6.65 g, 10.6 mmol) in dry THF (350 mL) was added ter-butyl nitrite (6.2 mL, 52.3 mmol) and the mixture was stirred at room temperature for 1 h. Additional nitrite reagent (2.0 mL) was added and the mixture was stirred at 50°-60° C. overnight. The mixture was evaporated and the residue was purified by flash column chromatography on silica gel using 8-10% acetone in CH 2 Cl 2 followed by 10-11%. The desired product eluted last to yield 3.45 g (46%) of 9 as a foam: UV λ max (EtOH) 220 nm (ε46600), 259 sh (11000), 271 sh (8400): 1 H NMR (DMSO-d 6 ) δ6.31 (d, J=6.45 Hz, 1H, C 1 , H), 7.38-7.98 (m, 15H, benzoyl aromatics), 8.25 (s, 1H, C 5 H), 13.16 (b, 1H, N 6 H, exchanged with D 2 O), and other sugar protons. Anal. Calcd. for C 31 H 23 N 3 O 9 :
EXAMPLE 5
3-β-D-Ribofuranosylthiazolo[4,5-d]pyrimidine-2,7(6H)-dione (10)
Compound 9 (1.0 g, 1.63 mmol) was combined with methanolic ammonia (saturated at 0° C., 50 mL) and heated at 90° C. for 14 h in a steel bomb. The solvent was evaporated and the residue was treated with hot benzene which was decanted off. The resulting solid was purified by silica gel flash chromatography using chloroform and then CHCl 3 --MeOH (6:1) to yield 280 mg (57%) of 10 after crystallization from water: mp 216°-218° C.: UV λ max (pH 1) 217 nm (ε25300), 259 (9700), 286 (6300): 1 H NMR (DMSO-d 6 ) δ5.85 (d, J=5.1 Hz, 1H, C 1 , H), 8.30 (s, 1H, C 5 H), 13.09 (b, 1H, N 6 H, exchanges with D 2 O), and other sugar protons. Anal. Calcd. for C 10 H 11 N 3 O.sub. 6 S: C, 39.87: H, 3.68: N, 13.95: S, 10.64. 3.61: N, 14.06: S, 10.43.
EXAMPLE 6
5-Amino-3-β-D-Ribofuranosylthiazolo[4,5-d]pyrimidine-2,7(6H)-dione 5'-Monophosphate Ammonium Salt (11)
To a suspension of 7 (2.1 g, 6.6 mmol) in freshly distilled trimethyl phosphate (25 mL) at -20° C. was added POCl 3 (0.64 mL, 6.6 mmol) and then an additional equivalent of POCl 3 after 1 h. The mixture was stirred at -5° C. for another 2 h and then poured into ethyl ether (150 mL, anhydrous) and centrifuged (6000 rpm, 10 min). The ether layer was decanted and ice water (100 mL) was added to the residual oil. The pH of the resulting solution was adjusted to 7.5 with aqueous ammonium bicarbonate and the solution was applied to a DEAE-cellulose column (3.2×35 cm), washed with water and eluted with a gradient (0 to 0.25 M, 2 L reservoirs) of aqueous ammonium bicarbonate. During the water wash, unreacted starting material eluted off (0.5 g). The appropriate fractions were pooled, evaporated and lyophilized several times to yield 1.01 g (48%, based on reacted starting material): mp 190°-194° C. UV λ.sub. max (pH 1,7) 243 nm (ε), 301 (): UV λ max (pH 11) 243 nm (ε), 289 (): 1 H NMR (DMSO-d 6 ) δ5.71 (s, 1H, C 1 , H), 7.15 (b, 5H, NH 2 and NH 4 + , exchanges with D 2 O), 11.25 (b, 1H, N 6 H, exchanges with D 2 O), and other sugar protons. Anal. C 10 H 14 N 5 O 8 SP.1.25H 2 O: C, 28.75: H, 3.98: N, 16.76: S, 7.67: P, 7.41. Found: C, 29.15: H, 3.68: N, 16.39: S, 7.76: P, 7.22.
EXAMPLE 7
5-Amino-3-β-D-Ribofuranosylthiazolo[4,5-d]pyrimidine-2,7(6H)-dione 3',5'-Cyclic Monophosphate Ammonium Salt (12)
Compound 11 (1.02 g, 2.28 mmol) was dissolved in water (10 mL) and pyridine (3 mL) and morpholino-dicyclohexylcarbodiimide (667 mg, 2.28 mmol) was added. The solution was evaporated and co-evaporated to a syrup several times with dry pyridine. After drying overnight over P 2 O 5 under vacuum, the syrup was dissolved in dry pyridine (100 mL) and added dropwise to a refluxing solution of pyridine (300 mL) containing DCC (25 g). The solution was refluxed for an additional 2 h, cooled and allowed to stir overnight. The mixture was evaporated to dryness and the residue was partitioned between water (150 mL) and ethyl ether (150 mL). The aqueous layer was concentrated to about 100 mL and applied, having pH 7.7, to a DEAE-cellulose column (3.2×30 cm) and washed with water followed by elution using a gradient of aqueous ammonium bicarbonate (0 to 0.19 M). The proper fractions were coolected based on UV monitoring, evaporated and lyophilized several times to yield 190 mg (22%) of the title compound: mp 244° C. (dec.): UV λ max (pH 1,7) 243 nm (ε), 300 (): UV λ max (pH 11) 243 nm (ε), 289 (): 1 H NMr (DMSO-d 6 ) δ5.60 (d, J=4.44, 1H, 2'OH, exchanges with D 2 O), 5.72 (s, 1H, C 1 , H), 7.15 (b, 6H, NH 2 and NH 4 , exchanges with D 2 O), 11.40 (b, 1H, N 6 H, exchanges with D 2 O), and other sugar protons. Anal. Calcd. for C 10 H 11 N 4 O 8 SP.NH 3 .1.25H 2 O: C, 28.75: H, 3.98: N, 16. Found: C, 29.15: H, 3.68: N, 16.39: S, 7.76: P, 7.22.
EXAMPLE 8
5-Amino-2-thioxothiazolo[4,5-d]pyrimidin-7(6H)-one (14)
A suspension of 5-amino-2-chlorothiazolo[4,5-d]pyrimidin-7(6H)-one (13: 1.5 g, 7.4 mmol) in ethylene glycol (30 mL) was heated to 110° C. and NaSH x H 2 O (420 mg, 74 mmol) was added. A clear solution was not obtaind, however, until an additional 250 mg were added. The clear solution was stirred at 110° C. for 2 h and then the reaction mixture was cooled to room temperature, poured into ice (300 mL), and the pH adjusted to 2-3 with 10% HCl. The resulting pink gelatinous mixture was boiled for 1 h and the pink solid was collected by filtration through a medium frit-glass filter, washed with water and dried: yield 1.2 g, 81%: an analytical sample was prepared by flash column chromatography using EtOAc--MeOH--H 2 O-acetone (7:1:1:1). mp >300° C.: UV λ max (pH 1) 243 nm (ε13700), 266 (16500), 351 (17200): UV λ max (pH7) 262 nm (ε14800), 345 (12700): UV λ max (pH 11) 250 nm (ε19300), 335 (14300): 1 H NMR (DMSO-d 6 ) δ6.91 (s, 2H, NH 2 ), 11.18 (s, 1H, N 6 H), 13.78 (s, 1H, N 3 H). Anal. Calcd. for C 5 H 4 N 4 OS 2 :
EXAMPLE 9
5-Amino-2-thioxo-3-(2,3,5-tri-O-benzoyl-β-D-ribofuranosyl)thiazolo[4,5-d]pyrimidin-7(6H)-one (15)
Compound 14 (1.0 g, 5 mmol) was glycosylated in the same manner as that used to prepare 6, requiring HMDS (20 mL), benzoyl-blocked sugar (5: 2.52 g, 5 mmol), and TMS-triflate (1.45 mL, 7.5 mmol). At the end of the 16 h reaction period, the reaction mixture was heated at 70° C. for 3 h in order to rearrange any S-glycoside formed to the more stable N-glycoside. After the same workup, 15 (2.1 g crude) was purified by flash column chromatography using hexanes-acetone (1:1) and crystallized from toluene-EtOAc: yield 1.9 g, 59%: mp 230°-233° C. (darkens 195° C.). Anal. Calcd. for C 31 H 24 N 4 O 8 S 2 : C, 57.76: H, 3.75: N, 8.69: S, 9.95. Found: C, 57.98: H, 3.46: N, 8.40: S, 9.66.
EXAMPLE 10
5-Amino-2-thioxo-3-β-D-ribofuranosylthiazolo[4,5-d]pyrimidin-7(6H)-one (16)
To a solution of 15 (1.25 g, 1.94 mmol) in dry methanol (100 mL) was added sodium methoxide powder until the pH reached 10. The solution was stirred overnight and then neutralized with Dowex H + resin and filtered. After evaporation of the filtrate, the residue was washed with ether to remove methyl benzoate and the crude material was crystallized from water: yield 520 mg, 81%: mp 220° C. dec.: UV λ max 1 H NMR (DMSO-d 6 ) δ6.48 (d, J=3.00 Hz, 1H, C 1 , H), 6.99 (s, 2H, NH 2 ), 11.47 (s, 1H, NH), and other sugar protons. Anal. Calcd. for C 10 H 12 N 4 O 5 S 2 .H 2 O: C, z34.28: H, 4.03: N, 15.99: S, 18.30. Found: C, 33.99: H, 3.92: N, 15.68: S, 18.22.
EXAMPLE 11
5-Amino-7-chloro-3-(2,3,5-tri-O-benzoyl-β-D-ribofuranosyl)thiazolo[4,5-d]pyrimidin-2-one (17)
Dry purified 6 (10 g, 16 mmol) was dissolved in dry methylene chloride (350 mL) and a solution of freshly distilled thionyl chloride (40 mL), dry DMF (20 mL), in dry methylene chloride was added dropwise over a 2 h period and the reaction was kept at 60° C. (reflux) for 16 h. The reaction mixture was poured carefully into ice and NaHCO 3 slutio and stirred for 30 min. The layers were separated and the aqueous layer extracted (2×150 mL) with methylene chloride and the combined layers dried over Na 2 SO 4 and evaporated in vacuo. The residual syrup was purified by passing throgh a silica gel column (4×40 cm) and eluting with CHCl 3 -acetone (4:1), to obtain the chloro compound as a white foam, 8.6 g, 84%: mp 88°-90° C.: Anal. Clcd. for C 31 H 23 C 1 N 4 O 8 S: C, 57.54: H, 3.58: Cl, 5.47: N, 8.66: S, 4.96. Found: C, 58.06: H, 3.99: Cl, 5.95: N, 9.41: S, 4.75.
EXAMPLE 12
5-Amino-7(6H)-thioxo-3-(2,3,5-tri-O-benzoyl-β-D-ribofuranosyl)thiazolo[4,5-d]pyrimidin-2-one (18)
Method 1 A mixture of 17 (3.3 g, 5 mmol), thiourea (0.719 g, 1 mmol) and EtOH (100 mL) was heated under reflux for 6 days. The reaction mixture was evaporated, and the residue was extracted with CHCl 3 (200 mL). The solvent was evaporated to dryness in vacuo, and the residue was purified by silica gel column chromatography with CHCl 3 -acetone (7:1) as the eluant. After evaporation the residue was crystallized from EtOH to afford a colorless powder: yield 1.9 g, 58%: mp 227°-229° C.: UV λ max (pH 1) 234 nm (ε26000), 280 sh (9000), 365 (11800): UV λ max (pH 11) 230 nm (ε40500), 267 (8700), 327 (14100): Anal. calcd. for C 31 H 24 N 4 O 8 S 2 : C, 57.75: H, 3,75: N, 8.69: S, 9.95. Found: C, 57.79: H, 3.79: N, 8.69: S, 9.98.
Method 2 To a solution of 6 (1 g, 1.6 mmol) in pyridine (50 mL) was added with stirring P 2 S 5 (1.5 g, 6.2 mmol). The solution was refluxed gently (bath temperature 130-140) for 29 h. The reaction mixture was evaporated to dryness in vacuo. The excess P 2 S 5 was decomposed by the addition of H 2 O (200 mL) at 60° C. The mixture was stirred for 1 h, then left at room temperature overnight. The resulting solid was filtered, dissolved in CHCl 3 , dried (Na 2 SO 4 ) and the solvent removed under vacuum. The residue was purified by silica gel column chromatography with CHCl 3 -acetone 7:1 as the eluant. After concentration the residue was crystallized from EtOH to give 18 (0.43 g, 43%). The physicochemical properties of compound 18 prepared by Method 2 were found to be identical in all respects to those of the compound prepared by Method 1 above.
EXAMPLE 13
5-Amino-7(6H)-thioxo-3-β-D-ribofuranoxylthiazolo[4,5-d]pyrimidin-2-one (19).
Method 1 A solution of 18 (1 g, 1.6 mmol) in methanol (50 mL) was adjusted to pH 9 with NaOCH 3 and stirred at room temperature for 16 h. The reaction mixture was evaporated to dryness and the residue was triturated with ether (2×75 mL). The ether insoluble solid was dissolved in water (15 mL) and acidified with acetic acid whereupon the crude product was precipitated. Recrystallization of this material from EtOH-H 2 O gave colorless prisms: yield 0.47 g, 87%: mp 185°-187° C.: UV λ max (pH 1) 214 nm (ε2700), 230 sh (14000), 263 (6700), 354 (): UV λ max (pH 7) 213 nm (ε25900), 247 (9100), 266 sh (7700), 334 (12100), 353 (11800): UV λ max (pH 11) 247 nm (ε12300), 266 sh (8800), 327 (16100): .sup. 1 H NMR (DMSO-d 6 ) δ5.76 (d, J=5.32 Hz, C 1 , H), 7.22 (s, 2H, NH 2 ), 12.41 (s, 1H, NH), and other sugar protons. Anal. Calcd. for C 10 H 12 N 4 O 5 S 2 .H20: C, 34.28: H, 4.03: N, 15.99: S, 18.30. Found: C, 34.28: H, 3.99: N, 16.24: S, 18.51.
Method 2 A solution of 18 (1.0 g, 1.6 mmol) in methanolic ammonia (saturated at 0° C., 60 mL) was stirred at room temperature for 48 h. The solvent was evaporated to dryness and the residue was triturated with boiling benzene (2×100 mL). The benzene insoluble solid was crystallized from EtOH--H 2 O to give 19 (0.36 g, 67%). The compound prepared by this method was identical to compound 19 prepared by Method 1 above, as judged by spectral and physical data.
EXAMPLE 14
5-Amino-7-(2,3,5-tri-O-benzoyl-β-D-ribofuranosyl)tetrazolo[1,5-c]thiazolo[4,5-d]pyrimidin-2-one (20).
To a solution of 17 (3.0 g, 4.6 mmol) in dry DMF (30 mL) was added sodium azide (0.3 g, 4.6 mmol) and the mixture was stirred at room temperature for 3 days. After evaporation of the solvent, the residue was dissolved in EtOAc (250 mL) and washed with water (2×50 mL), dried over sodium sulfate and evaporated. The resulting foam was purified by silica gel column chromatography using CHCl 3 -acetone 7:1. The product was crystallized from EtOH to give a white powder: yield, 2.0 g, 67%: mp 112°-114° C.: IR showed no azide band in the region of 2100 to 2200 cm -1 ; UV λ max (MeOH). Anal. Calcd. for C 31 H 23 N 7 O 8 S: C, 56.96: H, 3.55: N, 15.00: S, 4.91. Found: C, 57.19: H, 3.88: N, 15.26: S, 4.75.
EXAMPLE 15
2,5,7-Trichlorothiazolo[4,5-d]pyrimidine (22)
A mixture of 2-chlorothiazolo[4,5-d]pyrimidine-5,7(4H,6H)-dione (21, 15.8 g, 78 mmol), POCl 3 (220 ml) and N,N-dimethylaniline (12.3 g, 0.1 mmol) was refluxed for 3 h. The excess POCl 3 was removed under reduced pressure and the residue was poured into ice-water (500 mL) with stirring. The resulting aqueous solution was extracted with CHCl 3 (3×400 mL) and the organic layer was washed with water (2×400 mL), 0.1N NaOH (2×300 mL) and water (2×400 mL) successively and then dried over Na 2 SO 4 . Evaporation of the chloroform produced a residue which was purified by silica gel column chromatography using CHCl 3 to provide the title compound (22) after crystallization from EtOH. Yield 13.8 g, 74%: mp. 121°-122° C.: UV λ max (pH 1, 7, 11) 296 nm (ε10,800). Anal. Calcd. for C 5 Cl 3 N 3 S: C, 24.97: Cl, 44.22: N, 17.48. Found: C, 25.02: Cl, 44.39: N, 17.37.
EXAMPLE 16
5,7-Dichlorothiazolo[4,5-d]pyrimidin-2(3H)-one (24)
A suspension of the trichloro compound (22: 3.0 g, 12 mmol) in 1N NaOH (35 mL) was heated at 60° C. for 1 h. The solution was treated with decolorizing carbon and then acidified with 10% aqueous HCl. The resulting precipitate was collected and reprecipitated from dilute base with glacial acetic acid to provide 24 as orange needles (1.38 g, 50%): mp. 191°-192° C.: UV λ max (pH 1) 254 nm (ε5,300), 290 (11,400): UV λ max (pH 7, 11) 226 nm (ε28,900), 300 (14,100). Anal. Calcd. for C 5 HCl 2 N 3 OS: C, 27.04: H, 0.45: Cl, 31.93: N, 18.93. Found: C, 26.78: H, 0.61: Cl, 32.15: N, 18.66.
Single crystal X-ray analysis of 24 showed the structure assignment to be correct.
EXAMPLE 17
5,7-Dichloro-3-(2,3,5-tri-O-acetyl-β-D-ribofuranosyl)thiazolo[4,5-d]pyrimidin-2-one (26)
A finely powdered mixture of 24 (3.7 g, 16 mmol), 1,2,3,5-tetra-O-acetyl-D-ribofuranose (5.3 g, 16 mmol) and bis(p-nitrophenyl)phosphate (20 mg) was heated at 170° C. for 10 min under reduced pressure. After cooling to room temperature the brown solid mass was dissolved in EtOAc (500 mL) and washed with saturated aqueous sodium bicarbonate (3×300 mL). The dried (Na 2 SO 4 ) organic layer was evaporated to yield a syrup which was purified by silica gel column chromatography (4×40 cm) using toluene-EtOAc (5:1). The resulting syrup was crystallized from ethanol to give a colorless powder: yield 6.4 g, 80%: mp 125°-126° C.: 1 H NMR (DMSO-d 6 ) δ1.99, 2.06, 2.08 (3s, 9H, acetyl), 6.07 (d, J=3.40 Hz, 1H, C 1 ,H), and other sugar protons. Anal. Calcd. for C 16 H 15 Cl 2 N 3 O 8 S: C, 40.01: H, 3.15: Cl, 14.76: N, 8.75: S, 6.68. Found: C, 40.20: H, 3.31: Cl, 14.79: N, 8.61: S, 6.66.
EXAMPLE 18
7-Amino-2-chlorothiazolo[4,5-d]pyrimidine (28)
To a suspension of 2,7-diaminothiazolo[4,5-d]pyrimidine (27: 16.3 g, 97.3 mmol) in water (200 mL) at 55° C. was added enough 1N NaOH (about 100 mL) to dissolve the starting material and sodium nitrite (8.0 g) was then added. This solution was then added dropwise over 30 min. to a solution containing con HCl (400 mL), water (100 mL) and LiCl (60 g) at 30° C. The resulting mixture was warmed to 45° C. for 15 min. and then hot water (1 L, 90°) was added. The reaction mixture was stirred overnight at room temperature, filtered to remove unreacted starting material and the filtrate was neutralized with solid NaOH to pH 4. The resulting solid was filtered off, washed with water and dried to yield 28: 5.38 g, 34%: recrystallization from water gave an analytical sample- mp >234° C. decomp.: UV λ max (pH 1) 228 nm (ε), 296 (): UV λ max (pH 7) 232 nm (ε), 298 (): UV λ max (pH 119 227 nm (ε), 300 (): 1 H NMR (DMSO-d 6 ) δ7.82 (b, 2H, NH 2 , exchanges with D 2 O), 8.41 (s, 1H, C 5 H). Anal. Calcd. for C 5 H 3 N 4 SCl.0.1H 2 O: C, 31.87: H, 1.71: N, 29.74: S, 17.02: Cl, 18.82. Found: C, 31.71: H, 1.50: N, 29.35: S, 16.92: Cl, 19.54.
EXAMPLE 19
7-Aminothiazolo[4,5-d]pyrimidine-2(3H)-thione (29)
A suspension of compound 28 (1.11 g, 5.9 mmol) in dry DMF (10 mL) was cooled in an ice bath to 0° C. and NaSH x H 2 O (0.87 g, 11.8 mmol) was added. The resulting clear solution was stirred overnight at 0° C. and then at room temperature for 2 h. The reaction mixture was poured into ice (300 mL) and the pH adjusted to 3-4 with glacial acetic acid. The solid precipitate was filtered, washed with water and dried to yield 0.96 g (88%). An analytical sample was prepared by crystallization from DMF-water: mp >370° C.: UV λ max (pH 1) 248 nm (ε), 263 (), 345 (): UV λ max (pH 7, 11) 228 nm (ε), 258 (), 329 (): 1 NMR (DMSO-d 6 ) δ7.57 (b, 1H, NH 2 , exchanges with D 2 O), 8.23 (s, 1H, C 5 H), 14.13 (b, 1H, N 3 H, exchanges with D 2 O). Anal. Calcd. for C 5 H 4 N 4 S 2 : C, 32.60: H, 2.19: N, 30.41: S, 34.81. Found: C, 32.97: H, 2.13: N, 30.29: S, 34.59.
EXAMPLE 20
7-Aminothiazolo[4,5-d]pyrimidin-2(3H)-one (30)
To a suspension of 29 (770 mg, 4.2 mmol) in water (30 mL) was added 1N NaOH (4.2 mL) and 30% H 2 O 2 (1.0 mL) and the reaction was stirred for 1 h at room temperature. Additional peroxide (2.0 mL) and hydroxide (5.0 mL) were added and the mixture was stirred for 1 h at 70° C. The reaction mixture was filtered and the filtrate was neutralized with glacial acetic acid. The resulting precipitate was filtered off while still hot, washed with cold water and dried to yield 0.52 g (74%): mp >370 ° C.: UV λ max (pH 1) 267 nm (ε), 289 (): UV λ max (pH 7, 11) 285 nm (ε): 1 H NMR (DMSO-d 6 ) δ7.18 (b, 2H, NH 2 , exchanges with D 2 O), 8.12 (s, 1 H, C 5 H), 12.30 (b, 1H, N 3 H, exchanges with D 2 O). Anal. Calcd. for C 5 H 4 N 4 OS: C, 35.71: H, 2.40: N, 33.31: S, 19.07. Found: C, 35.50: H, 2.36: N, 33.13: S, 18.79.
EXAMPLE 21
7-Amino-4-(2,3,5-tri-O-benzoyl-β-D-ribofuranosyl)thiazolo[4,5-d]pyrimidin-2-one (31)
Compound 30 (460 mg, 2.7 mmol) was glycosylated in the same manner as that used to prepare 6, requiring HMDS (30 mL), benzoyl-blocked sugar (5: 1.5 g, 3.0 mmol), and TMS-triflate (0.76 mL, 3.9 mmol). The reaction mixture was allowed to stir overnight at room temperature and was then worked up as described for 6 to yield 1.6 g (95%) of 31 isolated as a foam: UV λ max MeOH) 230 nm (ε), 310 (): 1 H NMR (DMSO-d 6 9 δ6.45 (d, J=2.73 Hz, 1H, C 1 ,H), 7.4-8.0 (m, 15 H, benzoyl aromatics), 8.59 (s, 1H, C 5 H), and other sugar protons C 31 H 24 N 4 O 8 S: C, 60.78: H, 3.95: N, 9.15: S, 5.23. Found:
EXAMPLE 22
7-Amino-3-(2,3,5-tri-O-benzoyl-β-D-ribofuranosyl)thiazolo[4,5-d]pyrimidin-2-one (32)
Compound 30 (1.22 g, 7.25 mmol) was glycosylated as described for the preparation of 6, requiring HMDS (35 mL), benzoyl-blocked sugar (5: 4.4 g, 8.7 mmol) and TMS-triflate (2.0 mL, 10.3 mmol). After stirring overnight at room temperature, the reaction mixture was refluxed for 2 days and then worked up in the usual manner. The crude mixture was subjected to flash silica gel column chromatography using a gradient of methylene chloride to methylene chloride-acetone 10:1 (v/v) and yielded two products. The first to elute from the column was assumed by 1 H NMR to be a bis-glycoside which amounted to 660 mg. The second and major product off the column was obtained as a foam and assigned as the desired 3-ribosyl isomer by UV and 1 H NMR: yield 1.04 g (24%): UV λ max (EtOH) 232 nm (ε), 283 (): 1H NMR (DMSO-d 6 ) δ6.34 (t, 1H, C 1 ,H), 7.39-7.98 (m, 17H, benzoyl aromatics and NH 2 , 8.19 (s, 1H, C 5 H), and other sugar protons. Anal. Calcd. for C, 60.78: H, 3.95: N, 9.15: S, 5.23. Found: 3.93: N, 8.13: S, 4.85.
EXAMPLE 23
7-Amino-4-β-D-ribofuranosylthiazolo[4,5-d]pyrimidin-2-one (33)
Compound 31 (310 mg, 0.51 mmol) was dissolved in dry methanol (35 mL) and cooled to 5° C. To this solution was added solid sodium methoxide (82 mg, 1.5 mmol) and the solution was stirred at room temperature for 5 h. The mixture was neutralized with Dowex-50 H + resin, filtered and evaporated to dryness. The residue was triturated with ethyl ether and then recrystallized from aqueous ethanol to yield colorless needles: 120 mg, 80%: mp 132°-134° C.: UV λ max (pH 1) 227 nm (ε17230), 301 (15750): UV λ max (pH 7, 11) 233 nm (ε22300), 305 (19100): 1 H NMR (DMSO-d 6 ) δ5.96 (d, J=3.51 Hz, 1H, C 1 ,H), 7.75 (b, 2H, NH 2 ), and other sugar protons. Anal. Calcd. for C 10 H.sub. 12 N 4 O 5 S.O.2H 2 O: C, 35.71: 9.53. Found: C, 35.45: H, 4.88: N, 16.44: S, 9.50.
EXAMPLE 24
7-Amino-3-β-D-ribofuranosylthiazolo[4,5-d]pyrimidin-2-one (34)
Compound 32 (0.76 g, 1.2 mmol) was deblocked in the same manner as described for 31 above using sodium methoxide (200 mg, 3.7 mmol) in dry MeOH (50 mL). The title compound (34) was obtained (0.12, 32%) after crystallization from water: mp 248°-250° C.: UV λ max (pH 1) 222 nm (ε35100), 265 (14300), 290 (11400): UV λ max (pH 7, 11) 215 nm (ε45000), 262 (13200): 1 H NMR (DMSO-d 6 ) δ5.91 (d, J=5.43 Hz, 1H, C 1 ,H), 7.44 (b, 1H, NH 2 ), 8.22 (s, 1H, C 5 H), and other sugar protons. Anal. Calcd. for C 10 H 12 N 4 O 5 S: C, 40.00: H, 4.03: N, 18.66: S, 10.68. Found: C, 39.80: H, 3.99: N, 18.39: S, 10.57. ##STR7##
Natural killer cells have been implicated as providing defense against viral infections and malignant cells. Abnormalities in the natural killer cell's activity may thus result in the development of the diseases. Biological immunomodulators may restore or correct certain deficient immune functions. Recently interleukin-2 has been shown to have immunotherapeutic potential in tumor patients. Interleukin-2 and other known immunopotentiators are generally protein in nature and may cause severe side effects upon their administration. Non toxic low molecular synthetic compounds which are not proteins can be suggested for avoiding the side effects of known protein immuno therapeutic potentiators.
EXAMPLE 25
In Vitro Induced Potentiation of Natural Killer Cell Activity
The non protein nucleoside and nucleotide compounds of the invention have shown increased natural killer cell activity. In this example, natural killer cell activity is demonstrated in mice.
Spleen cells from CBA/CaJ or C57BL/6J mice were cultured with 0.05 mM concentrations of compound 7 for 20 to 44 hours at 37° C. in a 5% CO 2 humidified atmosphere as described in Djeu, J-Y, Heinbaugh, J. A., Holden, H. T., Herberman R. B.: Journal Immunology 122: 175, 1979, and Gonazles, H., Karriger, K., Sharma, B., Vaziri, N.: Federal Procedures 42: 1195, 1983. After incubation the cytotoxicity of the treated and untreated cells was determined against YAC-1 cells. In performing this test both a non-drug control and a control using Poly I:C were run concurrently with compound 7.
TABLE 1______________________________________In Vitro Induced Potentiation of Natural Killer cell Activity.sup.a % Natural Killer Cell CytotoxicityEffector Cells Treatment Time (Hour)From: Treatment With: 0 20 44______________________________________CBA/CAJ None 13 4 0.5 Compound 7 15 34 31 Poly I:C 14.5 18 19CBA/CAJ None 14 8 1 Compound 7 23 62 44 Poly I:C 22 31 9C57BL/6J None 16 1.5 2.5 Compound 7 18 35 34 Poly I:C 18 13 14C57BL/6J None 30 1.6 1.3 Compound 7 18 25 22 Poly I: 22 6 13______________________________________ .sup.a Spleen cells from mice were treated with 0.05 mM concentration of compound 7 in RPMl1640 medium containing 10% FCS, 0.1 mM nonessential amino acids and 5 × 10.sup.-5 M Mercaptoethanol. The effector cells were then tested for their cytotoxic activity against YAC1 target cells i 4 hr .sup.51 Cr release assay.
As is evident from Table 1 incubation for 20 hours with compound 7 augmented natural killer cell cytotoxicity compared 4, 8, 1.5 and 1.6% for untreated control to 34, 62, 35 and 25% respectively. Similar treatment for up to 44 hours also caused a distinct increase in natural killer cell activity. Using Poly I:C as a further control, which is a well known potentiator of natural killer cells, compound 7 demonstrated increased activity compared to Poly I:C. The results of Table 1 demonstrate compound 7 markedly induces a high increase in murine natural killer cell activity.
EXAMPLE 26
In Vitro Augmentation of Human Natural Killer Cell Activity
The natural killer cell activity in human cells was also measured. In conducting these tests peripheral blood mononuculear cells (PBMNC) were isolated on Ficoll-Hypague gradient, washed three times in Hanks and re-suspended in RPMI-1640 containing 10% human AB serum as described in Rosenberg, S. A.: Journal American Medical Association, 256: 3117, 1986 and the above referred to reference to Djeu, et al. Peripheral blood mononuclear cells (PBMNC) from eleven different donors were treated with compound 7 as described in Djeu, et al. as well Sharma, B., Odom, L. F.: Cancer Immunol. Immmunother. 7: 93, 1979, and Sharma, B., Odom, L. F.: Cancer Research 44: 3258, 1984.
The PBMNC cells were incubated with compound 7 at 37° C. for 20 to 68 hours in a 5% CO 2 humid atmosphere and after incubation the cytotoxicity was determined against K562 tumor cells. The results are shown in Tables 2a and 2b.
TABLE 2a______________________________________In Vitro Augmentation of Human Natural Killer Cell Activity.sup.a % Natural Killer Cell CytotoxicityDonor - Compound 7 + Compound 7______________________________________1 26 912 4 293 22 544 24 475 6 166 1 187 2 108 13 229 6 1510 14 2011 11 32______________________________________ .sup.a Peripheral blood mononuclear cells were treated with 0.05-0.4 mM cencentration of compound 7 in RPMl1640 containing 10% human AB serum for 20 to 68 hours. After the treatment, effector cells were tested against E562 target cells in 4 hour .sup.51 Cr release assay as described in Sharma et al. above. The data shown here represent the maximum response.
TABLE 2b______________________________________In Vitro Augmentation of Human Natural Killer Cell Activity.sup.a% Natural Killer Cell CytotoxicityDonor 1 Donor 2Exp. - Compound + Compound - Compound + Compound# 7 7 7 7______________________________________1 25 47 4 292 26 91 15 373 9 36 19 374 23 55 3 265 32 67 4 136 12 30 2 107 16 508 31 40______________________________________ .sup.a a Peripheral blood mononuclear cells were treated with 0.05-0.4 mM cencentration of compound 7 in RPMl1640 containing 10% human AB serum for 20 to 68 hours. After the treatment, effector cells were tested against K562 target cells in 4 hour .sup.51 Cr release assay as previously described above in Sharma et al. The data represent the maximum response.
As evident from Tables 2a and 2b the PBMNC from eleven donors had a mean natural killer cell cytotoxicity activity of 11.7%. The PBMNC from the same donors which was pretreated with compound 7 expressed a 32.2% mean natural killer cell cytotoxicity. While there is some variability between the eleven donors, eight of the donors showed over 100% potentiation in natural killer cell cytotoxicity. In the other four cases compound 7 treatment in vitro produced a marked increase in natural killer cell mediated cytotoxicity.
As is seen in Table 2b compound 7 also consistently mediated potentiation of the natural killer cells. In the first donor eight individual tests were run and an increase in the mediated potentiation was seen in seven of the eight tests. In the second donor the increase was seen in six of six tests. As is evident from Tables 2a and 2b compound 7 significiantly induced higher levels of increase in natural killer cell activity in human cells.
In further reproducibility tests compound 7 was tested for reproducibility in its increase in natural killer cell activity as is shown in Table 2c and further for its reproducability on human natural killer cell activity as is shown in Table 2d.
TABLE 2c______________________________________Reproducibility of Compound 7 InducedIncrease in Natural Killer Cell Activity % Increase in Natural Killer Cell Activity DonorExp. # 1 3______________________________________1 1031 2202 658 1023 413 2014 200 665 149 286 460 1367 91 1028 98 2009 200______________________________________
TABLE 2d______________________________________Effect of Compound 7 on Human Natural Killer Cell Activity % Increase in Induced Natural KillerDonor Cell Activity______________________________________1 10312 5483 2204 885 1236 1417 1678 1509 010 6311 8______________________________________
EXAMPLE 27
In Vivo Potentiation of Natural Killer Cell Activity in Mice
Compound 7 was further studied for potentiation of natural killer cell activity in vivo in mice. CBA/CaJ mice were treated with compound 7 by injecting 1.68 mg per 0.5 ml per mouse of compound 7. After 1, 2, 3 and 4 days of treatment the spleens of the mice were harvested and the cytotoxic activity of the spleen cells was determined against YAC-1 tumor target cells in the above referred to 51 Cr release assay as identified in EXAMPLE 25. The results of these tests are shown in Table 3, 4, 5 and 6.
TABLE 3______________________________________Natural Killer cell Activity in CBA/CaJ Mice.sup.a Days % Natural Killer After CytotoxicityMice Treatment Treat- Effector:TargetCBA/CaJ With: ment 50:1 100:1 150:1______________________________________Group - 1 Saline 1 11 ± 3 18 ± 2 23 ± 0.3Group - 2 Com- 1 53 ± 5 64 ± 5 71 ± 9 pound 7 (1.68 mg)Group - 3 Com- 2 46 ± 9 64 ± 5 65 ± 7 pound 7 (1.68 mg)Group - 4 Com- 3 38 ± 6.6 50 ± 7 63 ± 6 pound 7 (1.68 mg)Group - 5 Com- 4 30 ± 0.1 37 ± 1.5 48 ± 3 pound 7 (1.68 mg)______________________________________ .sup.a Three mice in each group were treated with saline or compound 7 (1.68 mg/mouse) by intraperitoneal route. Spleens were removed, cells wer isolated and then their cytotoxicity was determined against YAC1 target cells. Each value represents mean ±SD cytotoxic activity of three mice
As is evident from table 3 a single injection of compound 7 at 1.68 mg per mouse caused a profound increase in natural killer cell activity. A maximum response of 382% increase was obtained one day after treatment. More than a two fold increase was observed even after 4 days with compound 7.
EXAMPLE 28
Dosage Effects on Natural Killer Cell Activity in Mice
Table 4 shows a dose response treatment with compound 7.
TABLE 4______________________________________Dosage Effects on Natural Killer Cell Activity in Mice.sup.a % Natural Killer CytoxicityMice Treatment Effector:TargetCBA/CaJ With: 50:1 100:1 150:1______________________________________Group - 1 Saline 14 ± 4 20 ± 4 23 ± 3.5Group - 2 Compound 7 38 ± 7 48 ± 9 56 ± 8.5 (0.84 mg)Group - 3 Compound 7 44 ± 8 56 ± 12 61 ± 14 (1.68 mg)Group - 4 Compound 7 48 ± 6.6 62 ± 7 70 ± 5 (2.52 mg)Group - 5 Compound 7 48 ± 4.6 67 ± 10 74 ± 6.4 (3.36 mg)______________________________________ .sup.a Three mice in each group were treated with saline or compound 7 by i.p. route. Spleens were removed, cells were isolated and then their cytotoxicity was determined against YC1 target cells. Each value represen mean ±SD cytotoxic activity of three mice.
As is evident from Table 4 mice were treated with 0.84 mg to 3.36 mg per mouse of compound 7. Although all doses of compound 7 induced a marked increase in natural killer cell activity the maximum augmentation was displayed by mice that received 3.36 mg of compound 7.
EXAMPLE 29
Natural Killer Cell Activity in Old Mice
Twelve week old C57BL/6J mice have been shown (Djeu et al. above) to exhibit little spontaneous natural killer cell activity. Table 5 shows the effect of increase of natural killer cell activity in aging mice (8 Months Old). For this test compound 7 was injected at a dose of 1.67 mg per mouse and 3.34 mg per mouse and after a day the natural killer cell activity of the spleen cells was determined.
TABLE 5______________________________________Natural Killer Cell Activity in Old Mice.sup.a % Natural Killer Cell Cytotoxicity Effector:Mice Treatment TargetC57BL/6J With 50:1 100:1 150:1______________________________________Group - 1 (8 Mo. Old) Saline 4 9 14Group - 2 (8 Mo. Old) Compound 7 14 19 23 (1.67 mg)Group - 3 (8 Mo. Old) Compound 7 17 28 38 (3.34 mg)Group - 4 (8 Wk. Old) Saline 5 7 7Group - 5 (8 Wk. Old) Compound 7 15 20 24 (1.67 mg)Group - 6 (8 Wk. Old) Compound 7 17 27 31 (3.34 mg)______________________________________ .sup.a Three mice in each group were treated with saline or compound 7 by i.p. route. Spleens after treatment were removed, cells were isolated and then their cytotoxicity was determined against YAC1 target cells. Each value represent mean ±SD cytotoxic activity of three mice.
As is evident compound 7 showed an increase in natural killer cell activity ranging from 4% untreated to 17% treated at a 50:1 effector/target ratio. The magnitude of induction of increase was similar to that displayed by compound 7 in 8 week old mice. This low molecular weight nucleoside compound induced increases in natural killer cell activity which is as high as increases mediated by Poly I:C, LPS, Pyran or interferon as has been reported Djeu et al above.
EXAMPLE 30
Natural Killer Cell Activity in Nude/Nude Mice
Compound 7 was also able to potentiate markedly the natural killer cell activity in T cell deficient (nude/nude) mice as is shown in Table 6.
TABLE 6______________________________________Natural Killer Cell Activity in Nude/Nude Mice.sup.a % Natural Killer Cell CytotoxicityMice Treatment Effector: TargetNude-Nude With 50:1 100:1 150:1______________________________________Group-1 Saline 15 ± 5 25 ± 7.7 30 ± 11Group-2 Compound 7 43 ± 12 56 ± 12 61 ± 14 (1.67 mg)Group-3 Compound 7 38 ± 6 56 ± 6 61 ± 12 (3.34 mg)______________________________________ .sup.a Three mice in each group received saline or compound 7 through i.p route, spleens were removed on one day after the treatment, cells were isolated and then their cytotoxicity was determined against YAC1 target cells. Each value represent average ±SD cytotoxic activity of three mice.
As is evident from table 6 compound 7 showed an effective increase of over two fold of both doses tested with respect to a saline control.
EXAMPLE 31
In Vivo Potentiation of Cytotoxic Immune Functions Against Tumor
It has been shown in Bear, H. D. Cancer Research 46: 1805, 1986, that inoculation of tumor cells into mice resulted in tumor growths with concomitant induction of antigen specific T cell mediated immune response. These induced T cells have been shown to inhibit tumor growth in vivo and to cure and/or prolong the life span of tumor bearing mice. Others have further shown that tumor specific T cell mediated immune responses can be potentiated by immunomodulators. This has been shown in the above referred to reference by Bear as well as Herberman, R. B.: Journal Biol. Resp. Modifiers 3: 527, 1984, Cheever, M. A., Greenbert, P. D., Gillis, S., Fefer, A. In: A. Fefer and A. Goldstein (eds.) pp. 127, New York, Raven Press, 1982, and Rosenberg, S. A., Journal Biol. Resp. Modifiers 3: 501, 1984.
TABLE 7______________________________________In Vivo Potentiation of Cytotoxic Lymphocytes ActivityAgainst Mastocytoma (P815) Tumor Cells FollowingInjection of Tumor Cells and Drug.sup.a % Cytotoxicity Inoculation Treated DaysMice With With 3 5 7 9______________________________________DBA/2 P815 Saline 13 4 9 9DBA/2 P815 Compound 7 30 24 32 27DBA/2 P815 Recombinant 25 21 25 20 Interleukin-2______________________________________ .sup.a Ten mice in each group were inoculated with 2 × 10.sup.6 tumor cells. After 5 hours, saline or nucleoside compound 7 solution (2 mg/mouse) was administered to each mouse. On days 3,5,7 or 9, spleen cell were isolated and their cytotoxicity was determined against P815 tumor cells as described in Gonzales and Sharma.
Compound 7 was tested to determine whether or not it can increase cytotoxic lymphocytes response against mastocytoma tumor cells. In the test mice were immunized with mastocytoma cells (P815) and after 5 hours compound 7 as a solution was given in a dose of 2 ml per mouse. Further, recombinant interleukin-2 was utilized as a control given at 50 U per mouse. The ability of spleen cells to kill tumor cells was determined following a single injection of either compound 7 or recombinant interleukin-2.
As Table 7 shows cells from mice treated with compound 7 expressed statistically significant higher cytotoxicity in the control group p<0.05). Similarly recombinant interleuken-2 treated mice showed higher cytotoxicity activity as compared to the control group p<0.05). The activity of compound 7 and recombinant interleuken-2 was essentially the same showing that compound 7 can potentiate cytotoxic immune responses against tumor cells in vivo.
EXAMPLE 32
In Vitro Potentiation of IgM Production In Human Peripheral Blood Mononuclear Cells (PBMNC)
In this example B cell potentiation is measured by measuring increases of IgM production against Staphylococcus Aureus Cowan (SAC). PBMNC cells were cultured with SAC in the absence and in the presence of compound 7. After 7 and 10 days of incubation supernatants were harvested and assessed for the presence of Igm by ELISA as described in Engvall, E.: Methods of Enzymology 70: 419, 1980.
TABLE 8______________________________________Effect on IgM Production By Human Peripheral BloodMononuclear Cells In Vitro IgM (μg/ml) DayExp. # Culture 7 10______________________________________1 PBMNC alone 40 372 ± 38 PBMNC + SAC 1400 ± 282 2500 ± 250 PBMNC + SAC + 7875 ± 883 13400 ± 2545 Compound 7 (0.4 mM) PBMNC + Compound 7 1500 ± 424 2550 ± 353 (0.4 mM)2 B Cells Alone 38 B Cells + SAC 1800 B Cells + SAC + 8350 ± 212 Compound 7 B Cells + Compound 7 1225 ± 1763 PBMNC alone 50 PBMNC + Compound 7 1710 ± 127 (0.2 mM) PBMNC + PWM 560 ± 84 PBMNC + SAC 612 ± 53______________________________________ .sup.a PBMNC or enriched B cells from normal donors were cultured alone o with Staphylococcus Aureus Cowan (SAC) in the absence and presence of compound 7. After incubation, supernatants were harvested and checked for IgM by ELISA.
As is evident from Table 8 SAC activated PBMNC to produce IgM in both 7 and 10 day cultures. The SAC activated PBMNC cultures which included compound 7, however, displayed a significantly greater level of IgM over a two fold increase than the cultures without compound 7. Similar increases in IgM production was also observed when enriched B cells were activated with SAC in the presence of compound 7. Compound 7 was able to induce up to 34 fold increases in IgM production. This increase is much higher than the increases induced by the known mitogen"pokeweed." The results suggests that compound 7 mediates the potentiation of SAC induced IgM in vitro human culture systems.
EXAMPLE 33
In Vitro Enhancement of Primary Anti-sheep Red Blood Cell Antibody Response
Compound 7 was tested to determine its effects on primary antibody response against sheep red blood cells in vivo. Mice (C57BL/6) in groups of 4 were injected intraperitoneally with 0.1% sheep red blood cell suspended in saline. At various times compound 7 in various concentrations was administered intraperitoneally. The results of this test are shown in Table 9.
TABLE 9______________________________________Effect on Primary Anti-SheepRed Blood Cells Antibody Response.sup.aMice Compound 7(C57BL/6) SRBC (mg) PFC/10.sup.6 Spleen Cells______________________________________I Group-1 + -- 103 ± 33 Group-2 + 2.97 307 ± 156 Group-3 + 4.97 371 ± 56II Group-1 + -- 81 ± 29 Group-2 + 2.97 165 ± 28 Group-3 + 4.95 467 ± 170 Group-4 + 4.95 433 ± 172III Group-1 + -- 44 ± 18 Group-2 + 1.9 143 ± 140 Group-3 + 3.3 176 ± 105______________________________________ .sup.a Groups of four C57BL/6 mice were injected i.p. with 6.5 × 10.sup.6 SRBC and various doses of compound 7. The number of PFC to SRBC (shown as mean ± SD) were determined on day 6 as described in Cheever.
For Table 9 the number of antibody cells was determined by the modified Jerne, Nordin plaque assay as disclosed in Jerne, N. K., Nordin, A. A., Science 140:405, 1963. The results seen in the Table 9 shows that compound 7 induced a marked increase in the number of antibody forming cells.
Compounds of the invention have alo been tested for antiviral activity. Tests have been conducted for both the therapeutic and prophylactic effect of the compounds against a variety of both RNA and DNA viruses.
EXAMPLE 34
Antiviral Activity Against Herpes Simplex Virus Types 1 and 2
In this test Compound 7 was tested against both Herpes Simplex Type 1 Virus and Herpes Simplex Type 2 Virus. The tests were conducted as prophylactic treatments in vivo utilizing the mouse as a model. In each of these tests a placebo was utilized for control purposes. The survival time reflects survival time of those animals which succomed during the test.
TABLE 10______________________________________Antiviral Activity AgainstEffects of Herpes Simplex Virus Type 1 Infection Dose.sup.a Survivors/ Mean SurvivalCompound (mg/kg/day) Total (%) Time (days)______________________________________Placebo.sup.b -- 1/12 (0) 12.5 ± 3.0Compound 7 200 6/12 (50).sup.c 11.0 ± 1.7Compound 7 100 4/12 (25) 11.4 ± 1.8Compound 7 50 8/12 (75).sup.c 14.8 ± 5.0______________________________________ .sup.a Treatments were once a day at -48, -24, and -2 hours relative to virus inoculation. .sup.b A 2% sodium bicarbonate solution was used as the placebo and as diluent for Compound 7. .sup.c Statistically significant (.025) difference between the drugtreate and placebo control mice, determined by the twotailed Fisher exact test.
As is shown in Table 10 prophylactic treatment of a Herpes type 1 infection in mice was effectively treated with compound 7. There was some variability in the response with the response at 100 mg per kg dose being less effective than both the lower and higher dosages.
TABLE 11______________________________________Antiviral Activity AgainstHerpes Simplex Virus Type 2 Infection Dose.sup.a Survivors/ Mean SurvivalCompound (mg/kg/day) Total (%) Time (days)______________________________________Placebo.sup.b -- 0/12 (8) 9.8 ± 1.0Compound 7 200 2/12 (17) 7.2 ± 3.9.sup.cCompound 7 100 6/12 (50) 11.2 ± 1.5.sup.dCompound 7 50 6/12 (50) 11.8 ± 2.3.sup.d______________________________________ .sup.a Treatments were once a day at -48, -24 and -2 hours relative to virus inoculation. .sup.b A 2% sodium bicarbonate solution was used as the placebo and as diluent for Compound 7. .sup.c Statistically significant (p < .05) difference between the drugtreated and placebo control mice, determined by the twotailed ttest. Three mice died on days 1 and 2 postvirus inoculation from drug toxicity. The rest of the mice died at 9.6 ± 0.8 days which was about the same a the virus control. .sup.d Statistically significant (p < .05) difference between the drugtreated and placebo control mice, determined by the twotailed ttest.
As is shown in Table 11 prophylactic treatment of a Herpes type 2 infection was effective at all levels tested. At 50 and 100 mg per kg this statisticaly significance in mean survival time was just outside of the range of a statistical significance of p<0.1 by the two-tailed Fisher exact test. At 200 mg per kg in the mouse the dose was partially toxic.
EXAMPLE 35
Antiviral Activity Against Influenza B Virus Infection in Mice
Compound 7 was tested therapeutically against Influenza B Virus Infection in Mice. In addition to a saline control Ribavirin, a known antiviral, was utilized for test purposes. The results of this test is shown in Table 12.
TABLE 12______________________________________Antiviral Activity AgainstInfluenza B Virus Infection in Mice Dose Treat- (mg/ ment Survivors/ Mean SurvivalCompound kg/day) Schedule Total (%) Time (days)______________________________________Saline -- a 0/12 (0) 8.7 ± 2.7Ribavirin 100 a 10/12 (83).sup.c 8.0 ± 0.0Compound 7 100 b 2/12 (17) 6.6 ± 1.1 50 b 2/12 (17) 6.4 ± 1.5______________________________________ .sup.a Halfdaily doses were administered twice a day for 7 days starting hours previrus inoculation. .sup.b Treated once a day at -2 hours and on days 2, 4, and 6 relative to virus inoculation. .sup.c p < .001 twotailed ttest.
As is shown in Table 12 against influenza B in the mouse compound 7 as an efficacy between saline, having no antiviral activity against influenza, and Ribavirin, which has significant antiviral activity against influence.
EXAMPLE 36
Antiviral Activity Against San Angelo Virus Infection in Mice
In this example the antiviral activity against a San Angelo virus, an encephalitis type virus, was measured utilizing both a therapeutical and a prophylatic protocol. The results of this test are given i Table 13. As with the prior example Ribavirin was utilized as a positive antiviral control and saline as a negative. The results of this test is given in table 13.
TABLE 13______________________________________Antiviral Activity AgainstSan Angelo Virus Infection in Mice Dose Treat- (mg/ ment Survivors/ Mean SurvivalCompound kg/day) Schedule Total (%) Time (21 days)______________________________________Saline -- a 2/12 (17) 7.5 ± 1.2Ribavirin 200 a 11/12 (92).sup.e 12.3 ± 2.9Compound 200 b 12/12 (100).sup.e >21 100 c 12/12 (100).sup.e >21 50 c 12/12 (100).sup.e >13.0 ± 0.0Compound 200 d 12/12 (100).sup.e >217______________________________________ .sup.a Halfdaily doses were administered twice a day for 7 days starting hours previrus inoculation. .sup.b Treated once a day at -2 hours and on days 2, 4, and 6 relative to virus inoculation. Half daily doses were administered twice a day. .sup.c Treated once a day at -2 hours and on days 2, 4, and 6 relative to virus inoculation. .sup.d Halfdaily doses were administered at 24 and 16 hours previrus inoculation. .sup.e p < .02 twotailed Fisher exact.
As is evident from Table 13 in both a therapeutic and a prophylactic mode compound 7 showed antiviral activity equal to that of Ribavirin against San Angelo encephalitis virus.
EXAMPLE 37
Antiviral Activity Against Mouse Cytomegalovirus Infection in Mice
In this test compound 7 was also tested for both therapeutic or prophylactic efficacy against a mouse cytomegalovirus infection. The results of these tests are shown in Table 14 and 15.
TABLE 14__________________________________________________________________________Antiviral Activity Against Mouse Cytomegalovirus Infectionin Mice Dose Treatment Survivors/ Mean SurvivalCompound (mg/kg/day) Schedule Total (%) Time (days)__________________________________________________________________________Saline -- a 4/12 (33) 6.1 ± 0.4Compound 7 200 a 12/12 (100).sup.c >21 100 b 7/12 (58) 7.0 ± 1.4 50 b 6/12 (50) 6.5 ± 0.8__________________________________________________________________________ .sup.a Halfdaily doses were administered at 24 and 16 hours previrus inoculation .sup.b Single dose was administered 24 hours previrus inoculation .sup.c p < .005 twotailed Fisher exact test
TABLE 15__________________________________________________________________________Antiviral Activity Against Mouse Cytomegalovirus Infection in Mice Dose Treatment Survivors/ Mean SurvivalCompound (mg/kg/day) Schedule Total (%) Time (days)__________________________________________________________________________Saline -- a 3/12 (25) 6.1 ± 0.9Compound 7 100 b 0/12 (0) 6.0 ± 0.8 50 b 0/12 (0) 6.3 ± 1.1__________________________________________________________________________ a Treatments were once a day for 6 days starting 2 hours previrus inoculation b Treatments were once a day at 2 hours and on days 2, 4, and 6 relative to virus inoculation
As is evident at the 200 mg per kg dose compound 7 exhibited a 100% cure when tested in a prophylactic mode. However, as is seen in Table 15 this activity was not repeated in a therapeutic mode.
EXAMPLE 38
Antiviral Activity Against Semliki Forest Virus Infection in Mice
Antiviral activity was also tested against Semliki Forest Virus an Encephalitis type virus. In this example compound 7 was also tested for both therapeutic and prophylactic efficacy. Results of this test are shown in Table 16 for the therapeutic mode and in Table 17 for the prophylactic mode.
TABLE 16__________________________________________________________________________Antiviral Activity AgainstSemliki Forest Virus Infection in Mice Dose Treatment Survivors/ Mean SurvivalCompound (mg/kg/day) Schedule Total (%) Time (days)__________________________________________________________________________Saline -- a 0/12 (0) 6.7 ± 1.9Compound 7 200 b 7/12 (58).sup.e 4.2 ± 0.8 100 c 8/12 (67).sup.e 7.3 ± 0.5 50 c 4/12 (33) 6.6 ± 0.8__________________________________________________________________________ a Halfdaily doses were administered twice a day for 7 days starting 2 hours previrus inoculation b Treated at 2 hours and on days 2, 4, and 6 relative to virus inoculation. Halfdaily doses were administered twice a day because of insolubility c Treated once a day at 2 hours and on days 2, 4, and 6 relative to viru inoculation d Halfdaily doses were administered at 24 and 16 hours previrus inoculation .sup.e p < .01 twotailed Fisher
TABLE 17__________________________________________________________________________Prophylactic Antiviral Activity AgainstSemliki Forest Virus Infection in Mice Dose Treatment Survivors/ Mean SurvivalCompound (mg/kg/day) Schedule Total (%) Time (days)__________________________________________________________________________Saline -- d 1/8 (12) 10.4 ± 1.3Compound 7 200 d 4/8 (50) 11.8 ± 2.9__________________________________________________________________________ a Halfdaily doses were administered twice a day for 7 days starting 2 hours previrus inoculation b Treated at 2 hours and on days 2, 4, and 6 relative to virus inoculation. Halfdaily doses were administered twice a day because of insolubility c Treated once a day at 2 hours and on days 2, 4, and 6 relative to viru inoculation d Halfdaily doses were administered at 24 and 16 hours previrus inoculation .sup.e p < .01 twotailed Fisher
As is evident from Tables 16 and 17 compound 7 exhibited antiviral activity in both a therapeutic mode and a prophylactic mode against this virus.
As is evident from the above tables antiviral activity against a variety of viruses is seen. In a further test little or no antiviral activity for compound 7 was demonstrated against influenza B virus and Friend Leukemia virus induced spleenmegleoma.
EXAMPLE 39
Antiviral Activity of Nucleosides and Nucleotides on Murine Natural Killer Cell Activity In Vitro
Other compounds of the invention were tested with respect to their natural killer cell activity utilizing mouse spleen cells as per example 25 above. The results of these tests are tabulated in Table 18.
TABLE 18______________________________________Effect of Guanosine Nucleosides andNucleotides on Murine Natural Killer Cell Activity In Vitro.sup.a Effector Cells Concentration % Natural Killer CellExp # Pretreated with: (mM) Cytotoxicity______________________________________1 None -- 1.2 Compound 7 0.05 34.5 Compound 16 0.05 10 Compound 16 0.5 38 Compound 9 0.05 3 Compound 9 0.5 132 None -- 1.6 Compound 7 0.05 25 Compound 7 0.25 28 Compound 16 0.05 3 Compound 16 0.25 17 Compound 9 0.05 23 None -- 1.6 Compound 7 0.05 28 Compound 16 0.05 14 Compound 16 0.25 24 Compound 9 0.05 0.31 Compound 9 0.5 6.5______________________________________ .sup.a Spleen cells from mice were incubated in the absence and presence of various compounds. After incubation, cells were suspended in complete medium and then their cytotoxic activity was determined against YAC1 target cells as described in the text
EXAMPLE 40
Effect of Nucleosides and Nucleotides on Human Natural Killer Cell Activity In Vitro
Other Nucleosides and Nucleotides of the invention were tested for their activity in human natural killer cells in vivo as per example 26 above. The results are tabulated in Table 19.
TABLE 19______________________________________Effect of Guanosine Nucleosides andNucleotides on Human Natural Killer Cell Activity In Vitro Effector Cells Concentration % Natural Killer CellExp # Pretreated with: (mM) Cytotoxicity______________________________________1 None -- 26 Compound 7 0.4 91 Compound 16 0.4 69 Compound 12 0.4 39 Compound 11 0.4 632 None -- 23 Compound 12 0.2 433 None -- 17 Compound 12 0.4 224 None -- 9 Compound 11 0.4 195 None -- 3 Compound 7 0.4 37 Compound 16 0.4 10 Compound 9 0.05 66 None -- 16.53 Compound 7 0.4 50 None -- 40 Compound 9 0.2 437 None -- 4.5 Compound 7 0.2 10 Compound 8 0.2 5 Compound 19 0.2 7______________________________________
EXAMPLE 41
Tumoricidal Activity of Macrophages In Mice
The activity of compound 7 with respect to its ability to activate macrophages was tested by injecting CBA/CaJ mice with a single dose of compound 7 (2 mg per mouse) and after 24 hours the cytotoxcity of the spleen cells (SC), non adherent SC and adherent SC was determined. The results are shown in Table 20.
TABLE 20______________________________________Activation of Macrophages followingSingle Injection of Compound 7 in Mice.sup.aEffector Dose (mg) of % Cytotoxicity AssayCells Compound 7/mouse 4 hrs. 20 hrs.______________________________________Spleen Cells (SC) None 15 41Nonadherent (SC) 2 45 70Adherent cells 2 37 69______________________________________ .sup.a A group of four mice (CBA/CaJ) were injected with 2 mg/mouse of compound 7 solution. Control group received saline. After 24 hours of injection, spleens were harvested. Adherent and nonadherent cells were separated by incubation of spleen cells on plastic plates for one hour. Cell suspension of spleen cells, nonadherent cells (NC) and adherent cell (AC) were prepared in complete medium. Cytotoxicity of SC, NC and AC was then measured against YAC1 tumor target cells in 4 hrs and 20 hrs chromiu release assay.
As is evident from Table 20 compound 7 was able to activate both natural killer and adherent (macrophage) cells as evidenced by the ability of these cells to exert augmented cytotoxicity against tumor target cells.
In examples 42 and 43 the combination activity of compounds of the invention with the known antiviral agent Ribavirin against San Angelo Virus and Banzi Virus were measured utilizing compound 7 in a prophylatic protocol. The RibavirIn served as a further antiviral agent for use in combination with the compounds of the invention.
EXAMPLE 42
Combination Chemotherapy Against San Angelo Virus In Mice
The combination chemotherapy results against San Angelo Virus in Mice are shown in Table 21.
TABLE 21______________________________________Combination Chemotherapy Against San Angelo VirusTreatment.sup.a Survivors/ Mean Survival-24 Hrs Days 0-6 Total (%) Time.sup.b (Days)______________________________________Saline Saline 1/16 (6) 8.3 ± 1.8.sup.cCompound 7 (5).sup.d Saline 7/16 (44).sup.e 9.6 ± 1.6Saline Ribavirin (50) 6/16 (38) 9.0 ± 1.2Saline Ribavirin (25) 9/16 (56).sup.e 8.1 ± 0.7Compound 7 (5) Ribavirin (50) 8/16 (50).sup.e 8.9 ± 2.2Compound 7 (5) Ribavirin (25) 6/16 (38) 10.1 ± 3.6______________________________________ .sup.a A single injection of saline or compound 7 was given 24 hours before virus inoculation. Treatments on days 0-6 were twice a day for 7 days starting 2 hours previrus inoculation. .sup.b Of mice that died. .sup.c Standard Deviation. .sup.d The dose in mg/kg/day is in parentheses. .sup.e Statisically significant (p < .05), determined by the twotailed Fisher exact test.
EXAMPLE 43
Combination Chemotherapy Against Banzi Virus Infection In Mice
The combination chemotherapy results against Banzi Virus infection in mice are shown in Table 22.
TABLE 22______________________________________Combination Chemotherapy Against Banzi Virus InfectionTreatment.sup.a Treatment.sup.b Survivors/ Mean Survival-24 hours days 0-6 Total (%) Time.sup.c (days)______________________________________Placebo.sup.d Saline 0/12 (0) 7.7 ± 0.5Placebo Ribavirin 0/12 (0) 8.5 ± 1.0.sup.e 100 mg/kgPlacebo Ribavirin 0/12 (0) 9.1 ± 0.8.sup.e 200 mg/kgCompound 7 Saline 0/12 (0) 9.3 ± 1.0.sup.e100 mg/kgCompound 7 Ribavirin 0/12 (0) 10.2 ± 0.9.sup.e100 mg/kg 100 mg/kgCompound 7 Ribavirin 3/12 (25) 12.4 ± 3.5.sup.e______________________________________ .sup.a Single injection given 24 hours before virus inoculation. .sup.b Halfdaily doses given twice a day for 7 days starting 2 hours previrus inoculation. .sup.c Of mice that died. Survivors lived 21 days. .sup.d A 2% sodium bicarbonate solution was the placebo and diluent for compound 7. Ribavirin was dissolved in saline. .sup.e Statistically significant (p < .05), determined by a twotailed ttest.
As is evident from Tables 21 and 22, compound 7 in a prophylactic mode in combination with the known antiviral Ribavirin, exhibited efficacy against the test viruses.
The compounds of the invention can be given to a warm blooded host in need thereof in appropriate formulations wherein the compounds comprise the active ingredient of the formulations. Thus the compounds of the invention can be made up into injectables suitable for intravenous or other type injection into the host animal. Further they can be given in an appropriate oral formulation as for instance as an oral syrup preparation, an oral capsule or oral tablet. An additional route of administration might be as a suppository.
For an injectable the compounds would be dissolved in a suitable solution as for instance in a sodium bicarbonate or other buffer. Such a solution would be filtered and added to appropriate ampules or vials and sealed and sterilized.
As a syrup, the compounds in buffered solution would be mixed with an appropriate syrup with mild stirring. For capsules the dry compounds would be blended with appropriate fillers, binders or the like as for instance Lactose USP powder or Sterotex powder. For the preparation of tablets the compounds of the invention would be mixed with suitable binders and fillers as for instance corn starch NF, Microcrystalline Cellulose, Sterotex powder and water and dried to a low water content. This would be followed by screening, milling, further screening and pressing into the appropriate tablets.
For suppositories, the compounds would be dissolved into appropriate melts of Polyethylene Glycol as for instance Polyethylene Glycol 1540 and 8000 at 60° and formed into the suppositories by molding at 25°.
In addition to the above formulations, the compounds of the invention could also be administered utilizing other delivery technic such as incorporating the compounds of the invention with liposomes and the like.
Additionally, prodrug forms of the compounds of the invention could be utilized to facilitate dispensing, uptake, absorption, metabolic control and the like. One such prodrug would be the tri-acetate ester of compound 7. Further prodrugs might allow for enzymatic conversion in vivo of analogs of the compounds of the invention into compounds of the invention.
For the purpose of brevity in certain chemical figures and schemes of this specification and the claims attached hereto, different tautomeric forms of the heterocycles of certain compounds have been shown between the vaarious figures and schemes. It is understood that regardless of whether or not substituents are shown in their enol or their keto form, they represent the same compound. Thus, in the claims, the abstract and the brief description in order to utilize only a single structural figure, oxygen and sulfur substituents in the 5 and 7 ring positions are shown in an enolate form whereas in the various schemes these substituents are shown in their normal keto form. | Compounds of the structure: ##STR1## wherein R 1 and R 2 individually are H or C 1 -C 18 acyl and R 3 is H, C 1 -C 18 acyl or ##STR2## or R 1 is H and together R 2 and R 3 are ##STR3## and X is ═O or ═S, Y is --OH, --SH, --NH 2 or halogen, and Z is H, --NH 2 , --OH or halogen, wherein halogen is Cl or Br, or a pharmaceutically acceptable salt thereof are useful as antivirals, antitumors and as immune system enhancers. | 0 |
FIELD OF THE INVENTION
[0001] The present invention relates to semiconductor device manufacturing, and more particularly to a method of fabricating a metal oxide semiconductor field effect transistor (MOSFET) device having a Si channel region that is strained and adjoining source/drain junctions that are unstrained. The method of the present invention provides MOSFET devices having a very high channel carrier mobility, while maintaining a very low leakage junction.
BACKGROUND OF THE INVENTION
[0002] Improvements in transport properties, i.e., carrier mobility, through strain have been demonstrated in the operating characteristics of field effect transistors (FETs). For complementary metal oxide semiconductor (CMOS) devices, an improvement in device characteristics through enhanced carrier mobility has significant potential for the fabrication of very high-speed devices. Strained silicon on a relaxed SiGe substrate is one system where such an improvement occurs, see, for example, D. K. Nayak, et al., “High Mobility p-Channel Metal-Oxide-Semiconductor Field-Effect-Transistor on Strained Si,” Appl. Phys. Lett., 62 (22), p. 2853-2855 (1993).
[0003] Experimental research on enhanced carrier mobility MOSFETs caused by strain has concentrated on a strained Si layer grown on a relaxed SiGe substrate. MOSFET's fabricated using the Si/SiGe system exhibit the following disadvantages: (1) High source and drain junction leakage—the FET source and drain junctions, as well as the channel region, are formed in a strained Si area resulting in high junction leakage. (2) The Si/SiGe system MOSFET process is not compatible with mainstream CMOS fabrication techniques requiring specially prepared substrates using molecular beam epitaxy. (3) The Si/SiGe system MOSFET process is costly with low production rate.
[0004] In view of the drawbacks mentioned above, there is a need for providing a method of forming a MOSFET device in which the device channel is locally strained while the adjoining source/drain junctions are unstrained.
SUMMARY OF THE INVENTION
[0005] The present invention provides a novel method using a damascene-gate process to improve the transport properties of FETs through strained Si. In the inventive method, changes in mobility and FET characteristics are deliberately made in a bulk Si or silicon-on-insulator (SOI) structure through the introduction of local strain in the channel region, without introducing strain in the device source and drain junctions. The present method has the advantage of not straining the source and drain junctions resulting in very low leakage junctions and also it does not require any special substrate preparation like the case of the strained Si/relaxed SiGe system. Moreover, the method of the present invention is compatible with existing mainstream CMOS processing.
[0006] Moreover, the method of the present invention is capable of forming a localized strained Si channel while not requiring that the gate implantation be very shallow. Thus, the inventive method does not have to avoid long anneal cycles. Additionally, in the present method the source/drain implants are not carried out during the gate implantation therefore shallow source/drain junctions having a depth of about 20 nm or less are possible.
[0007] The above-mentioned objects and advantages are achieved in the present invention by forming the gate in a damascene-gate process in a gate opening by depositing amorphous silicon, i.e., a:Si, at a temperature of less than about 600° C., preferably at a temperature between 500° and 600° C. During a subsequent anneal, the a:Si is converted into a polySi gate while introducing the desired localized strain in an underlying Si region without impacting the adjoining source and drain area. Source/drain junction formation occurs after formation of the strained Si channel therefore the junctions can be very shallow.
[0008] Specifically, the method of the present invention comprises the steps of:
providing a structure comprising a dummy gate that has an upper surface that is coplanar with an upper surface of an oxide layer, said dummy gate is located on a sacrificial oxide that is positioned atop a Si-containing substrate; removing the dummy gate to provide a gate opening that exposes a portion of the sacrificial oxide, said gate opening defining a device channel in said Si-containing substrate; removing the exposed portion of the sacrificial oxide in the gate opening; forming a gate dielectric and amorphous Si gate in said gate opening; implanting dopants in said amorphous Si gate and annealing the dopants in said amorphous Si gate to convert said amorphous Si gate into a polySi gate, while introducing localized strain into said device channel; and removing the oxide layer and forming source/drain junctions in portions of the Si-containing substrate that adjoin the localized strained device channel.
[0015] The method above is a damascene method since the gate is formed in a gate opening. The inventive method is compatible with existing mainstream CMOS processes resulting in low cost and high production rate. The method of the present invention allows for n- or p-type devices to be formed atop the localized strain channel. This is unlike the process disclosed in K. Ota, et al., “Novel Locally Strained Channel Technique for High Performance 55 nm CMOS”, December 2002, IEDM conference where PMOS devices cannot be strained due to the lack of “heavy” implant acceptor ions to cause amorphization of the p-type gates.
[0016] The damascene method described above provides a CMOS device that comprises
a Si-containing substrate having a localized strained device channel and adjoining source/drain junctions; a gate dielectric located on said localized strained device channel; and a polySi gate located on said gate dielectric.
[0020] The source/drain junctions may be very shallow since they are formed after polySi gate formation and annealing.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] FIG. 1 is a pictorial representation (through a cross sectional view) illustrating an initial structure that can be used in the present invention.
[0022] FIG. 2 is a pictorial representation (through a cross sectional view) illustrating the structure that is formed after removing the pad oxide from the initial structure shown in FIG. 1 and forming a sacrificial oxide on exposed Si surface.
[0023] FIG. 3 is a pictorial representation (through a cross sectional view) illustrating the structure that is formed after a dummy gate has been formed on a portion of the structure shown in FIG. 2 .
[0024] FIG. 4 is a pictorial representation (through a cross sectional view) illustrating the structure after formation of an insulating spacer on each sidewall of the dummy gate shown in FIG. 3 .
[0025] FIG. 5 is a pictorial representation (through a cross sectional view) illustrating the structure that is formed after oxide deposition and planarization.
[0026] FIG. 6 is a pictorial representation (through a cross sectional view) illustrating the structure having a gate opening after the dummy gate has been removed from the planar structure shown in FIG. 5 .
[0027] FIG. 7 is a pictorial representation (through a cross sectional view) illustrating the structure that is formed after device channel implantation and annealing.
[0028] FIG. 8 is a pictorial representation (through a cross sectional view) illustrating the structure that is formed after the exposed portion of sacrificial oxide in the gate opening has been selectively removed.
[0029] FIG. 9 is a pictorial representation (through a cross sectional view) illustrating the structure that is formed after formation of the gate dielectric, deposition of a:Si on the gate dielectric, implantation and annealing.
[0030] FIG. 10 is a pictorial representation (through a cross sectional view) illustrating the structure after oxide removal and source and drain formation.
[0031] FIG. 11 is a pictorial representation (through a cross sectional view) illustrating the structure that is formed after silicide formation.
DETAILED DESCRIPTION OF THE INVENTION
[0032] The present invention, which provides a method of fabricating local strained channel MOSFETs, will now be described in greater detail by referring to the drawings that accompany the present application. In the accompanying drawings, like and/or corresponding elements are referred to by like reference numerals.
[0033] Reference is first made to FIG. 1 that illustrates an initial structure 10 that can be employed in the present invention. Specifically, the initial structure 10 shown in FIG. 1 comprises a Si-containing semiconductor substrate or wafer 12 having trench isolation regions 16 formed therein and a pad oxide layer 14 located on surface portions of the Si-containing semiconductor substrate 12 .
[0034] The term “Si-containing semiconductor substrate” denotes any semiconductor material that includes at least silicon. Illustrative examples of Si-containing semiconductor materials that can be used as substrate 12 include, but are not limited to: Si, SiGe, SiC, SiGeC, silicon-on-insulators (SOIs), or SiGe-on-insulators (SGOI). The substrate 12 may be undoped or doped depending upon the device to be fabricated thereon. In one preferred embodiment of the present invention, Si-containing semiconductor substrate 12 is a p-type Si substrate.
[0035] When SOI or SGOI substrates are employed, region 12 denotes the top Si-containing layer of the substrate that is isolated from a bottom Si-containing substrate (not shown) by a buried oxide layer (not shown).
[0036] After providing the substrate 12 , the pad oxide layer 14 is formed on an upper exposed surface of the substrate 12 by using a conventional thermal oxidation process. Alternatively, the pad oxide layer 14 may be formed by a deposition process, such as chemical vapor deposition (CVD), plasma-assisted CVD, evaporation, or chemical solution deposition. Pad oxide layer 14 formed at this point of the inventive process is a thin oxide layer that typically has a thickness of from about 6 to about 15 nm.
[0037] Next, trench isolation regions 16 are formed into the substrate 12 by first forming a hardmask (not shown) on the surface of the pad oxide layer 14 and then utilizing lithography and etching. The lithographic step employed in the present invention includes applying a photoresist (not shown) to the hardmask that overlies the pad oxide layer 14 ; exposing the photoresist to a pattern of radiation (in the present case a trench pattern is formed); and developing the pattern into the photoresist by utilizing a conventional resist developer. The etching step, which is used to transfer the trench pattern first into the hardmask and then into the pad oxide layer 14 and the substrate 12 , includes any conventional dry etching process such as reactive-ion etching, ion beam etching, plasma etching, laser ablation or any combination thereof A single etching process may be employed, or alternatively, more than one etching process may be employed to form trenches in the substrate 12 . After the pattern has been transferred into the hardmask, the photoresist is typically removed from the structure and then pattern transfer continues using the hardmask as an etch mask.
[0038] After trenches have been formed in the substrate 12 , the trenches are filled with a trench dielectric material such as high-density plasma (HDP) oxide or TEOS (tetraethylorthosilicate) using conventional deposition processes well known to those skilled in the art. The filled trenches form the trench isolation regions 16 shown in FIG. 1 . In some embodiments of the present invention, the walls of the trenches are lined with a liner material, such as SiO 2 or Si 3 N 4 , prior to filling with the trench fill material. After the filling process, a conventional planarization process and/or densification may be performed on the structure. The planarization process stops on the hardmask and thereafter the hadmask is typically removed by utilizing an etching process that selectively removes the hardmask material from the structure.
[0039] Next, and as illustrated in FIG. 2 , the pad oxide layer 14 is removed from the surface of substrate 12 using a stripping process that is highly selective in removing oxide and thereafter sacrificial oxide layer 18 is formed on the substrate 12 utilizing a conventional thermal oxidation process. Sacrificial oxide layer 18 formed at this point of the inventive process typically has a thickness of from about 3 to about 20 nm, with a thickness of from about 3 to about 6 nm being highly preferred. Note that the sacrificial oxide layer 18 is grown substantially over the substrate 12 , not atop trench isolation region 16 .
[0040] A dummy gate 20 comprising a sacrificial polysilicon region or other related material is then formed on a portion of the sacrificial oxide layer 18 providing the structure shown, for example, in FIG. 3 . The dummy gate 20 is formed by first providing a sacrificial polysilicon layer or other related material atop the sacrificial oxide layer 18 utilizing a conventional deposition process such as CVD or PECVD. The sacrificial polysilicon layer or other related material is then patterned by lithography and etching.
[0041] FIG. 4 shows the structure after an insulating spacer 22 is formed on each sidewall of the dummy gate 20 . Insulating spacers 22 , which comprise a nitride, oxynitride or a combination thereof, are formed by deposition and etching. Insulating spacers 22 may have a variable thickness, but typically insulating spacers 22 , as measured from a bottom surface, have a thickness of from about 10 to about 30 nm.
[0042] It should be noted that the present invention is not limited to forming just a single dummy gate 20 on the surface of the sacrificial oxide layer 18 . Instead, the present invention works equally well when a plurality of dummy gates 20 are formed. The formation of a plurality of dummy gates 20 will allow for the formation of a plurality of MOSFETs across the surface of the substrate 12 .
[0043] After forming the structure shown in FIG. 4 , an oxide layer 24 such as high-density plasma (HDP) oxide or TEOS is deposited and planarized such that an upper surface of the oxide layer 24 is coplanar with an upper surface of dummy gate 20 . The resultant structure including the planarized oxide layer 24 is shown, for example, in FIG. 5 .
[0044] Next, the dummy gate 20 , i.e., sacrificial polysilicon region or other related material, is removed from the structure using chemical downstream etching or KOH stopping atop the sacrificial oxide layer 18 . The resultant structure, which includes a gate opening 25 that is formed after this step has been performed, is shown, for example, in FIG. 6 . Note that the inner edges 21 of insulating spacers 22 , which define the boundaries of the gate opening 25 , define the length GL of device channel 26 .
[0045] At this point of the inventive method, device channel (i.e., body region) 26 is subjected to an ion implantation step and an annealing step. The conditions used in the ion implantation step and the annealing step are well known to those skilled in the art. The annealing step serves to activate the dopants within the device channel 26 . For example, the device channel 26 may be ion implanted with a p-type dopant using any ion dosage such 1E12 to about 5E13 atoms/cm 3 and annealed at any conditions such as, for example, 1000° C., for 5 seconds in Ar. An n-type dopant is also contemplated herein. The structure showing ion implantation into the device channel 26 is shown, for example, in FIG. 7 . In FIG. 7 , reference numeral 28 denotes ions being implanted into the device channel 26 .
[0046] The exposed sacrificial oxide 18 in the gate opening 25 is then removed from the structure to expose the device channel 26 . Specifically, the exposed sacrificial oxide 18 in the gate opening is removed by utilizing a chemical oxide removal (COR) process. The COR process employed in the present invention is carried out at relatively low pressures (6 millitorr or less) in a vapor, or more preferably, a plasma of HF and NH 3 . The HF and NH 3 mixture is used as an etchant that selectively removes oxide from the structure. The resultant structure that is formed after the COR step has been performed is shown, for example, in FIG. 8 .
[0047] Next, gate dielectric 30 is formed atop the exposed device channel 26 utilizing a conventional deposition process. Alternatively, the gate dielectric 30 may be formed by a thermal oxidation, nitridation or oxynitridation process. Combinations of the aforementioned processes may also be used in forming the gate dielectric 30 . The gate dielectric 30 may be composed of any conventional dielectric including, but not limited to: SiO 2 ; Si 3 N 4 ; SiON; SiON 2 ; high-k dielectrics such as TiO 2 , Al 2 O 3 , ZrO 2 , HfO 2 , Ta 2 O 5 , La 2 O 3 ; and other like oxides including perovskite-type oxides. Typically, the high-k dielectrics are capable of withstanding high-temperature (900° C.) anneals. Gate dielectric 30 may also comprise any combination of the aforementioned dielectric materials.
[0048] Gate dielectric 30 is typically thinner than the sacrificial oxide layer 18 . Generally, when the gate dielectric 30 is composed of SiO 2 , Si 3 N 4 , SiON or SiON 2 , it has a thickness of about 1 to about 5 nm. For the other gate dielectrics, the thickness would provide a equivalent oxide thickness in the range mentioned above.
[0049] After the gate dielectric 30 has been formed, amorphous Si is deposited using a deposition process such as low pressure chemical vapor deposition (LPCVD) that is performed at a temperature of less than about 600° C., preferably between 500° C.-600° C., and then the deposited amorphous Si is planarized providing an amorphous Si region in the gate opening 25 . Following the formation of amorphous Si region, a gate implantation and anneal step is performed. The dopant used during the implantation may be either a p-type dopant or an n-type dopant depending on the type of device to be fabricated.
[0050] The annealing conditions used at this point of the present invention cause recrystallization of the amorphous Si region into a polySi gate 32 , while causing activation and diffusion of the dopant to the interface between the polySi gate and the gate dielectric 30 . Moreover, the annealing step performed at this point of the present invention creates tensile strain in the device channel 26 . That is, a localized strained channel 34 is formed during the annealing step. This process allows one to build either n- or p-devices having a localized strained channel, which are both under a tensile strength. The activation and diffusion of dopant in amorphous Si requires much longer diffusion time than polySi due to the absence of grain boundaries in crystallized amorphous Si which speeds up dopant diffusion. The annealing step is performed at a temperature of about 1000° C. or greater for a time period of greater than 5 seconds, preferably about 30 min. The annealing is carried out preferably in nitrogen or any other inert gas.
[0051] The structure including gate dielectric 30 , polygate 32 and localized strained channel 34 is shown, for example, in FIG. 9 . In this structure the Si substrate adjoining the localized strained channel 34 has not be affected; therefore it is in a non-strained state.
[0052] Reference is now made to the structure shown in FIG. 10 which is formed after the following processing steps have been carried out: First, the oxide layer 24 is removed from the structure using an etching process that is highly selective in removing oxide. Note that the sacrificial oxide layer 18 underlying the oxide layer 24 is also typically removed from the structure during this etch. Source/drain junctions (or regions) 36 are then formed into substrate 12 using a conventional angle implantation process followed by an annealing step. The implant is activated by annealing using conditions well known to those skilled in the art. For example, the implant may be annealed at 1000° C. for 1 second or longer.
[0053] At this point of the present invention, raised source/drain regions (not shown) may be optionally formed atop the surface of the source/drain regions by epitaxially growing an epi Si layer thereon. To either the raised source/drain regions or to the previously formed source/drain regions 36 , salicide regions 38 may be formed using a conventional salicidation process that includes, for example, forming a refractory metal such as Ti, Co or Ni on Si surfaces; heating the structure to form silicide regions and thereafter removing any non-reactive metal that was not converted into a silicide during the heating process. The resultant structure including salicide regions 38 (self-aligned silicide) is shown, for example, in FIG. 11 . Since the gate is comprised of polySi, a salicide region 38 ′ is also formed thereon, unless appropriate steps (such as block mask formation) are taken to prevent the formation of a salicide region in the polysilicon gate conductor.
[0054] Further BEOL (back-end-of-the-line) processes may be formed on the structure shown in FIG. 11 . For example, a layer of insulating material such as BPSG (boron doped phosphorus silicate glass) can be formed over the structure by deposition and planarization. Contact openings can be formed into the insulating layer by lithography and etching and thereafter the contact holes can be filled with a conductive material, such as, for example, Cu, Al, W, polysilicon and other like conductive materials.
[0055] While the present invention has been particularly shown and described with respect to preferred embodiments thereof, it will be understood by those skilled in the art that the foregoing and other changes in forms and details may be made without departing from the spirit and scope of the present invention. It is therefore intended that the present invention not be limited to the exact forms and details described and illustrated, but fall within the spirit and scope of the appended claims. | The present invention provides a method using a damascene-gate process to improve the transport properties of FETs through strain Si. Changes in mobility and FET characteristics are deliberately made in a Si or silicon-on-insulator (SOI) structure through the introduction of local strain in the channel region, without introducing strain in the device source and drain regions. The method has the advantage of not straining the source and drain regions resulting in very low leakage junctions and also it does not require any special substrate preparation like the case of a strained Si/relaxed SiGe system. Moreover, the method is compatible with existing mainstream CMOS processing. The present invention also provides a CMOS device that has a localized strained Si channel that is formed using the method of the present invention. | 8 |
CLAIM OF PRIORITY
[0001] The present application claims priority from Japanese patent application serial no. 2014-218964, filed on Oct. 28, 2014, the content of which is hereby incorporated by reference into this application.
TECHNICAL FIELD
[0002] The present invention relates to a wireless communication base station system, a wireless communication system, and a wireless mobile station. More particularly, the invention relates to a wireless communication base station system, a wireless communication system, and a wireless mobile station elaborated to reduce time a wireless mobile station takes to complete a cell search.
BACKGROUND
[0003] Generally, when a wireless mobile station (hereinafter referred to as MS) initiates wireless communication, the MS performs network entry via a wireless base station (hereinafter referred to as BS). Network entry is processing that the MS must perform to establish connection to a network of a wireless communication system. In a phase before the MS performs network entry, the MS performs a cell search operation to search through radio waves emitted by its surrounding base stations. The MS searches through a search range of frequencies (from a start frequency to an end frequency) assigned to a wireless communication system in determined frequency gaps (frequency steps). The MS checks to see whether or not there is a BS whose center frequency matches a frequency to search for by the cell search. If the MS has detected a BS having a center frequency that enables communication during the search, the MS attains synchronization with the BS and then initiates network entry processing.
[0004] However, an MS typically performs a search in frequency steps that are finer than frequency steps between center frequencies that BSs use. Consequently, a cell search takes much time under the assumption that an MS searches through all applicable frequencies within a search range.
[0005] Accordingly, in a technique which is disclosed in Japanese Unexamined Patent Application Publication No. 2007-116561, from a mobile communication network accessed by a mobile terminal, the mobile terminal acquires information representing frequencies that are used in the mobile communication network and stores that information within it. When performing a cell search over a search range of frequencies, the mobile terminal skips frequencies that obviously do not match the center frequencies of BSs in the mobile communication network. Furthermore, based on a search result, the mobile terminal expands a range of frequencies to skip, thus reducing time for a subsequent cell search.
SUMMARY OF THE INVENTION
[0006] When an MS performs a cell search, the MS takes a certain amount of time to complete the cell search, if a search range and frequency steps are not taken into consideration. In a wireless communication system required to have high reliability, once an MS has entered a BS area, time the MS takes to connect to a network is desired to be as short as possible. Thus, it is needed to minimize time that the MS takes to complete a cell search.
[0007] In the present invention, Aeronautical Mobile Airport Communication System (AeroMACS) which is built on the basis of Mobile Worldwide Interoperability for Microwave Access (WiMAX) technology is assumed to be used. AeroMACS is one of wireless communication systems to which the present invention is intended to apply. An application scope of AeroMACS is the surface of an airport (the whole airport). AeroMACS provides a high-speed mobile communication system for airports. For AeroMACS, reliable and rapid communication is required to implement operations involved in flight operations on the surface of an airport, which are taking off and landing of aircrafts. Thus, it is required of AeroMACS to reduce time required to initiate communication with a BS and initiate communication reliably.
[0008] A cell search in AeroMACS is described. In the AeroMACS specs, a start frequency is 5095 MHz and an end frequency is 5145 MHz. Because frequency steps are 250 kHz, if an MS performs a search through all applicable frequencies within a search range, the MS is to search through frequencies from 5095 MHz to 5145 MHz in 250 kHz steps. However, the width of gaps between the center frequencies of BSs adopted in AeroMACS is 5 MHz (the center frequencies are adopted from among frequencies spaced by a 5-MHz gap including 5095 MHz, 5100 MHz, etc. up to 5145 MHz).
[0009] Consequently, at an MS, a cell search is to be performed in very fine frequency steps. Under the conditions mentioned above, if the center frequency of a BS selected as a target access point for an MS is 5095 MHz which is the start frequency in the AeroMACS specs, the MS will complete a cell search by one search action. But if the center frequency of the BS selected as the target access point is set to 5145 MHz which is the end frequency, the MS needs to perform search actions 201 times to complete a cell search.
[0010] A significant difference occurring in the number of search actions results in a difference in the cell search time until connection is established. When compared with the processing time required for network entry, it is undesirable that processing of a cell search takes very long for a BS whose center frequency is set to the end frequency, which is the worst-case scenario.
[0011] In addition, even if an MS is able to uniquely store the center frequencies of BSs to search and a situation allows the MS to complete a cell search by one search action, airport surface communications may be affected by weather or equipment trouble and, consequently, a destination network manager may change the center frequencies of BSs or the location to which the MS is destined to move. For this reason, it may happen that the MS cannot use information representing the center frequencies of BSs which are uniquely set within it because the center frequencies have been changed just by making an MS uniquely store the center frequencies of BSs, with the result that the MS has to perform a cell search over a search range of frequencies. A time-consuming cell search over a search range of frequencies defined in the specs of a communication system should be performed exclusively for use as a final measure.
[0012] To solve a problem discussed above, there is provided a wireless communication base station system including a first broadcasting wireless base station that broadcasts information on wireless base stations installed in a first location, a second broadcasting wireless base station that broadcasts information on wireless base stations installed in a second location, and a frequency management entity. The frequency management entity includes a control unit that performs message transmission and reception and a storage unit that stores information representing center frequencies which are used by wireless base stations in the second location and a coverage area. The control unit, upon receiving a message requesting information on the wireless base stations installed in the second location from a wireless mobile station which is going to move from the first location to the second location, transmits information on the wireless base stations installed in the second location, which is stored in the storage unit, to the wireless mobile station via the first broadcasting wireless base station.
[0013] There is also provided a mobile wireless station that may be connected to a wireless communication base station system including a first broadcasting wireless base station that broadcasts information on wireless base stations installed in a first location, a second broadcasting wireless base station that broadcasts information on wireless base stations installed in a second location, and a frequency management entity. The mobile wireless station includes a mobile station control unit that performs message transmission and reception and compares information on wireless base stations and a mobile station storage unit. The mobile station control unit, upon receiving information on base stations from the frequency management entity via the first broadcasting wireless base station and deciding that a plurality of the second wireless base stations serve the coverage area, creates an Area Search Configuration in which the smallest and largest ones of center frequencies used by the plurality of second wireless base stations are set as search start and end frequencies for a cell search and a frequency step size to search defined in the wireless communication system is set as frequency steps, and stores the Area Search Configuration into the mobile station storage unit. The mobile station control unit, upon receiving the information on base stations and deciding that one second wireless base station serves the coverage area, creates an Area Search Configuration in which a center frequency used by the second wireless base station is set as search start and end frequencies, and stores the Area Search Configuration into the mobile station storage unit.
[0014] There is further provided a wireless communication system combining the wireless communication base station system with the mobile wireless station.
[0015] According to the present invention, it is possible to reduce time that an MS takes to connect to a network. Even when a target access point (BS) has been changed, a cell search for an intended frequency of the target access point can be performed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] Preferred embodiments of the present invention will now be described in conjunction with the accompanying drawings, in which;
[0017] FIG. 1 is a block diagram to explain a network structure;
[0018] FIG. 2 is a block diagram to explain an MS structure;
[0019] FIG. 3 is a block diagram to explain a frequency management entity structure;
[0020] FIG. 4 is a sequence diagram to explain a process of updating a frequency list;
[0021] FIG. 5 is a diagram to explain a home location frequency list;
[0022] FIG. 6 is a diagram to explain a foreign location frequency list;
[0023] FIG. 7 is a sequence diagram to explain a process in which an MS receives a frequency list;
[0024] FIG. 8 is a flowchart to explain a process of creating Search Configs;
[0025] FIG. 9 is a diagram to explain a search list;
[0026] FIG. 10 is a flowchart to explain a process of using Search Configs;
[0027] FIG. 11 is a diagram to an aircraft which is going to arrive at an airport and the coverage areas of BSs;
[0028] FIG. 12 is a flowchart to explain a process of performing a cell search using Area Search Config;
[0029] FIG. 13 is a flowchart to explain a process of performing a cell search using Location Search Config;
[0030] FIG. 14 is a diagram to explain cell search processing using Area Search Config A;
[0031] FIG. 15 is a diagram to explain cell search processing using Area Search Config C;
[0032] FIG. 16 is a diagram to explain cell search processing using Location Search Config; and
[0033] FIG. 17 is a diagram to explain cell search processing using Default Search Config.
DETAILED DESCRIPTION
[0034] In the following, modes will be described in detail using embodiments and with reference to the drawings.
[0035] Referring to FIG. 1 , descriptions are provided for a structure of a communication system and AeroMACS networks. In FIG. 1 , a communication system 500 is configured including networks in locations (AeroMACS networks) 100 and an MS 200 . Each AeroMACS network 100 is comprised of an Access Service Network (ASN) 130 and a Connectivity Service Network (CSN) 150 .
[0036] The ASN 130 has a wireless connection function for communication with an MS 200 . The ASN 130 provides a function of connecting a MAC layer for management of radio resources information and a physical layer. The ASN 130 is configured including a broadcasting BS 131 , BSs 132 , and an ASN-Gateway (GW) 133 . The broadcasting BS 131 is a base station that provides a frequency list to the MS 200 . The BSs 132 are common base stations. The ASN-GW 133 ensures connectivity of the BSs 131 , 132 with a Home Agent (HA) server 151 between the CSN 150 and the ASN 130 . The broadcasting BS 131 in a location A is denoted as the broadcasting BS 131 -A and the BSs 132 in the location are denoted as the BSs 132 -A; the same applies to BSs in a location B.
[0037] The CSN 150 performs tunneling to an MS 200 . The CSN 150 provides an IP connection function including IP address distribution and communication channel processing using DHCP. The CSN is configured including an Authentication Authorization Accounting (AAA) server 152 , an HA server 151 , and a frequency management entity 300 . The AAA server 152 is a server that performs authentication, authorization, and accounting of an MS. The HA server 151 is a router that provides local communication within the CSN. The frequency management entity 300 transmits the frequencies of BSs in each location to an MS.
[0038] In the communication system 500 , an MS 200 is a wireless mobile station installed in an aircraft which moves from one location to another. While staying in the location A, the MS 200 connects to the CSN 150 including the frequency management entity 300 via the broadcasting BS 131 -A or any of the BSs 132 -A and the ASN-GW 133 . When the MS moves out of the location A, the MS 200 performs disconnection processing via the BS communicating with it. When the MS arrives in its destination location B, the MS 200 performs a cell search for the center frequency of a broadcasting BS 131 -B, which is stored within it at takeoff from the location A, and detects the center frequency of the broadcasting BS 131 -B.
[0039] The MS 200 attains synchronization with the broadcasting BS 131 -B and performs network entry processing. Once the MS has connected to the network, the broadcasting BS 131 -B transmits the center frequencies of BSs 132 - 1 to 132 - 3 in the location B to the MS 200 by use of the frequency management entity 300 . The MS 200 compares the center frequencies of the BSs 132 - 1 to 132 - 3 which are stored within it at takeoff from the location A with the center frequencies of the BSs 132 - 1 to 132 - 3 received from the broadcasting BS 131 -B in the location B and decides whether or not the comparison result is matched.
[0040] If the comparison result is matched, the MS 200 performs a cell search using a Search Configuration (hereinafter referred to as a Search Config) stored in a search list which the MS created when it is in the location A. The MS 200 checks to see whether or not there is a BS whose center frequency matches a frequency to search for among the BSs 132 - 1 to 132 - 3 in the location B. When the MS 200 has detected a BS whose center frequency matches a frequency to search for during the cell search, the MS 200 attains synchronization with the BS 132 and performs a handover from the broadcasting BS 131 .
[0041] If the comparison result is unmatched, the MS 200 creates a Search Config, using the center frequencies acquired from the broadcasting BS 131 -B, and performs a cell search. The MS 200 checks to see whether or not there is a BS having a center frequency that enables communication among the BSs 132 - 1 to 132 - 3 in the location B. When the MS 200 has detected a BS with which it can communicate during the cell search, the MS 200 attains synchronization with the BS 132 and performs handover processing from the broadcasting BS 131 .
[0042] Although only one MS 200 is depicted in FIG. 1 , plural MSs can connect to an appropriate one of the BSs. In the system structure depicted, respective frequency management entities 300 are installed in the locations A and B. However, the structure may be modified as follows: these entities are connected by the Internet which is indicated by a dotted line to provide a frequency management entity 300 that enables mutual management. If just one BS is used in an AeroMACS network due to the scale of a location, just one broadcasting BS may be provided in the network structure.
[0043] Referring to FIG. 2 , an MS structure is described. In FIG. 2 , an MS 200 includes a baseband unit 210 , a search list creating unit 220 , a control unit 230 , antenna 260 , a storage unit 280 , and a wireless communication unit 290 .
[0044] The baseband unit 210 performs modulation and demodulation processing on radio signals. The search list creating unit 220 creates a search list. The control unit 230 performs control of all components of the MS. The control unit 230 performs comparison between the center frequencies of base stations registered in a search list which the MS creates before its departure and the center frequencies of base stations in a location in which the MS has arrived, received from a broadcasting BS in the location in which the MS has arrived. The antenna 260 transmits and receives radio signals. The storage unit 280 records data. The wireless communication unit 290 executes communication with a BS.
[0045] The wireless communication unit 290 includes a wireless transmitter 291 which transmits radio signals and a wireless receiver 292 which receives radio signals. The storage unit 280 holds a search list 281 and a frequency list 282 .
[0046] Referring to FIG. 3 , a frequency management entity structure is described. In FIG. 3 , a frequency management entity 300 includes a control unit 310 , a frequency list updating unit 340 , a communication unit 350 , and a recording unit 360 .
[0047] The control unit 310 performs control of all components of the frequency management entity 300 . The frequency list updating unit 340 updates frequency lists 361 , 362 which are contained in the recording unit 360 . The communication unit 350 executes communication with a BS. The recording unit 360 records data.
[0048] The recording unit 360 contains a home location frequency list 362 and a foreign location frequency list 361 . The home location frequency list 362 is information representing the center frequencies used by BSs installed in the home location. The foreign location frequency list 361 is information representing the center frequencies used by BSs installed in a foreign location.
[0049] Referring to FIG. 4 , descriptions are provided for a process in which a frequency management entity updates a frequency list it manages. In FIG. 4 , a frequency management entity 300 creates an update inquiry message including a home location frequency list 362 which it has read from the storage unit 360 (S 401 ). Through the communication unit, the frequency management entity 300 transmits the update inquiry message to a broadcasting BS 131 installed in the home location (S 402 ). The broadcasting BS 131 transmits the update inquiry message to a BS 132 (S 403 ). The BS 132 receives the update inquiry message and transmits an update message to the broadcasting BS 131 (S 404 ).
[0050] The frequency management entity 300 transmits an inquiry message to inquire if a change has been made to the center frequency that each BS uses. If so, in an update message, a BS 132 transmits the center frequency of the BS that received the update inquiry message. The broadcasting BS 131 executes this message exchange processing to all BSs in the same location in a parallel way.
[0051] Through the communication unit 350 , the control unit 310 of the frequency management entity receives the update message 402 from the broadcasting BS. The control unit 310 instructs the frequency list updating unit 340 to update the home location frequency list 362 which is contained in the storage unit 360 , according to BSID and a center frequency included in the update message. The frequency list updating unit 340 updates the home location frequency list 362 , using information representing the BSID and a new center frequency.
[0052] The description with FIG. 4 assumes the system structure in which respective frequency management functions 300 are installed in the locations A and B. However, a single frequency management entity may be provided in a framework where the frequency management functions 300 are interconnected by the Internet and updated. In that case, the Internet-connected frequency management entity 300 will transmit an update inquiry message to each of the broadcasting BSs 131 in the locations A and B and receive an update message from each of them. In this case, the Internet-connected frequency management entity collectively manages the frequency lists in the locations without discrimination between home/foreign locations and, therefore, update message transmission becomes unnecessary. Also in examples that will be described hereinafter, the frequency management entities installed in the respective locations can also be interpreted as the Internet-connected frequency management entity in an alternative framework.
[0053] Referring to FIG. 5 , descriptions are provided for a home location frequency list which is managed by the frequency management entity. The home location frequency list 362 presented in FIG. 5 is the home location frequency list 362 (particularly, 362 -A) which is managed by the frequency management entity in the location A. The home location frequency list 362 stores information on the BSs 132 - 1 to 132 - 3 installed in the location A.
[0054] The home location frequency list 362 is comprised of the following fields: BSID 371 , location 372 , BS area 373 , and center frequency 374 .
[0055] BSID 371 is a BS identifier for identifying each BS. Location 372 indicates information representing a location to which an MS may move and where the BS is installed. BS area 373 indicates information representing a location to which an MS may move and which is a coverage area of the BS. Center frequency 374 indicates information representing a center frequency that the BS uses.
[0056] Referring to FIG. 6 , descriptions are provided for a foreign location frequency list which is managed by the frequency management entity. The foreign location frequency list 361 presented in FIG. 6 is the foreign location frequency list 361 (particularly, 361 -A) which is managed by the frequency management entity 300 in the location A. The foreign location frequency list 361 stores information on BSs installed in a location to which an MS may move and which is other than the location A. Like the home location frequency list 362 , the foreign location frequency list 361 is comprised of the following fields: BSID 381 , location 382 , BS area 383 , and center frequency 384 . Here, the list stores information on the location B and a third location to which an MS may be destined to move from the location A. A maintenance person is assumed to set up the foreign location frequency list 361 beforehand.
[0057] Referring to FIG. 7 , descriptions are provided for a process in which an MS receives a frequency list. In FIG. 7 , an MS 200 that stays in the location A receives its destination (S 411 ). The MS 200 creates a message requesting a frequency list that contains information representing the center frequencies used by a broadcasting BS and BSs installed in the destination location and transmits the message addressed to a frequency management entity 300 through the baseband unit 210 and wireless transmitter 291 (S 412 ). A broadcasting BS 131 relays the frequency list request message and transmits the frequency list request message to the frequency management entity 300 (S 413 ).
[0058] The frequency management entity 300 receives the frequency list request message. The control unit 310 of the frequency management entity 300 retrieves a requested frequency list (all records relevant to the location B in this case) in the destination location from the foreign location frequency list 361 in the storage unit 360 and creates a frequency list response message from that information. Through the communication unit 350 , the control unit 310 transmits the frequency list response message S 414 to the broadcasting BS 131 (S 414 ). The broadcasting BS 131 relays the frequency list response message and transmits the frequency list response message to the MS 200 (S 415 ).
[0059] The control unit 212 of the MS 200 receives the frequency list response message through the wireless receiver 292 and baseband unit 210 . The control unit 212 stores the received information into the frequency list 282 in the storage unit 280 . The frequency list 282 has the same structure as the foreign location frequency list 361 described with FIG. 6 and includes the fields of BSID, location, BS area, and center frequency. If the destination is the location B, the frequency list holds all records with “location B” in the location field in the foreign location frequency list 361 presented in FIG. 6 .
[0060] Referring to FIG. 8 , descriptions are provided for a process in which an MS creates Area Search Config/Location Search Config based on a frequency list. Here, Search Config is an individual search list component created from a frequency list table. A search list is a collection of Search Configs. In the present embodiment, Area Search Config which is information for performing a search on a per-BS basis, Location Search Config for performing a search for all BSs existing in a location, and Default Search Config for performing a default search are stored in the search list.
[0061] The search list creating unit 220 reads in the records of BS areas covering destination locations to move to from the frequency list 282 in the storage unit 280 (S 502 ). The search list creating unit 220 determines the number of BSs from the records that it reads in and determines how to create Search Config (S 503 ). To illustrate, based on, particularly, the frequency list presented in FIG. 6 , the search list creating unit 220 determines that one BS covers an area A in the location B and two BSs cover an area B in the location B.
[0062] If plural BSs cover an area of the destination, as determined at step 503 , the search list creating unit 220 determines a start frequency, an end frequency, and a frequency step size and creates a Search Config to be used in performing a cell search (S 504 ). As the start frequency, the unit 220 sets the smallest one of the center frequencies respectively used by the plural BSs that it reads in to the start frequency. As the end frequency, the unit 220 sets the largest one of the center frequencies respectively used by the plural BSs that it reads in to the end frequency. The unit 220 sets the frequency step size to 5 MHz.
[0063] On the other hand, if one BS, which is only a broadcasting BS, covers an area of the destination, as determined at step S 503 , the search list creating unit 220 determines a start frequency, an end frequency, and a frequency step size and creates a Search Config (S 505 ). As the start/end frequencies, the unit 220 sets the center frequency used by the one BS that it reads in to the start and end frequencies. However, the search list creating unit 220 does not set the frequency step size. This is because the number of BSs to search for by a cell search is only one.
[0064] The search list creating unit 220 creates a Search Configs (Area Search Configs) for each of the BS areas of the destination location and maintains them in the search list 281 in the storage unit 280 . The search list will be explained later, using FIG. 10 .
[0065] The search list creating unit 220 checks whether or not it has read in all records with information in the location field matching the destination (S 506 ). If there is a record of a BS read it has not read in yet, a return is made to step 502 . When the decision is “YES” at step 506 , the search list creating unit 220 creates a Location Search Config covering the frequencies used by the BSs in all BS areas (S 507 ) and terminates the process.
[0066] At step 507 , the search list creating unit 220 determines a start frequency, an end frequency, and a frequency step size and creates a Location Search Config to be used in performing a cell search. As the start frequency, the search list creating unit 220 sets the smallest one of the center frequencies used by the plural BSs that it reads in to the start frequency. As the end frequency, the search list creating unit 220 sets the largest one of the center frequencies used by the plural BSs that it reads in to the start frequency. The search list creating unit 220 sets the frequency step size to 5 MHz.
[0067] The search list creating unit 220 creates Search Configs (including a Location Search Config) in the destination and maintains them in the search list in the storage unit 280 .
[0068] For the frequency step size, the search list creating unit 220 sets an appropriate value according to the width of gaps between the center frequencies of BSs adopted in the wireless communication system. Because AeroMACS is assumed as the wireless communication system here, the search list creating unit 220 sets the frequency step size to 5 MHz. If there are plural wireless networks to which an MS may connect to, the search list creating unit 220 sets the frequency step size according to the width of gaps between the center frequencies of BSs prescribed in the communication system of a wireless network to which the MS is to connect to. In the present embodiment, the search list creating unit 220 of an MS sets the frequency step size to a fixed value (5 MHz) specific to the AeroMACS network.
[0069] Referring to FIG. 9 , a search list that an MS maintains is described. The search list 281 in FIG. 9 is comprised of Area Search Configs and a Location Search Config created according to the flowchart of FIG. 8 and a Default Search Config. The search list 281 is used when the MS performs a cell search in the destination location B.
[0070] The search list 281 in FIG. 9 includes the following fields: item 241 , location 242 , BS area 243 , start frequency 244 , end frequency 245 , and frequency step size 246 . How to use the search list will specifically be described later with reference to FIGS. 14 to 17 .
[0071] Referring to FIG. 10 , descriptions are provided for a process of comparing a frequency list that an MS maintains and a frequency list received from the broadcasting BS in the location B. In FIG. 10 , when an MS 200 moves to the destination location B, its control unit 212 completes network entry, using an Area Search Config identified with “Broadcasting” specified in the BS area field of the list of Area Search Configs.
[0072] The control unit 212 of the MS 200 reads in a frequency list in the location B received via the broadcasting BS 131 -B (S 512 ). The control unit 212 compares the frequency list with a frequency list 282 stored at takeoff from the location A (S 513 ). If both lists match, the control unit 212 performs a cell search for a location to move to, using Area Search Configs in the currently maintained list (S 514 ).
[0073] If the comparison result is unmatched at step 513 , the control unit 212 creates Area Search Configs/Location Search Config based on the frequency list received from the broadcasting BS 131 -B in the location B and performs a cell search using Area Search Configs identified with “Location B” specified in the BS area field (S 515 ).
[0074] When the MS performs a cell search using Area Search Configs, if the cell search is unsuccessful, the control unit 212 performs a cell search using a Location Search Config as recovery measures. If the cell search using the Location Search Config is unsuccessful again, the control unit 212 performs a cell search using a Default Search Config as recovery measures. The Default Search Config is defined with a search range and a frequency step size prescribed in the wireless communication system and pre-stored in the search list. Because AeroMACS is assumed as the wireless communication system here, if the MS performs a cell search using the Default Search Config, the MS performs a cell search in a range from 5095 MHz to 5145 MHz in frequency steps of 250 kHz.
[0075] Because the AeroMACS network is applied in the present embodiment, one Default Search Config only exists in the search list. If the MS 200 is a terminal which may connect to plural wireless communication systems, the search list includes as many Default Search Configs as the number of the wireless communication systems; in each Default Search Config, a start frequency, an end frequency, and a frequency step size prescribed in each wireless communication system are stored.
[0076] Referring to FIG. 11 , descriptions are provided for an aircraft approaching the destination location B and a coverage area α of the broadcasting BS and BSs installed in the location, where the AeroMACS network is applied. The coverage area α indicates a scope in which the broadcasting BS 131 and BSs 132 - 1 to 132 - 3 installed in the location B can connect with an MS. In particular, when an MS 200 initiates mobile communication, first, the MS is to connect to the broadcasting BS 131 and execute operations described in FIG. 10 . Then, the MS 200 is to perform communication with one of the BSs 132 - 1 to 132 - 3 . To perform communication with the BS 131 and one of the BSs 132 , the MS installed in the aircraft 400 must enter the coverage areas of the BSs. The location B is covered by the coverage areas of the BSs and a part of the location B is covered by the coverage areas of plural BSs.
[0077] The MS 200 is to perform communication with the broadcasting BS 131 at its arrival. The MS 200 is to perform communication with a BS 132 - 1 when it lands and moves on ground in an area A. The MS 200 is to perform communication with either a BS 132 - 2 or a BS 132 - 3 when it lands and moves on ground in an area B.
[0078] Referring to FIG. 12 , descriptions are provided for a process in which an MS performs a cell search using Area Search Config in the location B. In FIG. 12 , upon arrival and after connecting to the broadcasting BS 131 and executing operations described in FIG. 10 , the control unit 212 of the MS 200 reads in Area Search Configs, a Location Search Config, and a Default Search Config in the location B from the search list 281 in the storage unit 280 to perform communication with a BS in the location B (S 522 ).
[0079] To decide whether or not the MS has entered the coverage area of a BS installed in the location B, the control unit 212 executes Initial Ranging to search for a usable channel and a base station (S 523 ). When the decision is NO, the control unit 212 repeats step 523 . Once the MS 200 has entered a BS's coverage area (S 523 ; YES), the control unit 212 performs a cell search using an Area Search Config (S 524 ). The control unit 212 checks whether or not it has detected a BS using the Area Search Config (S 525 ). If no BS is detected, the control unit 212 performs a cell search using the Location Search Config (S 526 ). The control unit checks whether or not it has detected a BS using the Location Search Config (S 527 ).
[0080] If no BS is detected again, the control unit 212 performs a cell search using the Default Search Config (S 528 ). The control unit 212 checks whether or not it has detected a BS using the Default Search Config (S 529 ). The control unit 212 continues to perform a cell search using the Default Search Config until it detects a BS.
[0081] Upon detecting a BS with which the MS can communicate at step 525 , step 527 , or step 528 , the control unit 212 terminates cell search processing, attains synchronization with the detected BS, and then initiates network entry processing.
[0082] It is preferable that the control unit 212 uses Area Search Configs only in a phase prior to network entry which is first executed after disconnection from the broadcasting BS 131 . After network entry has once been performed and the MS has connected to a BS detected, using Area Search Configs, when the MS is disconnected from the network for any reason, e.g., disconnection from the network because of blockage within the BS area, and the MS attempts to connect to a BS installed within the location B again, the control unit 212 is to perform a cell search using the Location Search Config.
[0083] Referring to FIG. 13 , descriptions are provided for a process in which the MS performs a cell search using a Location Search Config. In FIG. 13 , in consequence of the process in FIG. 12 , network entry is completed (S 532 ). The control unit 212 reads in a Location Search Config and a Default Search Config in the destination location from the search list 281 in the storage unit 280 (S 533 ).
[0084] The control unit 212 checks whether or not the MS has been disconnected from the network after the completion of network entry (S 534 ). When the decision is NO, the control unit 212 repeats step 534 . When the decision at step 534 is YES, the control unit 212 performs a cell search using the Location Search Config (S 535 ). The control unit 212 checks whether or not it has detected a BS using the Location Search Config (S 536 ). If no BS is detected, the control unit 212 performs a cell search using the Default Search Config (S 537 ). The control unit 212 continues to perform a cell search using the Default Search Config until it detects a BS. Upon detecting a BS with which the MS can communicate at step 536 or step 538 , the control unit 212 terminates cell search processing, attains synchronization with the detected BS, and then initiates network entry processing.
[0085] During a period until a next destination of the MS 200 is determined and the MS starts to move, the control unit 212 performs a cell search using the Location Search Config or Default Search Config in the location B.
[0086] Descriptions are provided for a cell search that is performed at handover (i.e., the moving MS switches to another BS) after the previous connection (network entry). For a cell search to be performed at handover, the MS applies a cell search prescribed in mobile WiMAX. After completing network entry with a BS, the MS 200 receives a Mobility Neighbor Advertisement (MOB_NBR-ADV) message from the BS as broadcasting information. The NBR-ADV message includes the center frequency used by a neighboring BS as information. The mobile WiMAX prescribes that the MS should perform a cell search for only this center frequency when performing handover and switching to another BS to which it should connect.
[0087] Referring to FIG. 14 , descriptions are provided for a scheme of cell search processing with Area Search Config A in FIG. 9 . In FIG. 14 , the MS 200 searches for 5095 MHz only. The MS 200 performs a search only once. Here, this Search Config is used as the Area Search Config in a case where only one BS exists; i.e., a cell search for the broadcasting BS 131 is performed.
[0088] Referring to FIG. 15 , descriptions are provided for a scheme of cell search processing with Area Search Config C in FIG. 9 . In FIG. 15 , the MS 200 performs a search in a range from 5105 MHz to 5110 MHz in frequency steps of 5 MHz. The MS 200 performs a search twice from the start frequency of 5105 MHz.
[0089] Referring to FIG. 16 , descriptions are provided for a scheme of cell search processing with Location Search Config in FIG. 9 . In FIG. 16 , the MS 200 performs a search in a range from 5095 MHz to 5110 MHz in frequency steps of 5 MHz. The MS 200 performs a search four times from the start frequency of 5095 MHz.
[0090] Referring to FIG. 17 , descriptions are provided for a scheme of cell search processing with Default Search Config in FIG. 9 . In FIG. 17 , the MS 200 performs a search in a range from 5095 MHz to 5415 MHz in frequency steps of 250 kHz. The MS 200 performs a search by 201 times at a maximum if the center frequency of a BS 200 with which the MS is to attain synchronization is set to 5145 MHz.
[0091] A cell search using Default Search Config should be performed as recovery measures against the failure of cell searches using Area Search Config and Location Search Config. Except for a cell search for the broadcasting BS 131 , the MS 200 should perform a cell search using Area Search Config only once and a cell search using Location Search Config only once. After the failure of all these searches which should be performed once, the MS 200 is to perform a cell search using Default Search Config. The MS 200 should perform a cell search using Default Search Config repeatedly until it detects a BS with which it can communicate.
[0092] In the illustrations of cell searches in the AeroMACS communication system, presented in FIGS. 14 to 16 , the number of cell search actions required for a cell search using Area Search Config or Location Search Config is reduced in comparison with a cell search using Default Search Config. Accordingly, time for a cell search is reduced, and additionally, it is possible to succeed a cell search reliably because the MS is provided with cell search schemes in three stages.
[0093] According to the present embodiment, before an MS performs a cell search in its destination (more specifically, at takeoff), the MS is provided in advance with information representing the center frequencies used by BSs for which a cell search will be performed. After moving to the destination, by comparing a frequency list that the MS maintains with a frequency list received from the broadcasting BS in the destination location, it can be checked whether or not the frequency list maintained is applicable. Accordingly, time that the MS takes to complete a cell search is reduced and a cell search can be performed reliably.
[0094] Further, it would be easy to response to an unexpected change in a destination network after moving to the destination. By executing the process illustrated in FIG. 10 by the MS, an adaptive operation can be carried out in a case where the destination network has intentionally changed a frequency list and the MS has to perform a cell search for an arbitrary frequency. More efficient use of BS resources can be achieved.
[0095] Because the MS has a function of changing the frequency step size as a function of creating a search list, the present example is applicable to an MS which may connect to plural wireless communication systems where the width of gaps between the center frequencies used by BSs differs.
[0096] While the present embodiment concerns the wireless airport surface communication system, the present embodiment can also be applied to a system where an MS moves from a location to another and moves to another network and another wireless communication system, other than the airport surface communication system. In that case, once a destination location has been determined, the MS receives a frequency list of BSs covering areas in the destination location before disconnection from the network. According to the contents of the frequency list, the MS calculates a search range and a frequency step size and creates and stores Search Configs which are used in performing a search.
[0097] When performing a cell search in the destination location, the MS connects to a broadcasting BS using Search Config created in advance, based on the frequency list in the destination location, and compares the pre-acquired frequency list before it moves with a frequency list in the destination location received from the broadcasting BS. According to the result of the comparison, the MS performs a cell search for a BS using Search Config created in advance before it moves or Search Config created based on the frequency list received from the broadcasting BS in the destination. Thereby, it is possible to reduce time for a cell search and perform a cell search reliably. If no BS is detected by searching in a search range defined in the Search Config, the MS performs a cell search by searching through all applicable frequencies that are used in the destination wireless communication network as recovery measures. If no BS is detected yet, as further recovery measures, the MS is to perform a cell search for a BS by continuing to search in a search range in fine frequency steps, defined in the wireless communication system that the MS supports.
[0098] As the application scope of the technique set forth in the present specification, the technique is applicable to mobile wireless communication systems other than AeroMACS. The technique is applicable to wireless communication systems which are currently put in practical use, including, in particular, Long Term Evolution (LTE) and WiMAX, and wireless communication systems which will be put into practical use in the future. | Once an MS's destination area has been determined, the MS receives a frequency list of BSs belonging to the destination area from a broadcasting BS before disconnecting the current network connection, and creates and stores several Search Configurations. When performing a cell search upon arrival at the destination area, the MS connects to a broadcasting BS in the destination and receives a frequency list of the BSs belonging to the destination area. The MS compares the frequency list that it maintains with the frequency list broadcasted from the BS in the destination and performs a cell search according to the result of the comparison. This leads to achieving reliable network connection and reducing time to establish connection. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to the field of bedclothes holders and rack devices and, more particularly, to a unique device to be temporarily secured to the undersurface of a standard bed foundation and, after being used to receive and hold bedclothes, to be unobtrusively stowed beneath a standard bed.
2. Description of the Related Art
The daily effort of making a bed can become a frustrating and time consuming chore, because items of bedclothes must be removed, temporarily stored, then rearranged in proper sequence and placement. Since the surfaces of adjoining furniture are normally in use, a bedclothes storage device or rack alleviates the frustration of finding an unused storage space and of folding and unfolding bedclothes, continually searching for the appropriate edges. Most devices used to store bedclothes are free standing or rest between the mattress and foundation of a standard bed. Although existing designs are simple in their construction and relatively easy to use, they often take up desirable space when not being used. Some bedclothes holders incorporate folding or slide away features in their design, but none compare with the convenience, stowing ease and time saving aspect of the present invention.
The relevant prior art in the field of bedclothes stands and storage devices includes U.S. Pat. No. 1,186,032 to Peele. The Peele invention is described as a light frame with top mounted diagonally intersecting members to store bedclothes. After unfolding and positioning for use, the frame must be refolded and stowed away. Although portable, the Peele invention exhibits inadequate load bearing characteristics and appears troublesome in set-up and use.
U.S. Pat. No. Des. 273,643 to Sanker et al. discloses a slidable bedclothes rack for insertion between a mattress and box spring. The Sanker device consists of a simple rack that is pulled out from between the mattress and box spring. The rack operates as a shelf to hold the bedclothes. The Sanker rack design displays minimal load bearing ability as evidenced by its size and method of retention. During withdrawal from beneath a mattress the device would likely dislodge neatly arranged bedclothes and is limited for use to beds without a mattress covering footboard.
U.S. Pat. No. Des. 353,847 to Station discloses a bedclothes storage device comprising a vertical rack attached to a horizontal rack at right angles. The exact operation of the Station invention is not obvious, however, the design is quite simple. It may be a free-standing rack or one side may be inserted between a mattress and box spring, similar to the Sanker device.
In each of the prior art examples provided, manipulation of the device requires significant additional mechanical or ergonomic effort to effect the bed making process. The instant invention, designed to accept today's larger blankets and comforters may be secured to any edge of a standard bed, requires little effort to use and less to replace beneath a bed.
SUMMARY OF THE INVENTION
It is therefore an objective of this invention to provide a portable storage device for the efficient and organized daily repositioning and retrieval of bedclothes, in a convenient and timely manner, during the various phases of preparation related to the use of a bed.
It is further an objective of this invention to provide an ergonomically designed device that is quickly and easily positioned to receive and hold bedclothes during periods of need and to easily adjust for placement beneath a bed.
It is still further an objective of this invention to provide a stable and reliable structure of a size and dimension to effectively receive and hold large blankets and comforters for temporary or continuous periods of time as desired by the user.
These as well as other objectives are accomplished by a portable bedclothes storage device, designed to be an adjunctive accessory for a standard bed or similar structure that can provide an elevated upper mounting plane in reference to a lower mounting plane, in this application, exemplified by a floor. The bedclothes storage device is comprised of a bedclothes storage surface, compatible in width to the breadth of a bed or structure that is to form a mounting base for its use, projecting upward at an approximate forty five degree angle with reference to the lower mounting plane of the floor at the base of a bed or similar elevated structure, forming a containment or support surface of maximum storage capacity, yet minimum linear extension, between the storage surface of the device and the vertical facing of the structure under which the device has been mounted. In the present example, decorative and personnel pillows are stored within the containment of bedclothes storage surface and the horizontal bar defining the top of the storage device is used to drape or fold a bedspread, blanket or sheets over the bedclothes storage surface structure with the outer edges readily available for replacement over a bed.
The portable bedclothes storage device is transformable in configuration to meet multiple objectives; to provide a stabilized storage surface for bedclothes, to lie flat on the reverse side and to be of minimum height for stowage beneath a bed, and to be capable of a stand-alone configuration by resting on an end surface, during which the bedclothes storage surface projects upward.
The portable bedclothes storage device comprises of multiple subassemblies; an adjustable wedge assembly, the bedclothes storage surface and the adjustable stabilizing leg assemblies. The purpose of the adjustable wedge assembly is to anchor a horizontally arranged, rectangular, tubular, box-like structure, equal in width to the bedclothes storage surface, between a floor and the under surface of a bed as the device is drawn forth from beneath a bed and rotated upward to an erected angular position. The wedging function is achieved because, while lying flat, the device fits beneath a bed, but when rotated upward, the hypotenuse of the cross section of the rectangular box-like adjustable wedge assembly is greater in length than the distance between a floor and the under surface of a bed. The bedclothes storage surface, a sheeting of sturdy, resilient material, is adhered within and follows the contour of the undulating support frame that is assembled to and projects from the adjustable wedge assembly and in the preferred embodiment displays an undulating surface to maximize the bedclothes storage surface and to provide a shelving feature for the receipt of pillows. The adjustable stabilizing leg assemblies, located on the reverse, or non-loading side of the bedclothes storage surface, comprises freely rotating and adjustable stabilizing legs that operate to rotate, through the force of gravity, to a mechanically established position of support and there to act as a fulcrum for the cantilevered bedclothes storage surface and to rotate, in response to an inward and down thrust applied to the device, to a counter position, there to lie flat against the reverse side of the device and lastly to be manually placed in a position of maximum counter rotation, in the stand-alone configuration.
Although the height of well-made bed frames available from leading department stores is seven and one-half inches, measured from the surface of a floor to the bed support rails, the wedge assembly and stabilizing leg assemblies are adjustable to accommodate the varying heights of bed foundations or similar elevated structure.
The present invention, when not in use, lies on the reverse, or non-loading side beneath a bed. For use to store bedclothes, a top positioning bar of the device is grasped and the device is drawn forth from beneath a bed, or similar elevated structure, to an extent and in an alignment provided by a bed footboard or specially provided alignment guides. During the withdrawal action the top positioning bar is rotated upward causing the wedge assembly to become compressed beneath an elevated upper mounting plane and the stabilizing legs to drop into a support position, there to function as a fulcrum for the cantilevered load bearing surface now projecting upward at a forty-five degree angle with reference to the lower mounting plane or floor surface. A moderate inward and down thrust applied to the top positioning bar results in the release of the wedge assembly and a counter rotation of the stabilizing legs as the legs rotate to lie loose within the confines of the reverse side of the device in a position that allows the portable bedclothes storage device to again be replaced beneath the elevated upper mounting plane or a bed.
BRIEF DESCRIPTION OF THE DRAWINGS
A preferred embodiment of the present invention is described herein with reference to the drawings wherein:
FIG. 1 of the drawings is a perspective view of the present invention showing the device oriented for use in storing bedclothes.
FIG. 1a of the drawings is an exploded view of the corner of the bedclothes storage device showing union of the perimeter bars of the support frame.
FIG. 2 of the drawings is a side view of the securing means of the present invention to the underside edge of a standard bed frame or bed foundation.
FIG. 2a of the drawings is an exploded view of the upper compression bar as it presses against an elevated horizontal plane.
FIG. 2b of the drawings is break-away view of the components making up the split socket connection of the adjustable wedge assembly.
FIG. 3 of the drawings is a perspective view of the bedclothes storage surface of the present invention and the operation of the stabilizing and wedge assemblies as it is secured to the underside edge of a standard bed frame or foundation.
FIG. 3a of the drawings is an exploded view of the adjustable stabilization leg.
FIG. 3b of the drawings is break-away view showing the components of the adjustable stabilization leg.
FIG. 4 of the drawings is a side view of the present invention in a stowed position underneath a bed.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings by numerals of reference, there is shown in FIGS. 1, 2, 3 and 4 the portable bedclothes storage device (10). This portable bedclothes storage device (10) comprises a bedclothes storage surface (16) which is supported in an upright position from the rear by a first and second adjustable stabilizing leg (20) and by an adjustable wedge assembly including an upper compression bar (33) designed to be wedged against the underside edge of a standard bed foundation (40).
Referring to FIG. 1, the various elements of the portable bedclothes storage device are presented. The bedclothes storage surface (16) is supported by a support frame comprising a first and second side support bar (12), a top positioning bar (14), and a lower compression bar (37). The frame as shown in FIG. 1 detailed in FIG. 1b of the bedclothes storage device is of sufficient diameter and wall thickness as to support anticipated storage loads and to accommodate the installation of dynamic components. The bedclothes storage frame and surface (16) is designed with an undulating configuration to both maximize usable surface area and to hold bedclothes in position while making a bed. The adjustable wedge assembly of the portable bedclothes storage device (10) includes an adjustable upper compression bar (33), a lower compression bar (37), a compression pivot bar (39) and a first and second bottom wedge frame (38) extending orthogonally from both first and second side support bars (12). The basic adjustable stabilizing leg assembly, of exact placement and angular relationship, includes a first and second stabilizing leg (20) as previously defined, pivoted within the reverse side of the first and second side support bars (12).
Referring to FIGS. 2, 2a and 2b which is a side view of the structure of a standard bed without a footboard, showing the operation of the securing mechanism of the portable bedclothes storage device (10) as it is erected at the foot of a bed. Manual positioning is effected by grasping a top positioning bar (14) as the device, previously lying flat and concealed beneath the bed foundation (40), is pulled forth and lifted upward. As the portable bedclothes storage device (10) is pulled from beneath the bed foundation (40), the upper compression bar (33) comes in contact with the first and second alignment guides (42), installed equidistant from each side edge of the bed foundation (40), to limit and align the withdrawal motion. Upon achieving alignment, the bedclothes storage surface's top positioning bar (14) is lifted upward causing the upper compression pad (31) and upper compression bar (33) to become wedged against an elevated upper mounting plane exemplified by the under-structure of the bed foundation (40) and to form a point of pivot as the lower compression pad (35) and lower compression bar (37) rotate to a compressed position against the lower mounting plane exemplified by the floor, while flexing about the compression pivot bar (39). The upper compression pad (31) and lower compression pad (35) are horizontally splined rubberized pads provided to protect outward compression surfaces and to enhance the wedging function. When the bedclothes storage surface (16) is lifted slightly past a forty five degree angle from horizontal, which naturally occurs, the first and second adjustable stabilizing legs (20) drop to a mechanically limited position. A further downward break in the longitudinal axis of the adjustable stabilizing legs (20) accomplishes two objectives; to provide a stabilized point of fulcrum for load bearing support and to provide the optimum angular relationship for transition to the stowed position. Once the first and second adjustable stabilizing legs (20) have dropped to position, release of the upper position bar (14) allows the portable bedclothes storage device (10) to settle into position, ready for use in storing bed clothing.
Continuing with FIG. 2, to stow the portable bedclothes storage device (10) beneath the bed, a moderate inward and down thrust on the upper positioning bar (14) releases the compressed grip of the lower compression pad (35) and the lower compression bar (37) allowing a counter rotation of the wedge assembly in coincidence with a counter rotation of the adjustable stabilizing legs (20). During the stowage process and as the adjustable stabilizing legs (20) commence their reverse rotation, a slight rise of the portable bedclothes storage device (10) will occur because of the positive attitude of the adjustable stabilizing legs (20) with regard to the vertical. The rise, having no effect on operation, is quickly passed as the adjustable stabilizing legs (20) rotate to the stowed position as portrayed by FIG. 4.
Continuing with reference to FIG. 2, to accommodate varying dimension between the upper and lower mounting planes, plus or minus one inch of adjustment is provided in form of the adjustable stabilizing legs (20) and an adjustable upper compression bar (33). The details of the adjustable wedge assembly and upper compression bar (33) are forthwith presented. The adjustable wedge assembly is comprised of a split socket (32), a tapered cinch nut (34) and an adjustable tube (30). The upper compression bar (33) can be extended or retracted by using the tapered cinch nut (34) to adjust the first and second adjustable tube (30) up or down inside the split socket (32) to establish effective wedging of the upper compression pad (31) against the elevated upper mounting plane, in the depicted application, a bed foundation (40).
Referring to FIGS. 3, 3a and 3b, the reverse surface of the portable bedclothes storage device (10) is shown, as are the first and second adjustable stabilizing legs (20) in the down or load bearing position. Slotted mechanically limiting cutouts of the tubular frame allow the legs to rotate, with regard to a reference established by the apparent vertical component of the first and second side support bars (12), from one hundred sixty two degrees of arc anti-clockwise for load support to minus thirty fifteen degrees of arc clockwise or within the envelope described by the undulating reverse side of the portable bedclothes storage device (10). This rotational capability allows the load bearing stabilization position and the stowage position of the legs to be established as well as a lodged position when resting the device on the first and second bottom wedge frame (38) of the wedge assembly for stand-alone convenience.
Continuing with FIG. 3, the adjustable stabilizing legs (20) are equipped with a threaded shaft and sleeve mechanism comprised of a threaded shaft (25), a threaded sleeve (22), a lock screw (23) and a rubberized friction pad (24). Adjustment is accomplished by rotating the threaded sleeve (22) clockwise or anti-clockwise to the desired length for effective storage of bed clothing. The lock screw (23) is then turned inward to lock the threaded sleeve (22) in position. A rubberized friction pad (24) is provided to the threaded shaft and sleeve mechanism to prevent unintentional slippage of the adjustable stabilizing legs (20) when in contact with the lower mounting plane, exemplified by the surface of a floor.
Referring to FIG. 4, the portable bedclothes storage device (10) is shown in a stowed position between an elevated upper mounting plane and a lower mounting plane, in this instance, a bed without a footboard. The first and second alignment guide (42) controls and aligns withdrawal of the device, a function performed by a footboard should a bed be so equipped. In the stowed configuration, the portable bedclothes storage device (10) measures six and one half inches from the floor support to the extended curvature of the upper compression pad (31). A standard bed frame supporting a bed foundation measures seven and one half inches from the floor to the under surface of the foundation (40), providing a clearance of one inch between the upper compression pad (31) and the bottom of a bed foundation (40). When not compressed, the diagonal measurement between the extended curved surfaces of the upper compression pad (31) and the lower compression pad (35) is eight inches, allowing a compressible variance of one half inch when erected for use to receive and hold bed clothing as shown by FIG. 3.
A preferred embodiment of the present invention is described herein. It is to be understood, of course, that changes and modifications may be made in the embodiment without departing from the true scope and spirit of the present invention as defined by the appending claims. | A bed accessory for the efficient and organized daily storage and retrieval of bedclothes defined by a symmetrically undulating bedclothes storage surface supported by an adjustable wedge assembly and stabilizing leg assembly. When the bedclothes storage surface is pulled from beneath a bed and rotated upward into an erected position, the adjustable wedge assembly, remaining beneath the bed, becomes compressed between the floor and the under surface of the bed, as adjustable stabilizing legs, located on the reverse side, rotate to a position of support. After use, a moderate down and in force applied to the upper edge of the bedclothes storage surface causes the adjustable wedge and stabilizing leg assemblies to rotate to a stowed position for reinsertion of the apparatus beneath the bed. | 0 |
FIELD OF THE INVENTION
The invention relates generally to processes for preparation of block copolymers; particularly to processes for preparation of block copolymers by a two-step polymerization and most particularly to processes for preparing diblock and triblock copolymers comprising the steps of: (a) performing radical polymerization of N-vinyl-2-pyrrolidone in the presence of a radical initiator, a chain transfer agent (optionally) and an alcoholic solvent to form hydroxy-terminated poly(N-vinyl-2-pyrrolidone) and (b) performing ionic polymerization of monomers or comonomers in the presence of a catalyst or base and a macroinitiator wherein said macroinitiator is the hydroxy-terminated poly(N-vinyl-2-pyrrolidone) formed in step (a) thereby preparing said diblock and triblock copolymers. Poly(N-vinylpyrrolidone) formed in step (a) has a molecular weight between 1,000 D and 700 kD and the diblock and triblock copolymers have a molecular weight between 2,000 D and 700 kD.
BACKGROUND OF THE INVENTION
The synthesis of well-defined polymers with controlled chain end functionalities is important for the achievement of nanotechnology. These polymers have been especially important as potential drug delivery vehicles. In the last decade, the use of various controlled polymerizations have resulted in well-defined copolymers with different designs. For example, nitroxide-mediated polymerization, dithio component-mediated reversible addition-fragmentation chain transfer and atom transfer radical polymerization (ATRP) are controlled processes, which offer control over molecular weight and molecular architecture (diblock, grafted or tapered copolymers). However, a few monomers such as vinyl acetate and N-vinyl-2-pyrrolidone (VP) do not form radicals stabilized by resonance and inductive effects, and therefore the polymerization of these monomers has not yet been performed efficiently by controlled radical polymerizations. Matyjaszewski et al. (Am. Chem. Soc. Symp. Ser. 685:258 1998 and J. Polym. Sci. Part A:Polym. Chem. 36:823-830 1998) reported the homopolymerization of VP using Me 4 Cyclam as a ligand. Chain end functionalities were difficult to obtain using the synthetic pathway described by Matyjaszewski et al.
The instant inventors are interested in functionalized and well-defined poly(N-vinyl-2-pyrrolidone) (PVP) as a replacement for poly(ethylene glycol) (PEG) in diverse drug delivery systems. Although a number of diblock or triblock copolymers can form micelles in aqueous solution, few among them are truly suitable as drug carriers due to biocompatibility issues [Alexandridis et al. Current Opinion Colloid & Interface Science 2:478-489 1997; Rapoport et al. J. Pharm. Sci. 91:157-170 2002; Kabanov et al. Adv. Drug Deliv. Rev. 54:223-233 2002; Nishiyama et al. Langmuir 15:377-383 1999; Kakizawa et al. Langmuir 18:4539-4543 2002; Katayose et al. Bioconjugate Chem. 8:702-707 1997; Yamamoto et al. J. Controlled Release 82:359-371 2002; Liggins et al. Adv. Drug Deliv. Rev. 54:191-202 2002; Kim et al. J. Controlled Release 72:191-202 2001; Yoo et al. J. Controlled Release 70:63-70 2001; Luo et al. Bioconjugate Chem. 13:1259-1265 2002; Lim Soo et al. Langmuir 18:9996-10004 2002; Gref et al. Science 263:1600-1603 1994 and Burt et al. Colloids Surf. B 16:161-171 1999]. Many studies have reported the use of polyester-block-poly(ethylene glycol) block copolymers [Yamamoto et al.; Liggins et al.; Kim et al.; Yoo et al.; Luo et al.; Lim Soo et al.; Gref et al. and Burt et al. journal citations, supra]. PEG is widely used as hydrophilic arm on the surface of nanoparticles [Kissel et al. Adv. Drug Deliv. Rev. 54:99-134 2002], liposomes [Gabizon et al. Adv. Drug Deliv. Rev. 24:337-344 1997]and polymeric micelles [Jones et al. Eur. J. Pharm. Biopharm. 48:101-111 1999; Kataoka et al. Adv. Drug Deliv. Rev. 47:113-131 2001 and Kabanov et al. Adv. Drug Deliv. Rev. 54:759-779 2002]. The PEG-based outer shell can actually prevent the nanocarrier uptake by the mononuclear phagocytic system via steric effects [Jones et al.; Kataoka et al. and Kabanov et al. journal citations; supra]. This prevention substantially improves the circulation time of polymeric micelles in the blood stream. In cancer treatment, this prolonged time generally results in a selective accumulation in a solid tumor due to the enhanced permeability and retention effect of the vascular endothelia at the tumor site [Yokoyama et al. Cancer Res. 50:1693-1700 1990; Yokoyama et al. Cancer Res. 51:3229-3236 1991; Kwon et al. J. Controlled Release 29:17-23 1994; Yokoyama et al. J. Controlled Release 50:79-92 1998 and Yamamoto et al. J. Controlled Release 77:27-38 2001]. However, since aggregation of nanoparticles with PEG as corona occurs during lyophilization, it features some limitations. Thus, PEG is not ideally suited for efficient use in drug delivery systems.
Functionalized and well-defined PVP is an ideal component for replacement of PEG in drug delivery systems. PVP has been proven to be biocompatible [Haaf et al. Polymer J. 17:143-152 1985] and has been extensively used in pharmaceutical industry. Particularly, PVP can be used as cryoprotectant [Doebbler et al. Cryobiology 3:2-11 1966] and lyoprotectant [Deluca et al. J. Parent. Sci. Technol. 42:190-199 1988]. Hence, replacing PEG with PVP in drug delivery systems might help to overcome some freeze drying problems.
Torchilin et al. [J. Microencapsulation 15:1-19 1998] pioneered the study of PVP as hydrophilic corona of liposomes. The design of polymeric micelles with PVP outer shell have presented promising features for pharmaceutical uses. Thus, Benahmed et al. [Pharm. Res. 18:323-328 2001] reported the preparation of PVP-based micelles consisting of degradable diblock copolymers. In the work of Benahmed et al., PVP synthesis using 2-isopropoxyethanol as chain transfer agent was inspired from by previous work of Ranucci et al. [Macromol. Chem. Phys. 196:763-774 1995 and Macromol. Chem. Phys. 201:1219-12252000]. However, this synthetic procedure produced a lack of control over molecular weight, and did not quantitatively provide hydroxyl-terminated PVP, which is essential for polymerizing DL-lactide [Benahmed et al. Pharm Res. 18:323-3282001]. Moreover, the removal of 2-isopropoxy-ethanol from the polymer turned out to be difficult because of its high boiling point (42-44° C. at 13 mmHg) and its binding to PVP via hydrogen bonding [Haaf et al. Polymer J. 17:143-1521985]. Alcohol entrapment into polymer might cause problems for subsequent reactions which require anhydrous and aprotic conditions such as the synthesis of poly(D,L-lactide). Sanner et al. [Proceeding of the International Symposium on Povidone, University of Kentucky: Lexington, Ky., 1983, pp. 20] reported the synthesis of hydroxyl-terminated PVP oligomers via free radical polymerization in isopropyl alcohol (IPA), using cumene hydroperoxide as an initiator. 1 H-NMR spectra have shown that there were 1.3 end groups of 2-hydroxyisopropyl per chain. It is suggested that significant termination by bimolecular combination occurred, between either a primary solvent radical and the propagating chains [Liu et al. Macromolecules 35:1200-1207 2002].
U.S. Pat. No. 6,338,859 (Leroux et al.) discloses a class of poly(N-vinyl-2-pyrrolidone)-block-polyester copolymers. Such PVP block copolymers represent new biocompatible and degradable polymeric micellar systems which do not contain PEG, but which exhibit suitable properties as drug carriers. PVP shows remarkable diversity of interactions towards non-ionic and ionic cosolutes. Prior to the disclosure by Leroux et al., only a random graft copolymer, poly(N-vinyl-2-pyrrolidone)-graft-poly (L-lactide) had been described in the literature [Eguiburu et al. Polymer 37:3615-3622 1996].
In the synthesis of the amphiphilic diblock copolymer disclosed by Leroux et al. hydroxy-terminated PVP was prepared by radical polymerization using 2-isopropoxyethanol as a chain transfer agent. The block copolymer was obtained by anionic ring opening polymerization. Although the strategy of Leroux et al. works very well for the preparation of the desired amphiphilic diblock copolymers in the laboratory, several problems remain to be solved in order to achieve a scalable process. The use of crown ether and the need of dialysis and ultra-centrifugation for the copolymer purification are not desirable on an industrial scale. Furthermore, in the process disclosed by Leroux et al., the degree of functionalization of hydroxyl-terminated PVP was not assessed.
What is lacking in the art is a process for preparing hydroxyl-terminated PVP, and using such functionalized PVP to prepare amphiphilic PVP-block-polyester block copolymers as well as other diblock or triblock copolymers consisting of PVP as one block; wherein the molecular weight, polydispersity index and functionality of the PVP can be controlled and wherein the process can be carried out on an industrial scale.
SUMMARY OF THE INVENTION
The instant invention provides a two-step polymerization process for preparing hydroxyl-terminated PVP and amphiphilic PVP-block-polyester as well as other diblock or triblock block copolymers consisting of PVP as one block. The process enables control of the molecular weight, polydispersity and functionality of the PVP. The diblock and triblock copolymers of the instant invention can be synthesized on an industrial scale for utilization in drug carrier systems.
The process of the instant invention comprises a two-step polymerization. The first step comprises free radical polymerization of VP in the presence of a radical initiator and an alcoholic solvent resulting in the synthesis of a low molecular weight PVP with a terminal hydroxyl group (PVP-OH). This step can be carried out with or without a chain transfer agent. The newly synthesized PVP-OH is purified by re-precipitation. The molecular weight of the PVP-OH can be effectively tuned and controlled by adjusting the molar ratios of radical initiator, chain transfer agent and alcohol to VP. With the use of higher concentrations, recombination of polymer chains is favored so that PVP with a hydroxyl group at both ends of each polymer chain (HO-PVP-OH) can be selectively obtained. Illustrative, albeit non-limiting examples of radical initiators are 2,2′-azobis(2-methyl-N-(2-hydroxyethyl)-propionamide (AMPAHE), 2,2′-azobis(2-methyl-N-[2-(1-hydroxybutyl)]-propionamide and 1,1′azobis(cyclohexane-carbonitrile). AMPAHE is a particularly preferred radical initiator, the use of which is illustrated in the examples herein. Illustrative, albeit non-limiting examples of alcoholic solvents are methanol, ethanol, isopropyl alcohol, n-propanol, n-butanol, tert-butanol, 1-pentanol and 2-pentanol. Isopropyl alcohol (IPA) is a particularly preferred alcoholic solvent, the use of which is illustrated in the examples herein. Illustrative, albeit non-limiting examples of chain transfer agents are 2-mercaptoethanol, 3-mercapto-1-propanol, 3-mercapto-2-propanol, 4-mercapto-1-butanol, 3-mercapto-2-butanol and 6-mercapto-1-hexanol. A particularly preferred chain transfer agent is 2-mercaptoethanol (MCE), the use of which is illustrated in the examples herein.
The second step of the process comprises anionic polymerization of a monomer or comonomers using the dry hydroxyl-terminated PVP, synthesized in the first step, as a macroinitiator resulting in the formation of amphiphilic PVP-block-polyester diblock or triblock copolymers or other diblock and triblock copolymers consisting of PVP as one block. The second step is carried out using a catalyst or base in an inert aprotic solvent without the use of crown ether or other complexation agents. The newly formed block copolymers are isolated by precipitation and purified by dissolution and re-precipitation. No dialysis is necessary for purification. Charcoal treatment can be used to remove any color from the newly formed block copolymers. The molecular weight of the block copolymer and the percentage content of polyester can be controlled by adjusting the ratio of the macroinitiator and the monomer(s). Illustrative, albeit non-limiting examples of catalysts are aluminium and tin alkoxides. Illustrative, albeit non-limiting examples of bases are potassium and sodium hydride. Illustrative, albeit non-limiting examples of inert aprotic solvents are tetrahydrofuran, toluene, diethyl ether and tert-buytl methyl ether. Tetrahydrofuran is a preferred inert aprotic solvent, the use of which is illustrated in the examples herein.
Accordingly, it is an objective of the instant invention to provide a two-step polymerization process for preparing PVP, amphiphilic PVP-block-polyester copolymers and other diblock or triblock copolymers consisting of PVP as one block.
It is a further objective of the instant invention to provide a two-step polymerization process for preparing diblock and triblock copolymers wherein said process enables control of the molecular weight, polydispersity and functionality of the components of each of the polymerizations.
It is yet another objective of the instant invention to provide a two-step polymerization process for preparing diblock and triblock copolymers wherein said process can be carried out on an industrial scale.
It is a still further objective of the invention to provide (PVP)-block-polyester copolymers for use as drug carriers.
Other objects and advantages of this invention will become apparent from the following description taken in conjunction with the accompanying drawings wherein are set forth, by way of illustration and example, certain embodiments of this invention. The drawings constitute a part of this specification and include exemplary embodiments of the present invention and illustrate various objects and features thereof.
Definitions
The following list defines terms, phrases and abbreviations used throughout the instant specification. Although the terms, phrases and abbreviations are listed in the singular tense the definitions are intended to encompass all grammatical forms.
As used herein, the abbreviation “PEG” refers to poly(ethylene glycol).
As used herein, the abbreviation “PM” refers to polymeric micelles.
As used herein, the abbreviation “VP” refers to N-vinyl-2-pyrrolidone.
As used herein, the abbreviation “PVP” refers to poly(N-vinyl-2-pyrrolidone).
As used herein, the abbreviation “PVP-OH” refers to PVP with a hydroxyl group at one terminus of each polymer chain.
As used herein, the abbreviation “HO-PVP-OH” refers to PVP with hydroxyl groups at both termini of each polymer chain.
As used herein, the abbreviation “PDLLA” refers to poly(D,L-lactide).
As used herein, the abbreviation “PVP-b-PDLLA” refers to poly(N-vinylpyrrolidone)-block-poly(D,L-lactide).
As used herein, the abbreviation “MALDI-TOF” refers to matrix-assisted laser/desorption/ionization time-of-flight mass spectrometry.
As used herein, the abbreviation “MW” refers to molecular weight.
As used herein, the abbreviation “M W ” refers to weight average molecular weight.
As used herein, the abbreviation “M n ” refers to number-average molecular weight.
As used herein, the abbreviation “NMR” refers to nuclear magnetic resonance.
As used herein, the abbreviation “EA” refers to elementary analysis.
As used herein, the abbreviation “SEC-LS” refers to size-exclusion chromatography coupled to light-scattering detection.
As used herein, the abbreviation “IPA” refers to isopropanol or isopropyl alcohol.
As used herein, the abbreviation “AMPAHE” refers to 2,2′-azobis(2-methyl-N-(2-hydroxyethyl)-propionamide.
As used herein, the abbreviation “MCE” refers to 2-mercaptoethanol.
As used herein, the abbreviation “TBME” refers to tert-butyl methyl ether.
As used herein, the abbreviation “MIBK” refers to 4-methyl-2-pentanone.
As used herein, the abbreviation “THF” refers to tetrahydrofuran.
As used herein, the abbreviation “NaH” refers to sodium hydride.
As used herein, the abbreviation “LA” refers to D,L-lactide.
As used herein, the abbreviation “ATRP” refers to atom transfer radical polymerization.
As used herein, the abbreviation “DMF” refers to N,N-dimethylformamide.
As used herein, the abbreviation “TBA” refers to tert-butyl alcohol.
As used herein, the abbreviation “CAC” refers to critical association concentration.
As used herein, the abbreviation “DLS” refers to dynamic light scattering.
As used herein, the abbreviation “TGA” refers to thermogravimetry analysis.
As used herein, the abbreviation “CTA” refers to chain transfer agents.
As used herein, the abbreviation “PI” refers to polydispersity index.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 shows NMR data from example 1 ( 1 H NMR (CDCl 3 ), δ (ppm). The product of step 1 is dried until the solvent peak disappears in NMR.
FIG. 2 shows NMR data from example 2 ( 1 H NMR (CDCl 3 ), δ (ppm). The product of step 2 is dried until the solvent peak disappears in NMR.
FIG. 3 illustrates the synthesis of PVP-OH homopolymer (first polymerization) and PVP-b-PDLLA diblock copolymer (second polymerization).
FIG. 4 shows a spectrum resulting from MALDI-TOF spectrometry (example 8). MALDI-TOF analysis is useful for evaluation of the hydroxyl groups of PVP-OH.
FIGS. 5A-B show data evidencing the influence of the ratios of MCE ( FIG. 5A ) and IPA ( FIG. 5B ) to .VP on the M n of PVP-OH.
FIG. 6 shows a 1 H NMR spectrum of PVP-OH-2500 in CDCl 3 (example 6).
FIGS. 7A-B show 1 H NMR spectra of PVP-b-PDLLA (Diblock-47) in CDCl 3 ( FIG. 7A ) and in D 2 O ( FIG. 7B ).
FIG. 8 shows a thermogravimetric profile of PVP-b-PDLLA diblock copolymer (Diblock-47).
FIG. 9 shows the size distribution of micelles composed of PVP-b-PDLLA (Diblock-47) in water measured by DLS.
FIG. 10 shows data for determination of CAC of PVP-b-PDLLA (Diblock-47) in water at 25° C.
DETAILED DESCRIPTION OF THE INVENTION
The synthesis of the diblock and triblock copolymers is a two-step polymerization process.
The first step is a free radical polymerization of VP, carried out in an alcoholic solvent such as methanol, ethanol, isopropanol, n-propanol, n-butanol, 2-butanol, tert-butanol, 1-pentanol and 2-pentanol. Ideally, the boiling point of the solvent is in the vicinity of the cracking temperature of the radical initiator. Isopropanol (IPA) is a preferred solvent. The presence of a radical initiator is required. The radical initiator is selected from the group of azo derivatives comprising 2,2′-azobis(2-methyl-N-(2-hydroxyethyl)-propionamide) (AMPAHE), 2,2′-azobis{2-methyl-N-[2-(1-Hydroxybutyl)]propionamide and 1,1′-azobis(cyclohexane-carbonitrile). The preferred initiators are those having hydroxyl end groups, with 2,2′-azobis(2-methyl-N-(2-hydroxyethyl)-propionamide) (AMPAHE) being the most preferred. Thiol derivatives such as 2-mercaptoethanol, 3-mercapto-1-propanol, 3-mercapto-2-propanol, 4-mercapto-1-butanol, 3-mercapto-2-butanol and 6-mercapto-1-hexanol can be used as chain transfer agents. The preferred chain transfer agent is 2-mercaptoethanol (MCE). The molecular weight can be controlled by adjusting the molar ratios of MCE, AMPAHE and IPA to VP. The resulting first block homopolymer PVP can be evaluated using techniques such as MALDI-TOF, SEC-LS, EA and NMR. PVP-OH is isolated by precipitation of its solution to an inert organic solvent with poor solubility for the polymer. The solvent or combination of solvents for dissolution is selected from the group comprising methanol, ethanol, IPA, acetone, 2-butanone, 4-methyl-2-pentanone, dichloromethane and tetrahydrofuran. The preferred solvents for dissolution are isopropanol and 4-methyl-2-pentanone, the use of which are illustrated in the examples herein. The inert organic solvent for precipitation is selected from the group comprising diethyl ether, tert-butyl methyl ether, hexane derivatives, heptane derivatives, ethyl acetate, isopropyl acetate, toluene and xylene derivatives. The preferred solvent for precipitation is tert-butyl methyl ether, the use of which is illustrated in the examples herein.
For the preparation of PVP-OH (first step of the process), once all reagents and solvent are charged, the reaction mixture is degassed prior to heating. The reaction temperature ranges from 60-140° C. depending on the initiator and solvent chosen. In a preferred embodiment of the invention, a combination of IPA as solvent, AMPAHE as initiator and MCE as chain transfer agent is used and the reaction is carried out at reflux. The reaction time ranges from 16 hours to 72 hours depending on the solvent, initiator and chain transfer agent. In the above preferred combination, a typical reaction time is between 30-48 hours.
It is important to ensure the dryness of the PVP-OH in order to succeed with the anionic ring opening polymerization in the next step. The drying of the polymer is performed using a vacuum oven with the temperature ramping towards 110° C. Alternatively, further drying can be optionally performed using azeotropic distillation with an inert solvent such as toluene, xylene derivatives or heptane derivatives prior to the second polymerization.
The second step is based on an anionic polymerization of cyclic ester, other cyclic lactone, methacrylate, or methacrylamide. This polymerization can be anionic via a macroinitiator or it can be catalyzed by aluminum or tin alkoxides. The macroinitiator is a metal PVP-hydroxylate obtained from the deprotonation of the terminal hydroxyl group with a metal hydride reagent such as sodium hydride or potassium hydride. The resulting second block is poly(ester) wherein the repeating unit is a lactide, ε-caprolactone, γ-caprolactone or other cyclic ester. The resulting second block also can be poly(amino acid), polymethacrylate, polymethacrylamide or their copolymers. The blocks of homopolymers are linked chemically by a covalent bond. The chemical linker between block homopolymers is a hydroxy derivative emerging from the radical initiator or chain transfer agent or an alcoholic solvent. An inert anhydrous aprotic solvent or combination of solvents such as tetrahydrofuran, toluene, diethyl ether, tert-butyl methyl ether can be used for the reaction, with tetrahydrofuran being preferred. The reaction temperature ranges from room temperature to about 70° C. with preferred temperature being 20-25° C. Upon completion of the reaction as evidenced by 1 H NMR (solvent peak disappears), the reaction mixture is filtered and the block copolymer is isolated from the filtrate by precipitation into an inert organic solvent which has poor solubility for the polymer. Similar solvent systems as for the precipitation of PVP-OH are used, with tert-butyl methyl ether being the most preferred solvent. Optionally, any color of PVP block copolymers can be removed by charcoal treatment and a white to off-white powder of the product is obtained.
The invention is further illustrated by the following non-limiting examples.
EXAMPLE 1
Preparation of poly(N-vinyl-2-pyrrolidone) with a Hydroxyl-Bearing Chain End (PVP-OH)
VP (200 g, 1.8 mol), AMPAHE (5.2 g, 0.018 mol) and MCE (5.0 mL, 0.072 mol) were dissolved in 3000 mL of IPA. The solution was degassed by nitrogen purge for 1 hour. The radical polymerization was carried out at reflux (about 89° C.) with stirring under a dry nitrogen atmosphere for 44 hours. Then, after cooling to room temperature, most IPA was removed under reduced pressure and 400 mL of MIBK were added. Afterwards, the polymer was slowly precipitated into 5000 mL of TBME. The suspension was filtered. The filter cake was washed twice with 200 mL of TBME. The white powder thus obtained was purified by solubilization in 400 mL of MIBK and 100 mL of IPA and re-precipitation from 5000 mL of TBME. Finally, the product was dried under vacuum (starting at room temperature then at 110° C., 1 torr) until disappearance of the solvent peak by NMR ( FIG. 1 ). The PVP-OH was obtained as a white powder: 122 g. M n : 2060, M w : 2600, M w /M n : 1.3.
The instant inventors performed similar preparations of PVP-OH varying the different parameters such as the ratio of solvent/VP and the molar percentage of AMPAHE and MCE. Table 1 demonstrates that the molecular weight (M w ) and number-average molecular weight (M n ) of PVP-OH can be tuned effectively. The results showed also that the polydispersity index (M w /M n ) is generally lower when MCE is present. Lower M w and M n are obtained when the solvent/VP ratio is higher.
TABLE 1
Characterization of PVP-OH prepared under various conditions
AMPAHE
MCE
IPA/VP
M n
M w
Entry
VP (g)
(% mol)
(% mol)
(volume ratio)
(gmol −1 )
(gmol −1 )
M w /M n
1
5
1.0
¾
10
10290
21300
2.1
2
5
1.0
¾
15
6760
15820
2.3
3
5
1.0
¾
20
6300
12460
2.0
4
20
0.5
1.0
10
5100
11600
2.3
5
50
1.0
2.0
12
4000
6220
1.6
6
50
1.0
2.0
16
2510
3470
1.4
7
15
1.0
4.0
12
3230
4520
1.4
8
200
1.0
4.0
15
2060
2600
1.3
9
50
1.0
4.0
16
2170
3190
1.5
EXAMPLE 2
Preparation of Diblock Copolymer poly(N-vinyl-2-pyrrolidone)-block-poly(DL-lactide) (PVP-PDLLA)
PVP-OH (100 g, 48.5 mmol, Mn=2060) was dissolved in 600 mL of anhydrous THF and sodium hydride 60 wt. % in mineral oil (3.0 g, 75 mmol) was added. The mixture was stirred for 30 minutes at room temperature and LA (125 g, 125% w/w) was then added. The anionic polymerization was carried out at room temperature with stirring under dry nitrogen atmosphere for 26 hours. Excess of sodium hydride was removed by filtration. The volume of filtrate was adjusted to 900 mL by addition of THF. Afterwards, the polymer solution was slowly precipitated into 4500 mL of TBME. The suspension was filtered. The filter cake was washed twice with 100 mL of TBME. The slightly yellow powder so obtained was purified by solubilization in 1215 mL of THF and 40.5 g of charcoal was added. The black suspension was stirred for 16 hours at room temperature then filtered over celite. The polymer was precipitated in 6000 mL of TBME. The suspension was filtered. The filter cake was washed twice with 100 mL of TBME and finally dried under vacuum until disappearance of the solvent peak by NMR ( FIG. 2 ). The PVP-PDDLA was obtained as a white to off-white powder: 62 g. M n : 3140, M w : 3445, M w /M n : 1.1.
Empirical equations (Equation 1) and (Equation 2) were created to evaluate the molar percent PDLLA content by proton NMR and by Elemental Analysis, respectively.
Equation 1: Determination of PDLLA (% mol) Content by Proton NMR
PLA ( % mol ) = I 5.2 ppm [ ( I 4.5 - 0.8 ppm ) - 3 × I 5.2 ppm 9 H ] + I 5.2 ppm × 100 ( 1 )
Where I 5.2 ppm represents the integration of the signal at 5.2 ppm which corresponds to the tertiary proton on C-10. I 4.5-0.8 PPM represents the integration of the signals of the protons of the PVP-OH. The contribution of the linker is omitted.
Equation 2: Determination of PDLLA (% mol) Content by Elemental Analysis (EA)
PLA ( % mol ) = 7 C - 36 N 7 C - 18 N × 100 ( 2 )
The block compositions of PVP and PDLLA correspond to the repeating unit of C 6 H 9 NO and C 3 H 4 O 2 , respectively. The PDLLA content (% mol) can be determined using equation (2) and based on the content of (c) and (N) atoms determined by EA.
Table 2 demonstrates the reproducibility of the molar percent PDLLA contents as well as the narrow polydispersity using the process.
TABLE 2 Preparation of PVP-PDLLA diblock copolymers according to Example 2. M n PVP-OH M n M w M w / PDLLA PDLLA used SEC SEC M n contents A contents B Entry (gmol −1 ) (gmol −1 ) (gmol −1 ) SEC (% mol) (% mol) 1 2060 3140 3445 1.1 38 48 2 1850 3350 3690 1.1 38 48 3 2220 3680 4050 1.1 37 48 A from equation 1, 1 H-NMR B from equation 2, EA ratio
Table 3 demonstrates that the molar contents of PDLLA in the diblock copolymer are influenced by the weight ration of Lactide/PVP-OH charged to the reaction. A desired PDLLA % content can be predictably obtained.
TABLE 3
Characterization of PVP-PDLLA diblock copolymers.
Lactide
M n PVP-OH
M n
M w
PDLLA
PDLLA
used
used
SEC
SEC
M w /M n
contents A
contents B
Entry
(% w/w)
(gmol −1 )
(gmol −1 )
(gmol −1 )
SEC
(% mol)
(% mol)
1
90
2180
3145
4040
1.3
27
38
2
110
2165
3380
3720
1.1
35
42
3
125
2220
3680
4050
1.1
37
48
A from equation 1, 1 H-NMR
B from equation 2, EA ratio
EXAMPLE 3
Synthesis of poly(N-vinylpyrrolidone) with a Hydroxyl-Bearing Chain End (PVP-OH)
As shown in FIG. 3 , PVP-OH was synthesized by free radical polymerization of VP. VP (30 g, 270 mmol), AMPAHE (0.7783 g, 2.7 mmol) and MCE (0.844 g, 10.8 mmol) were dissolved in 540 mL of IPA. The solution was degassed with argon for 15 minutes. The polymerization was carried out at 85° C. for 24 hours. Then, most of IPA was removed under reduced pressure. Afterwards, the polymer was precipitated in about 300 mL of diethyl ether. The polymer was dissolved in 60 mL of methylene chloride, and precipitated again in 300 mL of diethyl ether. Finally, the product (white powder) was transferred into a Whatman cellulose extraction thimble, and purified by diethyl ether Soxhlet extraction for 24 hours. The polymer was dried at 80° C. under vacuum overnight.
EXAMPLE 4
Synthesis of Diblock Copolymer poly(N-vinylpyrrolidone)-block-poly(D,L-lactide)
As illustrated in FIG. 3 , PVP-b-PDLLA was synthesized by anionic polymerization of LA using PVP-OH as macroinitiator. PVP-OH M n : 2500 (15 g, 5.77 mmol) was dissolved in 250 mL toluene. Using a Dean-Stark trap, all products were dried with toluene as azeotropic solvent. Toluene was then removed by distillation under reduced pressure. The polymer was dried under vacuum over P 2 O 5 at 150° C. for 4 hours. After cooling down to room temperature, potassium hydride (KH, 0.346 mg, 8.65 mmol) in mineral oil was added into the flask under argon atmosphere. The flask was placed under vacuum again for 30 minutes. A volume of 75 mL freshly distilled and anhydrous THF was added to dissolve the mixture. After the polymer was dissolved, the solution was stirred for 10 minutes. LA (30 g, 20.8 mmol) and 18-crown-6 (2.29 mg, 8.65 mmol), both previously dried under vacuum at 80° C. for 4 hours, were placed in a flask and then, dissolved with a volume of 150 mL of anhydrous THF. The solution was transferred into the alcoholate solution under argon atmosphere, and stirred. The polymerization was carried out at 60° C. for 18 hours. PVP-b-PDLLA was precipitated in 1.2 L of cold diethyl ether. The polymer was collected and dried under vacuum at room temperature. PVP-b-PDLLA (20 g) was dissolved in 100 mL of DMF. 100 mL of deionized water was added to the polymer solution for micellization. The micelle solution was placed in dialysis bag (Spectrum, MW cutoff: 3500) and dialyzed against water (8 L) at 4° C. for 24 hours. Water was changed at least 4 times over that period. The aqueous solution was centrifuged at 11600 g at 4° C. for 30 minutes, and then filtered through a 0.2-hum filter. The filtered solution was collected and freeze-dried during 48 hours. The diblock copolymer was stored at −80° C. to avoid degradation.
EXAMPLE 5
Size-Exclusion Chromatography
The SEC analysis was carried out on a Breeze Waters system using refractometer Waters 2410 (Milford, Mass.) and light-scattering (LS) detector Precision Detectors PD2000 (Bellingham, Mass.). LS data were collected at 15 and 90°. SEC was performed in DMF containing 10 MM LiBr. 200 μL of solution (about 3% w/v) was injected through a series of 3 columns Styragel® Waters HT2, HT3 and HT4 at a flow rate of 1.0 mL/min, in order to separate MW ranging from 10 2 to 10 6 . The temperature of columns (separation) was maintained at 40° C., while the temperature of refractometer/LS detectors was set at 35° C. The instrument was calibrated with monodisperse polystyrene standards.
EXAMPLE 6
Nuclear Magnetic Resonance
1 H- and 13 C-NMR spectra were recorded on Varian 300 and Bruker AMX 600 spectrometers (Milton, Ontario) in CDCl 3 at 25° C. The PDLLA content (% mol) was determined using equation 1 (as noted in Example 2). Where I 5.2 ppm represents to signal intensity at 5.2 ppm, and corresponds to the tertiary proton (α-position of carbonyl group). This signal was normalized to 1. 1 H-NMR was also performed in deuteriated water (D 2 O) at 25° C. to evidence the presence of self-assembled micelle.
EXAMPLE 7
Elementary Analysis
EA was carried out in an oxidative atmosphere at 1021° C. Using a thermal conductivity probe, the amount of nitrogen oxide, carbonic acid, sulfur oxide (NO 2 , SO 2 and CO 2 ) and water were quantified and provided the amount of nitrogen (N), carbon (C), hydrogen (H) and sulfur (S) atoms into the sample. The block compositions of PVP and PDLLA correspond to the repeating unit of C 6 H 9 NO and C 3 H 4 O 2 , respectively. The PDLLA content (% mol) was determined using equation 2 (as noted in Example 2) and based on the content of (C) and (N) atoms.
EXAMPLE 8
MALDI-TOF Spectrometry for Analysis of PVP
MALDI-TOF mass spectra were obtained with a Micromass TofSpec-2E mass spectrometer (Manchester, UK). The instrument was operated in positive ion reflectron mode with an accelerating potential of +20 kV. Spectra were acquired by averaging at least 100 laser shots. Dithranol was used as a matrix and chloroform as a solvent. Sodium iodide was dissolved in methanol and used as the ionizing agent. Samples were prepared by mixing 20 μL of polymer solution (6-8 mg/mL) with 20 μL of matrix solution (10 mg/mL) and 10 μL of a solution of ionizing agent (2 mg/mL). Then 1 mL of these mixtures was deposited on a target plate and the solvent was removed in a stream of nitrogen. An external multipoint calibration was performed by using bradykinin (1060.2 g/mol), angiotensin (1265.5 g/mol), substance P (1347.6 g/mol), renin substrate tetradecapeptide (1759.0 g/mol), and insulin (5733.5 g/mol) as standards.
EXAMPLE 9
Viscosity-Average Molecular Weight (M v ) Determination of PVP
The limiting viscosity number “K-value” (or Fikentscher K-value) of homopolymer PVP-OH was determined in accordance with BASF protocol (US Pharmacopoeia) using Ubbelohde viscometer Type 1a. With the K-value, M v , is directly obtained from the following equation: M v =22.22(K+0.075K 2 ) 1.69 .
EXAMPLE 10
Critical Association Concentration (CAC)
CAC was measured by the steady-state pyrene fluorescence method (Benahmed et al. Pharm. Res. 18:323-328 2001). The procedure is described briefly as follows. Several polymeric solutions in water containing 10 −7 M of pyrene were prepared and stirred overnight in the dark at 4° C. Steady-state fluorescent spectra were measured (λ ex ,=390 nm) after 5 minutes under stirring at 20° C. using a Series 2 Aminco Bowman fluorimeter (Spectronic Instruments Inc., Rochester, N.Y.). Experiments were run in duplicate.
EXAMPLE 11
Dynamic Light-Scattering (DLS)
DLS was used for the determination of particle size in water. For this analysis, a series of aqueous solutions of PVP-b-PDLLA with concentrations of 0.5, 1 and 2 mg/mL was prepared by dissolving the polymer directly in water. The solutions were analyzed with a Malvern instrument Autosizer 4700 (Mississauga, Ontario). Each measurement was carried out in triplicata at 25° C. at an angle of 90° C. The size distribution of particles and the intensity mean size were recorded.
EXAMPLE 12
Thermogravimetry Analysis (TGA)
TGA measurements were collected on a TA Instrument Hi-Res TGA 2950 Thermogravimetric Analyser (New Castle, Del.).
About 1 mg of polymer was used for the experiments. Temperature ramp was 20° C./minutes between room temperature and 700° C. The residual amount of water was quantified after freeze-drying. PDLLA and PVP contents (% w/w) in diblock copolymer were also analyzed.
Experimental Results from Examples
Mercapto compounds are good chain transfer agents capable of functionalizing chain ends and controlling indirectly polymer molecular weight (Ranucci et al. Macromol. Chem. Phys. 196:763-774 1995; Ranucci et al. Macromol. Chem. Phys. 201:1219-1225 2000; Sanner et al. Proceedings of the International Symposium on Povidone; University of Kentucky: Lexington, Ky., page 20, 1983). A Hydroxyl group can be introduced at the end of polymer chains by using MCE as CTA in free radical polymerization of vinyl monomers. However, it was reported that when VP was radically polymerized in the presence of mercapto derivatives, only a small fraction of functionalized short oligomers was obtained. Moreover, a large amount of high MW polymers without terminal functionality was found in the product. This was due to the high transfer constant of thiol to VP (Ranucci et al. Macromol. Chem. Phys. 196:763-774 1995; Ranucci et al. Macromol. Chem. Phys. 201:1219-1225 2000). In the free radical polymerization of VP, radicals can transfer to solvent and possibly to a monomer. Hence, functionalized PVP had been synthesized using particular solvents (i.e. isopropoxyethanol). However, the functionality of PVP was not under control quantitatively (Ranucci et al. Macromol. Chem. Phys. 196:763-774 1995; Ranucci et al. Macromol. Chem. Phys. 201:1219-1225 2000). In order to get quantitative hydroxyl-terminal PVP homopolymers and also to control their molecular weight profile, IPA, MCE and a hydroxyl-bearing azo initiator (AMPAHE) have been all combined in the instant invention for the radical polymerization of VP (see FIG. 3 ).
As shown in FIG. 4 , MALDI-TOF spectrometry showed that the majority of PVP chains (>95%) bore a hydroxyl group at one chain end of PVP. FIG. 4 shows a MALDI-TOF spectrum of PVP-OH-2500. Most chains featured a 2-hydroxyisopropyl group at the end, meaning that the solvent was the main specie initiating polymer growth. Using diluted conditions of polymerization, MALDI-TOF data suggests that no significant termination by bimolecular combination occurred during the reaction, because the mass of chain end was only that of IPA plus the sodium ion (59 IPA +23 NA +=82, at n equals 0 in the linear equation). Two other distributions were also observed, which were attributed to PVP bearing MCE and VP as chain end, respectively. These distributions were only significant at low values of m/z (<1000 g mol −1 ) and represented less than 5% of the spectrum, related to MCE- and VP-terminated chains. Since MCE is more efficient as a chain transfer agent than IPA, all the MCE were consumed early in the reaction. Previous syntheses of PVP in THF (instead of IPA) using MCE have shown that radicals may also transfer directly to monomers (Ranucci et al. Macromol. Chem. Phys. 196:763-774 1995; Ranucci et al. Macromol. Chem. Phys. 201:1219-1225 2000). In consequence, by combining MCE and IPA as CTA, the synthesis of low MW PVP could be achieved with the quantitative insertion of hydroxyl group on one chain end.
The molecular weights of PVP-OH were determined by SEC and viscometry (Table 4). Polydispersity indexes (PI) of about 1.5 indicated that radial transfers prevailed over bimolecular combination, being consistent with MALDI-TOF data. Results from SEC and viscometry were in good agreement. M v might be slightly overestimated because the universal equation established by BASF referred to a wide range of PVP MW (10 3 to 10 6 ). Mark-Houwink constants (K and α) of low MW polymers differ from those having very high MW, which may explain this overestimation. Analysis of PVP-OH by EA revealed that the weight ratios of N/C atoms in all PVP-OH were similar to the theoretical number (0.194).
TABLE 4
Characterization of hydroxyl-terminated PVP homopolymers.
M n
M w
M v
SEC
SEC
M w /M n
Viscometer
N/C
Polymers
(g mol −1 )
(g mol −1 )
SEC
(g mol −1 )
EA
PVP-OH-2300
2300
3600
1.56
5400
0.192
PVP-OH-2500
2500
4000
1.60
5500
0.190
PVP-OH-4000
4000
7400
1.85
9000
0.193
PVP-OH-6100
6100
9600
1.57
11100
0.197
Molecular weight profile of PVP-OH was controlled by changing ratios of both MCE (the CTA) and IPA, to VP monomer. As expected, the molecular weights of PVP-OH decreased when either CTA/VP or IPA/VP ratios increased ( FIGS. 5A-B ). In FIG. 5A the ratios of IPA/VP are fixed at (▪) 18 mL/g and (●) 15 mL/g. In FIG. 5B the ratio of MCE/VP is fixed at (▴) 2.5%.
The 1 H NMR spectrum of PVP-OH-2500 in CDCl 3 is shown in FIG. 6 . The chemical shifts of the methylene groups of MCE are 2.7 and 3.8 ppm. When MCE was introduced at the end of the PVP-OH chains by forming S—C bond instead of S—H bond, the peaks of one methylene group appear at 2.7 and 2.75 ppm instead of 2.7 ppm, and the signal located around 3.8 ppm is overlapped with the peaks of PVP-OH in the spectrum. Signals between 1.1 and 1.3 ppm are assigned to the methyl protons of the 2-hydroxyisopropyl group (IPA fragment). These results suggest that PVP radicals transferred to both MCE and IPA, and this is in agreement with the results obtained from MALDI-TOF spectrometry.
Potassium hydroxylate derivatives are widely used for anionic ring-opening polymerization of LA (Nagasaki et al. Macromolecules 31:1473-1479 1998; Iijima et al. Macromolecules 32:1140-1146 1999; Yasugi et al. Macromolecules 32:8024-8032 1999). In the instant invention, the reaction between the OH group at the chain end of PVP-OH and potassium hydride produced potassium PVP-hydroxylate as macroinitiator for the polymerization of LA. Water and alcohol molecules in the reaction system may initiate the formation of free PDLLA homopolymer. Since there are strong hydrogen bonds between PVP and water as well as alcohol, residues of these protic solvents, which interact with the polymer are difficult to remove (Haaf et al. Polymer J. 17:143-152 1985). In the present case, low MW PVP-OH were synthesized in IPA. Therefore, traces of IPA and water molecules might be contained in the polymer. Two drying steps were required for solvent removal. Briefly, at first, PVP-OH was dissolved in toluene and then, an azeotropic distillation was made. Then, the polymer was dried under vacuum at 150° C. over P 2 O 5 for 4 hours. The polymer was actually molten under these conditions, and resulted in a highly dried material.
Molecular weight and PI of PVP-b-PDLLA were determined by SEC using light-scattering and a differential refractometer as detectors (Table 5). As expected, PVP-b-PDLLA MWs were larger than that of corresponding PVP-OH, while PI decreased. Anionic polymerization leads to very small PI {Nagasaki et al. Macromolecules 31:1473-1479 1998; Iijima et al. Macromolecules 32:1140-1146 1999; Yasugi et al. Macromolecules 32:8024-8032 1999). Therefore, the second polymerization step might decrease the PI of the diblock copolymer, suggesting that resulting materials were diblock copolymers and not a mixture of homopolymers. Another plausible explanation of lower PI was that PVP-b-PDLLA having shortest PVP chains were removed by the precipitation in diethyl ether.
The PDLLA contents (% mol) in the diblock copolymers was determined by 1 H-NMR, EA and SEC. A 1 H-NMR spectrum of PVP-b-PDLLA (Diblock-47) copolymer in CDCl 3 is shown in FIG. 7A . The peak at 5.2 ppm corresponds to the —CH— group of PDLLA. Signals from 0.8 ppm to 4.5 ppm were assigned to all protons associated to PVP segment, which overlap the peak of PDLLA methyl group (1.4 ppm). PDLLA content was calculated using equation 1, and results are presented in Table 5. Since traces of water in PVP-b-PDLLA copolymers slightly overestimated the integration of PVP signals, EA was performed and the amount of nitrogen and carbon atoms were used for the calculation of PDLLA content using equation 2. As shown in equation 2 hydrogen atoms of moisture, even from the polymer, are not taken in account into the calculation of PDLLA content by EA. Contrary to 1 H-NMR analysis, EA results were quite constant and reproducible regardless of the moisture content. EA analysis turned out to be suitable for the quantification of PDLLA content into PVP-b-PDLLA. Actually, PDLLA content from NMR data was usually 6 to 8% less than that determined by EA. Although SEC resulted in higher PDLLA contents (about 5%) than EA, the consistence between EA, SEC and NMR were quite good (Table 5).
TABLE 5
Characterization of PVP-b-PDLLA diblock copolymers.
M n
M w
PDLLA
PDLLA
PVP-b-
PVP-OH
SEC
SEC
M w /M n
N M R B
PDLLA
SEC D
PDLLA A
used
(g mol −1 )
(g mol −1 )
SEC
% mol
EA C % mol
% mol
Diblock-47
PVP-OH-
4380
5000
1.14
38
47
54
2500
Diblock-35
PVP-OH-
3840
5030
1.30
27
35
45
2500
Diblock-37
PVP-OH-
8290
10360
1.39
32
37
36
6100
Diblock-39
PVP-OH-
6070
8960
1.48
34
39
44
4000
Diblock-45
PVP-OH-
3770
4860
1.29
37
45
50
2300
A labeling based on PDLLA content into PVP-b-PDLLA diblock copolymers, obtained from EA.
B from equation 1
C from equation 2
D from the M n of PVP-OH and its corresponding PVP-b-PDLLA
Thermogravimetry (TGA) was also a good method for characterizing the diblock copolymer (Liggins et al. Adv. Drug Deliv. Rev. 54:191-202 2002). As shown in FIG. 8 , the trace of solvents (less than 4%) in the diblock polymer was removed below 100° C. FIG. 8 shows a thermogravimetric profile of PVP-b-PDLLA diblock copolymers (Diblock-47). PDLLA in the diblock copolymer was then degraded between 200 to 350° C., followed by the degradation of PVP from 350 to 480° C. Hence, the PDLLA content could also be determined by TGA. For instance, TGA of diblock-45 revealed a PDLLA content of 48% mol, which was in good agreement with EA results.
Because of their amphiphilic properties, the well-defined PVP-b-PDLLA diblock copolymers can self-assemble in aqueous solution to form micelles. The size of micelles was measured by DLS at different concentrations. As shown in FIG. 9 , micelles composed of PVP-b-PDLLA (Diblock-47) in water at a concentration of 2 mg/mL feature a single narrow size distribution of about 40 nm. FIG. 9 shows size distribution of micelles composed of PVP-b-PDLLA (Diblock-47) in water measured by DLS. Upon dilution towards 0.5 mg/mL, no change in the size of micelles was observed. The results indicate that there is no micelle aggregation in the solutions. In contrast, Benahmed et al. (C. Pharm. Res. 18:323-328 2001) reported bimodal size distributions for PVP-b-PDLLA micelles. It has been suggested that the larger population reflects the aggregation of small individual micelles, governed by a secondary order of aggregation. The plausible explanation of the difference is that the molecular weights, PDLLA contents and polydispersity indices reported in Benahmed et al. were higher than the polymers described in the instant application.
Steady-state fluorescence, using pyrene as hydrophobic fluorescence probe, is well used as technique to show the formation of micelles (Zhao et al. Macromolecules 30:7143-7150 1997; Kabanov et al. Macromolecules 28:2303-2314 1995; Wilhelm et al. Macromolecules 24:1033-1040 1991). The polarity of the surrounding environment of the probe molecules affects some vibrational bands in the fluorescence emission spectrum. The changes in the relative intensity of the first and the third vibrational bands (I 338 /I 333 ), which is due to the shift of the (0,0) band from 333 to 338 nm in the emission spectrum have been suggested to examine the polarity of the microenvironment. The CAC of micelles can be determined by this method. After micellar formation, pyrene partitions into the micellar phase and the water phase. Since the core of the micelle is hydrophobic, the intensity ratio of I 338 /I 333 is changed. The extrapolation of tangent of the major change in the slope of the fluorescence intensity ratio leads to CAC. As illustrated in FIG. 10 , PVP-b-PDLLA copolymers exhibited a CAC of about 6 mg/L. FIG. 10 shows the determination of CAC of PVP-b-PDLLA (Diblock 47) in water at 25° C.
The micellization of PVP-b-PDLLA also can be assessed by 1 H-NMR in D 2 O (Benahmed et al. C. Pharma. Res. 18:323-328 2001; Yamamoto et al. J. Controlled Release 82:359-371 2002; Heald et al. Langmuir 18:3669-3675 2002). FIG. 7B shows an 1 H-NMR spectrum of PVP-b-PDLLA (Diblock-47) in D 2 O. As is shown in FIG. 7B , the peaks of the methyl protons (—CH 3 ) and the methine proton (CH—) of PDLLA are highly suppressed while the peaks of PVP still appear in the spectrum, providing evidences of the formation of core-shell structures. The mobility of PDLLA chains in the core is highly restricted, resulting in masking of the PDLLA signals. On the other hand, PVP chains are still observed by 1 H-NMR because of their high mobility as outer shell of micelles.
By combining MCE and IPA as chain transfer agents, PVP bearing one terminal hydroxyl group on one extremity was successfully synthesized by the first polymerization step of the process of the instant invention. PVP MWs were efficiently controlled by changing ratios of either MCE or IPA, to VP. Terminally functionalized low MW PVP were used to efficiently synthesize the PVP-b-PDLLA diblock copolymer by anionic ring-opening polymerization of D,L-lactide in the second polymerization step of the process of the instant invention. PVP-b-PDLLA self-assembled into micelles in water. These micelle-forming copolymers presented very low CAC of a few mg/L, leading to the formation of 40-nm polymeric micelles. These polymeric self-assemblies based on low molecular weight PVP blocks are useful as drug carriers for parenteral administration.
All patents and publications mentioned in this specification are indicative of the levels of those skilled in the art to which the instant invention pertains. All patents and publications are herein incorporated by reference to the same extent as if each individual patent and publication was specifically and individually indicated to be incorporated by reference.
It is to be understood that while a certain form of the invention is illustrated, it is not to be limited to the specific form or arrangement of parts herein described and shown. It will be apparent to those skilled in the art that various changes may be made without departing from the scope of the invention and the invention is not to be considered limited to what is shown and described in the specification.
One skilled in the art will readily appreciate that the present invention is well adapted to carry out the objects and obtain the ends and advantages mentioned, as well as those inherent therein. The methods, procedures and techniques described herein are presently representative of the preferred embodiments, are intended to be exemplary and are not intended as limitations on the scope. Changes therein and other uses will occur to those skilled in the art which are encompassed within the spirit of the invention and are defined by the scope of the appended claims. Although the invention has been described in connection with specific preferred embodiments, it should be understood that the invention as claimed should not be unduly limited to such specific embodiments. Indeed various modifications of the described modes for carrying out the invention which are obvious to those skilled in the art are intended to be within the scope of the following claims. | The instant invention provides a two-step polymerization process for preparing amphiphilic poly(N-vinyl-2-pyrrolidone), (PVP)-block-polyester copolymers and other diblock and triblock copolymers consisting of PVP as one block. The block copolymers of the invention can be used as vehicles for drug delivery. | 2 |
FIELD OF THE INVENTION
This invention relates to hydrogenation and more particularly, to the hydrogenation of organic nitrites into primary amines
BACKGROUND OF THE INVENTION
Hydrogenation of organic nitriles to primary amines, as aminomethyl groups, can be accomplished via the use of a Raney sponge nickel or cobalt aqueous slurry catalyst or precious metal catalysts. The nitrile and catalyst are charged into a stirred autoclave, oxygen is removed by reducing pressure or applying heat or both or by sparging with hydrogen or an inert gas, the autoclave is pressurized with hydrogen and heated to temperature. After completion of the reaction the primary amine is separated from the slurry catalyst by decantation or filtration. Fixed bed reactors have been used in an analogous way. Unfortunately, this process, without more, often produces undesirable quantities of secondary and tertiary amines, also known as "heavies." Attempts to reduce the amount of secondary and tertiary amines have generally involved the use of additives to the initial charge. For instance, when 25% nitrile in an ether solvent is hydrogenated in the presence of 5 to 15% water, catalyst and ammonia has been found to yield about 93% primary amine. Consider also, that when an aliphatic dinitrile is hydrogenated in the presence of water, 1 to about 100 wt. % ammonia based on nitrile and catalyst, that the heavies can be as low as 2.3% at maximal ammonia usage. In a different lab, a rhodium catalyst was used in conjunction with water, an alkali metal hydroxide and an immiscible organic solvent such as alkanes, aromatic or alicyclic hydrocarbons to hydrogenate an organic nitrile group. If hydrogen cyanide is not objected to, the cautious investigator may find it of interest that the hydrogenation of acetonitrile to ethylamine in basic aqueous solution may be carried out in its presence. Additionally, Raney cobalt, in combination with 0.5 to 4% water may be used to produce C4 to C12 amines.
Perhaps the prototypical prior art process for the hydrogenation of fatty acid nitrites is as follows: fatty acid nitrile is mixed with 1-2 wt. % water, 0.1 wt. % alkali metal hydroxide, Raney nickel catalyst, sparged with hydrogen to remove dissolved oxygen, and hydrogenated at 200 psi at 140° C. for 110 minutes to yield fatty amine at 78% yield.
In a prior art industrial (ca. 5 mt capacity) autoclave process to produce a primary amine, dimer diamine from an organic nitrile, dimer dinitrile, an autoclave was fed an approx. 4200 kg charge that ultimately comprised dimer dinitrile, about 0.8 wt. % water, about 0.1 wt. % sodium hydroxide (about 16% of catalyst) and about 2 to about 2.4 wt. % Raney nickel. The process comprised the following steps:
1) Charging the organic nitrile to an autoclave.
2) Removing oxygen from the organic nitrile, in this reactor, by heating the dimer nitrile under vacuum and breaking vacuum with an inert gas such as nitrogen.
3) Adding Raney catalyst slurry and aqueous alkali metal hydroxide, about 0.2 wt. % of about 50 wt% sodium hydroxide, under the inert gas blanket.
4) Drying the charge to less than about 0.1 wt. % moisture, in this reactor by pulling a vacuum of at least about 686 mmHg and heating to about 127° C.
5) Cooling the autoclave to below the boiling point of water, about 88° C.
6) Adding water, about 0.77 wt. %, to the charge.
7) Pressurizing with hydrogen, to about 200 to about 400 psi.
8) Heating the converter, to about 160° C.
9) Controlling the reaction exotherm that occurs by, for instance, restricting hydrogen feed and using cooling water.
10) Cooling the resulting amine when the reaction is complete
11) Separating the primary amine from the catalyst, by filtering or decanting, to obtain the desired primary amine product, which may then be optionally distilled.
Total amines yield is greater than 95%. The product specifications are a primary amine value of 185 minimum and a secondary plus tertiary amine value of 15 maximum. The dimer amine typically obtained contains 3-4% moisture and 5% secondary and tertiary amines, for a process yield of about 91% primary amine. The product typically has an amine value of about 191 and a secondary plus tertiary amine value of about 2.5 to 3.5% and a Gardner color of about 9.7.
Note here that water is being added to the initial charge from the sodium hydroxide solution and from the catalyst, as Raney nickel catalyst is shipped as a nickel sponge powder slurry in 50% water to avoid pyrophoric ignition. The water is present as a supernatant fluid which is decanted prior to adding catalyst to the charge. Variability in the settling and compaction of the catalyst leads to some uncertainty as to exactly how much water is being added to the charge, perhaps explaining the current industry practice to dry the charge, to get a consistent baseline, and then to add back a specific amount of water, so as to get repeatability in the process and product. While the percent variability in the water charge may not be high when the water content in the catalyst is low compared to the total added water desired, a high amount of water in the charge is not desirable when low-moisture content product is desired, such as when the product is intended for use in making polyurethanes.
SUMMARY OF THE INVENTION
An improved, optimized industrial process has been found for the hydrogenation of organic nitriles into primary amines, which essentially consists of contacting a dried charge of at least one organic nitrile, aqueous alkali metal hydroxide, at least one Raney slurry hydrogenation catalyst, water and hydrogen for an effective time and at an effective temperature and pressure, wherein the improvements comprise eliminating the steps of drying the charge and adding water and reducing the required water to about 0.2%. Secondary and tertiary amine formation is low, as is moisture content and neither precious metals such as rhodium, nor strategic metals, such as cobalt, nor ammonia gas, nor solvents are required. Surprisingly, it has been found that water levels less than that taught in the prior art are effective at suppressing secondary and tertiary amine production, while still producing repeatable product on an industrial scale and with reduced cycle time, energy and catalyst charge. In one embodiment of the invention, a prior art process for making primary amines from nitriles comprises the steps of charging an organic nitrile to an autoclave, removing oxygen from the organic nitrile, adding Raney catalyst slurry and aqueous alkali metal hydroxide under an inert gas blanket, drying the charge in the autoclave, adding water to the autoclave charge, pressurizing with hydrogen, heating the autoclave toward a final temperature, controlling the reaction exotherm that occurs as the organic nitrile is reduced to a primary amine, cooling the resulting primary amine when the reaction is complete and separating the amine from the catalyst to obtain the desired primary amine product, is improved by eliminating the steps of drying the charge in the autoclave and adding water to the autoclave charge.
In another embodiment, a prior art process for the hydrogenation of organic nitrites into primary amines, which consists of contacting at least one organic nitrile, about 0.1 part alkali metal hydroxide, at least one Raney hydrogenation catalyst, 1 to 2 wt. % water for 110 minutes reaction time at 140° C. and 200 psi hydrogen pressure is improved by decreasing the water to less than 0.6 wt. %, and preferably to between about 0.1 and 0.3 wt. %, and most preferably to about 0.2 wt. %.
DETAILED DESCRIPTION OF THE INVENTION
Based on actual tests, it has been found that repeatable primary amine products may be made on an industrial scale without the necessity of drying the charge to establish a baseline water content level. Unexpectedly, the use of water levels lower than those in general use allows for increased charge size per unit catalyst and reduced energy use while still maintaining acceptably low levels of secondary and tertiary amines.
The primary amines of the present invention have a multiplicity of uses ranging from epoxy and urethane curing agents to polyamide and textile antistat precursors.
The reactor charge of this invention has three major components (other than hydrogen). The first component is an organic nitrile the second component is a Raney hydrogenation catalyst and the third component is aqueous alkali metal hydroxide. The nature of these components will be addressed in turn below. Discussion of the reaction conditions, time, temperature and pressure, follows.
The Organic Nitrile
"Organic nitrile" is defined herein as an organic material containing at least one nitrile, also known as cyano, (--CN) group. The organic material may be an aliphatic-, aromatic-, cycloaliphatic-, heterocyclic-, heteroaliphatic-nitrile, such as alkylene oxides and amines and their cyanoethylated products and the like. Of course, the organic material may have more than one nitrile group, both amine and nitrile groups, and may also be unsaturated. Fatty dimer dinitriles, and unsaturated fatty dimer dinitriles are preferred starting materials, but others that may be used include: acrylonitrile, methacrylonitrile, propionitrile, benzonitrile, 2-methylglutaronitrile, isobutyronitrile, dicyanocyclooctane, nitrilotriacetonitrile, iso- and terephthalonitrile, 1,3,5-tricyanobenzene, o-, m-, or p-tolunitrile, o-, m-, or p-aminobenzonitrile, phthalonitrile, trimesonitrile, 1-naphthonitrile, 2-naphthonitrile, cyclobutanecarbonitrile, cyclopentanecarbonitrile, cyclohexanecarbonitrile, 1,4-cyclohexanedicarbonitrile, 1,2,4,5-cyclohexanetetracarbonitrile, cycloheptanecarbonitrile, 3-methylcycloheptanecarbonitrile, cyclooctanecarbonitrile, butyronitrile, valeronitrile, capronitrile, 2,2-dimethylpropanenitrile, enanthonitrile, caprylnitrile, pelargonitrile, decanenitrile, hendecanenitrile, lauronitrile, tridecanenitrile, myristonitrile, pentadecanenitrile, palmitonitrile, heptadecanenitrile, stearonitrile, phenylacetonitrile, malononitrile, succinonitrile, glutaronitrile, adiponitrile, 1,3,5-tricyanopentane, 4-methyl-3-hexenedinitrile, 4-ethyl-3-hexenedinitrile, 5-methyl-4-nonenedinitrile, 5-ethyl4-decenedinitrile, 7-methyl-6-tridecenedinitrile, 7-methyl -6-pentadecened initrile, 12-methyl-1 2-tetracosenedinitrile, 10-hexyl-9-tetracosenedinitrile, 2,3-dimethyl-3-hexenedi nitrile, 2,4,6-trimethyl-3-heptenedinitrile, 4-ethyl-6,7-dimethyl-3-octenedinitrile, 2,4,6-triethyl-3-octenedinitrile, 2-ethyl-4,6-dipropyl-3-octenedinitrile, 2-methyl-4,6,8, 10-tetrapropyl-3-dodecenedinitrile, 2,4,7,9,11,13,15-heptaethyl-6-hexadecenedinitrile, 3-methylenehexanedinitrile, 4-methyleneheptanedinitrile, 5-methylenenonanedinitrile, 6-methyleneundecanedinitrile, 7-methylenetridecanedinitrile, 8-methylenepentadecanedinitrile, 12-methylenetetracosanedinitrile, 15-methylenenonacosanedinitrile, 2-methyl-3-methylenepentanedinitrile, 2,4-dimethyl-3-methylenepentanedinitrile, 2-methyl-4-methyleneoctanedi nitrile, 2-methyl-7-ethyl-4-methyleneoctanedinitrile, 2,4, 8-tri methyl-6-methylenedodecanedinitrile 2,4,8,10-tetrapropyl-6-methylenedodecanedinitrile, 2,26-dimethyl-14-methyleneheptacosanedinitrile, aminoacetonitrile, hexamethylene-1,6-dinitrile, the cyanoethylated derivatives of methanol, ethanol, butanol, pentanol, and the like; from methyl amine, ethyl amine, butyl amine, octyl amine, ethylene glycol, propylene glycol, butylene glycol, propylene glycol, diethylene glycol, dipropylene glycol, hydroquinone, phloroglucinol, 1,4-cyclohexanediol, 1,4-di(hydroxymethyl)cyclohexane, polyethylene glycols, polypropylene glycols, polyoxyalkylene polyethers, polyester polyols, polyol adducts derived from ethylene and/or propylene oxide and methylenedianiline and polyethylene polyphenylamine mixtures, vinyl reinforced polyether polyols, e.g. polyols obtained by the polymerization of styrene or acrylonitrile in the presence of the polyether, polyacetals from glycols such as diethylene glycol and formaldehyde, polycarbonate polyols such as from butanediol and diaryl carbonates, resole polyols, hydroxy terminated polybutadiene resins, ethylene diamine, butylene diamine, polyamines such as primary amine terminated polyether resins and the like, compounds including C 12 H 25 CN, NC--(CH 2 ) 6 --CN, NC--(CH 2 ) 18 --CN, CH 3 CH 2 CH 2 -O-CH 2 CH 2 --CN, NC--CH 2 CH 2 CH 2 --O--CH 2 CH 2 --O--CH 2 CH 2 --CN NCCH 2 CH 2 OCH 2 CH 2 CH 2 OCH 2 CH 2 CN, NCCH 2 CH 2 OCH 2 CH(CH 3 )OCH 2 CH 2 CN, NCCH 2 CH 2 O(CH 2 ) 4 OCH 2 CH 2 CN, NCCH 2 CH 2 OCH 2 CH 2 CH(CH 3 )OCH 2 CH 2 CN, NCCH 2 CH 2 OCH(CH 3 )--! 2 , (CH 3 ) 2 C(OCH 2 CH 2 CN)CH 2 OCH 2 CH 2 CN, NCCH 2 CH 2 O(CH 2 ) 3 CH(CH 3 )OCH 2 CH 2 CN, NCCH 2 CH 2 O(CH 2 ) 5 OCH 2 CH 2 CN, NCCH 2 CH 2 O(CH 2 ) 6 OCH 2 CH 2 CN, NCCH 2 CH 2 O(CH 2 ) 10 OCH 2 CH 2 CN, NC--CH 2 CH 2 NH(CH 2 ) 12 NHCH 2 CH 2 --CN, and 3,3'-(ethylenedioxy)-dipropionitrile (NC--C 2 H 4 --O--C 2 H 4 --O--C 2 H 4 --CN) and mixtures thereof.
Particularly preferred starting organic nitrites are dimer di- and higher- nitrites, known as a class as "dimer dinitriles." They are made by converting dimer acids to nitrites, as is well known in the art, and their molecular weights, functionality, degree of unsaturation and other properties are determined by those of the dimer acids from which they are made. Dimerized fatty acids are also known as polymerized fatty acids, which include aliphatic dicarboxylic acids having from about 32-40 carbon atoms obtained by the polymerization of olefinically unsaturated monocarboxylic acids having from 16-20 carbon atoms, such as palmitoleic acid, oleic acid, linoleic acid, linolenic acid and the like. Polymeric fatty acids and processes for their production are well known. See, for example, U.S. Pat. Nos. 2,793,219 and 2,955,121, both incorporated herein by reference as if set forth in their entirety. Polymeric fatty acids particularly useful in the practice of this invention preferably will have as their principal component C-36 dimer acid. Such C-36 dicarboxylic acids are obtained by the dimerization of two moles of a C-18 unsaturated monocarboxylic acid, such as oleic acid or linoleic acid, or mixtures thereof, e.g., tall oil fatty acids. These products typically contain 75% by weight or more of C-36 dimer acid and have an acid value in the range of 180-215, saponification value in the range of 190-215 and neutral equivalent from 265-310. Examples of commercial dimer acids of this type are EMPOL® 1008, EMPOL® 1015, EMPOL® 1061, EMPOL® 1016, EMPOL® 1018, EMPOL® 1022 and EMPOL® 1024, all trademarked products of the Henkel Corporation. To increase the C-36 dimer content and reduce the amount of by-product acids, including unreacted monobasic acid, trimer and higher polymer acids, the polymeric fatty acid may be molecularly distilled or otherwise fractionated. VERSADYME 288 (TM Henkel Corp.) is a preferred distilled tall oil dimer acid precursor of the dimer dinitrile used as starting material in Examples 1-4 given below. Typical properties are an acid value of 193-201 and a composition that is about 2.55 wt. % monobasic, about 92.5-95.5 wt. % dibasic and about 1.5-3.5 wt. % poly (tri- and higher-) basic. It is substantially converted to a dinitrile, #513, prior to use. The dimer acids may be hydrogenated prior to conversion to dinitrile to reduce unsaturation and color. EMPOL® 1061, also known as VERSADYME 52, both trademarked products of the Henkel Corporation, is also used as a starting material to make the dimer dinitrile, #523, of Example 5, and it is a hydrogenated version of Versadyme 288 and it has an iodine value of about 20 maximum.
The Raney Hydrogenation Catalyst
The preferred catalysts are Raney nickel and cobalt slurry catalysts, with or without group VIB metal and manganese and iron promoters, with nickel being more preferred as it will work and is not an expensive, strategic metal like cobalt. These catalysts are generally made by preparing, for example, a 50-50 aluminum-nickel powder and then reacting that powder with aqueous sodium hydroxide solution to leach away most of the aluminum, leaving substantially nickel powder with very high surface area. The high surface area imparts catalytic activity, but it also renders the powder pyrophoric. Therefore, the powder is shipped under about 50% water for safety. Excess water is decanted off prior to use, but the powder cannot be dried prior to use because it would ignite. Hence, it is added to the charge while wet. The water content of the wet powder will vary according to how long the powder has had an opportunity to settle, how well it was drained and whether it got compacted ("tap" density) during handling. An estimate of water content based on the random packing of spheres might indicate about 35 vol. % water, while measurement taken from depth occupying a jar of A-5000 Sponge Nickel Catalyst indicates that 32 vol. % might be reasonable. The range for low porosity, well packed spheres of optimal diameter may be as low as about 20 vol %, while the maximum, is less than, 50 vol. % water, for which supernatant is always present, say 40 vol% water. The density of nickel is about 8.9 times that of water so 20 vol. % water would be about 2.7 wt. % water and 40 vol. % would be about 7 wt. % water and 35 vol. % water would be about 5.7 wt. % and 32 vol. % would be about 5 wt. % water. Therefore, a likely range in water content of the catalyst as added to the charge would be about 3 to about 7 wt. %, with about 5 wt. % most likely. The process of the prior art used about 2.0 wt. % to about 2.44 wt. % Raney catalyst, therefore about 0.06 to about 0.17 wt. %, and probably about 0.11 wt. % total water was added to the charge from this source, which was removed by the drying step. The improved process of the present invention may be done with about 15 wt. % less catalyst than the prior art if desired, and so about 1.7 to about 2.1 wt. % catalyst is used, contributing from about 0.05 to about 0.15 wt. % water, more probably about 0.10 wt. %, water to the charge.
The Alkali Metal Hydroxide
About 50 wt. % sodium hydroxide solution is preferred due to cost and availability, but 45 wt. % KOH solution may be used as well as aqueous lithium hydroxide. For industrial use, the aqueous form provides ease of meter, mix, dispense and to avoid needless exotherm from heat of mixing. When 50 wt. % sodium hydroxide is used, it is used at about 8% of the catalyst weight. Therefore, the amount of water introduced by the sodium hydroxide solution will vary from about 0.07 wt. % (0.017×0.5×0.08×100) to about 0.10 wt. % (0.0244×0.5×0.08×100) of the charge. Therefore, the water introduced to the charge by the catalyst and aqueous hydroxide combined will range from about 0.1 wt. % to about 0.3 wt. %, and most likely be about 0.2%. This compares to about 0.8% for the prior art industrial process.
The reaction conditions of this invention, time, temperature and pressure, are to a large extent interchangeable, as will be recognized by the skilled practitioner. Shorter reaction times may be had at higher temperatures, as is understood through the Arrhenius relationship, but individual characteristics of reactors, like materials and strength of construction, Watts of heat available for the mass of the charge, thermal insulation losses, temperature control to reduce reaction rate and the like all contribute to practical decisions of what temperature is desirable. These equivalencies should be kept in mind when considering the preferred reaction conditions presented below, which are used in the bench experiments to simulate an existing unique industrial scale autoclave reactor, as opposed to being a search for greenfield optimal conditions.
The Temperature
The temperature should be at least about 150°0C., but about 160° C. is preferred and the temperature can go to about 220° C., if the equipment allows. Note that it is sometimes desirable to increase the hydrogen pressure prior to reaching final temperature, say from about 300 psi to about 400 psi at about 121° C.
The Hydrogen Pressure
The hydrogen pressure should be at least about 250 psi, but about 300 psi is more preferred and about 400 psi is most preferred and the pressure can go to as high as the equipment allows, which for some autoclaves is as high as about 2500 psi.
The Reaction Time The reaction time should be at least 2 hours to get meaningful conversion, but 3 hours is more preferred for product with acceptable amine values and about 4 hours is most preferred.
Examples 1 and 2 are an attempt to simulate the industrial autoclave prior art process on a laboratory scale. The process involves charging the reagents, drying them under vacuum, cooling the mixture, back adding water and finishing the reaction. Example 3 introduces the elimination of the drying and water addition steps. Example 4 is a comparison of the improved process to the prior art process on an industrial (1000 kg) scale as opposed to the lab (kg) scale of Examples 1, 2 and 3, to make sure that the reaction would work on a large scale. Example 5 uses partially pre-hydrogenated dimer dinitrile as a starting material.
The following examples will serve to further illustrate the invention, but should not be construed to limit the invention, unless expressly set forth in the appended claims. The reactants and other specific ingredients are presented as being typical, and various modifications can be derived in view of the foregoing disclosure within the scope of the invention. All parts, percentages, and ratios are by weight unless otherwise indicated in context.
EXAMPLES
Example 1
In order to simulate the aforementioned prior art autoclave process for possible cycle time improvements, a reaction was run based on that procedure. The equipment used was a 500 ml. 3-neck flask equipped with a mechanized stirrer, Claissen head with vacuum take off, heating mantel, pot thermometer. The reagents used were 300.22 g (300 g theoretical) dimer dinitrile #513, 7.50 g (7.33 g theoretical) A-5000 Sponge Nickel Catalyst (Activated Metals & Chemicals, Inc., Seiverville, Tenn.), 0.67 g (0.59 g theoretical) sodium hydroxide 50% in H 2 O and 2.3 g (2.2 g theoretical) water. The nitrile, catalyst, and caustic solution were charged to the flask.
______________________________________Time Pot Temp (°C.) Vacuum ("Hg)______________________________________ 9:15 22 -- Heat, Stirrer, Vacuum on 9:30 57 24.5 9:45 89 25.010:35 130 25.510:50 130 25.5 Heat off12:45 35______________________________________
The material was transferred to a 600 ml. Parr Autoclave, the water added, and the hydrogenation run.
______________________________________Time Temp. (°C.) Press. (psi H.sub.2)______________________________________1:05 36 -- Stirrer → Heat on1:10 102 → 400 PSI1:20 177 50 → 4001:30 167 70 → 4001:45 159 150 → 4002:00 160 100 → 4002:15 160 100 → 4002:30 160 180 → 4002:45 159 160 → 4003:00 160 200 → 4003:15 160 200 → 4003:40 160 250 Cooling on, Heat off______________________________________
After cooling the mixture was filtered through Perlite 476 (made by Grefco); 271 .1 g was recovered. Analysis of the product showed 80% primary amine and 20% nitrile, no secondary or tertiary amines were seen with C-13→APT NMR (nuclear magnetic resonance) and confirmed by IR (infrared spectrophotometry). Based on these results, the reaction was repeated, see Example 2 below, to get a higher conversion by hydrogenating the organic nitrile longer than the 2 hours and 20 minutes used in this example.
Example 2
Since there was still ca. 20% nitrile remaining in the product of Example 1, the test was repeated for a longer time. The equipment used was the same as used in Example 1 except a magnetic stirrer was used in place of the mechanical stirrer. The reagents used were 300.1 g dimer dinitrile #513, 7.8 g A-5000 Sponge Nickel Catalyst, 0.8 g sodium hydroxide 50% in H 2 O and 2.2 g distilled water. The nitrile, catalyst, and sodium hydroxide solution were charged to the flask.
______________________________________Time Pot. Temp (°C.) Vacuum ("Hg)______________________________________9:00 19 -- Heat and Vacuum on9:15 51 269:30 73 269:50 104 2610:10 135 26 Heat off10:30 100 26 Vacuum off.______________________________________
The material was transferred to a 600 ml. autoclave, the water was added and the mixture was hydrogenated.
______________________________________Time Temp. (°C.) Press. (psi H.sub.2)______________________________________10:45 43 -- Heat on11:00 119 → 40011:01 172 40011:45 159 40012:02 160 40012:24 160 40012:36 160 40012:52 160 400 1:08 160 410 1:26 160 390 → 400 1:48 160 390 → 400 2:04 159 400 Sampled 2:20 160 390 → 400 2:33 160 400 3:01 160 400 Cooling______________________________________
The 2:04 sample, which was at temperature for 3 hours and 4 minutes, and product, which was at temperature for 4 hours, were filtered through Perlite 476; the weight of the final product was 230 g. IR analysis showed the 2:04 cut to have ca. 5% nitrile remaining and the final product had ca. 1% nitrile. The amine value for the final product averaged 190.2, while that of the 2:04 cut averaged 185.0. Both samples meet the 185 minimum specification. Subsequent hydrogenation examples are run at 4 hours.
Example 3
Dimer diamine was prepared without the drying and back adding water steps. The equipment used was the same as the autoclave used in the previous example. The reagents used were 300.1 g dimer dinitrile #513, 8.1 g A-5000 Sponge Nickel Catalyst and 0.8 g sodium hydroxide 50% in water. The reagents were charged to the autoclave and hydrogenated.
______________________________________Time Temp. (°C.) Press. (psi H.sub.2)______________________________________10:00 18 -- Heat and Stirrer on10:10 136 → 30010:15 166 100 → 30010:18 173 200 → 30010:20 171 200 → 30010:25 167 200 → 30010:30 160 100 → 30010:45 160 100 → 30010:50 160 100 → 30011:35 159 250 → 30011:45 160 190 → 30012:15 160 280 → 30012:45 160 280 → 300 1:15 160 300 2:15 160 300 Heat off______________________________________
The material was cooled and then filtered through Perlite 476. The dimer diamine product weighed 270.7 g and had an amine value of 189.9 and a Gardner color of 9.0. IR showed no nitrile and a very small amount of amide. The moisture content averaged 0.71 wt. %.
Analysis by IR of the above material and the prior art sample showed that the only apparent difference was a small peak at 1670- cm. This could be due to a very small amount of carbonate present. NMR results agreed with the above IR results. The secondary amine is slightly higher in the lab sample but within specification.
Example 4
Twenty-six ca. 4,200 kg batches of dimer diamine were produced in the industrial autoclave. Four of these runs were done using the improved process steps and low water content of Example 3 and the rest done as in the prior art Example 2, and both used the temperature, time and pressure parameters of Examples 2 and 3. One of the prior art runs was removed from consideration since it had to be re-hydrogenated and one of the new procedure batches was disregarded since it "ran away" (uncontrolled exotherm). The successful results from the prior art runs were compared to the improved process runs:
______________________________________TEST Prior Art Improved Process______________________________________Total Amine Value 194.9 195.3II & III Amine Value 3.45 3.83______________________________________
All improved process lots met specification. The observation was made that the improved process was a "hotter" procedure and provides the opportunity to reduce catalyst loading. This is now done by increasing the dimer dinitrile charge by about 10 to about 15%. When the resulting primary dimer diamine is distilled, typical properties are an amine value of about 200 to about 210, an iodine value from about 80 to about 120, a specific gravity of about 0.84 to about 0.92, a viscosity of about 173 cps and a combining weight of about 282.
Example 5
Dimer dinitrile #523 is used as a precursor and processed as in Example 4 to make dimer diamine. Typical properties after distillation are an amine value of about 200 to about 210 and an iodine value from about 5 to about 20, a specific gravity of about 0.84 to about 0.92, a viscosity of about 257 cps and a combining weight of about 280.
A new procedure for the production of primary amines, particularly dimer diamines, has been developed and shown to be viable. The main advantage of this new procedure is to reduce cycle time by eliminating the drying and water back adding steps from the current procedure. The new procedure also has the potential of allowing reduced catalyst loadings or increased nitrile charge and shorter cycle time and reduced energy consumption.
The principles, preferred embodiments and modes of operation of the present invention have been described in the foregoing specification. The invention which is intended to be protected herein, however, is not to be construed as limited to the particular forms disclosed, since these are to be regarded as illustrative rather than restrictive. Variations and changes may be made by those skilled in the art without departing from the spirit of the invention. | An improved, optimized industrial process has been found for the hydrogenation of organic nitrites into primary amines, which essentially consists of contacting a dried charge of at least one organic nitrile, aqueous alkali metal hydroxide, at least one Raney slurry hydrogenation catalyst, water and hydrogen for an effective time and at an effective temperature and pressure, wherein the improvements comprise eliminating the steps of drying the charge and adding water and reducing the required water to about 0.2%. Secondary and tertiary amine formation is low, as is moisture content and neither precious metals such as rhodium, nor strategic metals, such as cobalt nor ammonia gas nor solvents are required. Surprisingly, it has been found that water levels less than that taught in the prior art are effective at suppressing secondary and tertiary amine production, while still producing repeatable product on an industrial scale and with reduced cycle time, energy and catalyst charge. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
Not Applicable
STATEMENT RE: FEDERALLY SPONSORED RESEARCH/DEVELOPMENT
Not Applicable
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to control valves, and more particularly to an axial control valve product that provides high capacity and low noise performance characteristics.
2. Description of the Related Art
As is known in the control valve industry, three well known types of conventional fluid valves include rotary stem valves, sliding stem valves, and sleeve valves. Rotary stem valves generally comprise a rotary shaft or stem which is maintained within a valve body. The rotation of the shaft may be used to facilitate the alignment of a radial port of the shaft with a fluid port of the valve body to open a valve passage. Conversely, the rotation of the shaft may facilitate a misalignment of the ports to effectively close the valve passage. In operation, a typical rotary valve shaft or stem must rotate about 90° relative to the valve body between the fully open and closed positions. There exists in the prior art other types of rotary valve designs which utilize alternative geometries requiring a shaft rotation that is less than 90°, such as three way or angled ball valves.
Rotary valves typically employ the use of seals, and often bearings, which are disposed between the rotary shaft and the valve body to prevent fluid from leaking from the valve body between the shaft and the valve body. In this regard, one of the primary drawbacks of rotary valves is that the significant movement of the shaft typically causes substantial wear to the seals and, if present, the bearings. Thus, the bearings and seals of a rotary valve must typically be replaced over time. Another drawback is that the seals, in order to function properly, also add friction between the valve body and the shaft. Substantial force is therefore typically necessary to overcome the seal friction and rotate the shaft.
A sliding stem valve typically operates on a principle similar to a piston, and includes a valve plug on a stem that slides linearly within a valve body. The valve plug bears against a seat or closes a passage when moved to a closed position, and is spaced from the seat or clears the passage when moved to an open position. The valve stem and the valve plug must usually move relative to the valve body a significant distance between the fully open and closed positions. Like rotary stem valves, sliding stem valves typically employ seals, and often guides, between the stem and the valve body to prevent fluid from leaking from the valve body between the stem and the valve body. In this regard, one of the primary drawbacks of sliding stem valves is that the significant linear movement of the stem causes wear on the seals, thus often necessitating that the seals be replaced over time. Another drawback is that the seals also create friction that must be overcome in order to move the linear stem valve between its open and closed positions.
Sleeve valves typically have a valve body defining an axial fluid flow passage. A stationary valve plug is usually fixed within the valve passage and carries or defines a valve seat positioned on an upstream end of the plug. A slideable valve sleeve is positioned in the valve passage and can be selectively moved between a fully closed position with a downstream end of the sleeve bearing against the valve seat, and a fully opened position with the downstream end of the sleeve being spaced a prescribed distance from the valve seat. Fluid can flow through the valve passage and the sleeve, around the valve plug, and an exit outlet of the valve.
Sleeve valves as known in the prior art typically have a number of prescribed performance characteristics, such as fluid flow rate, fluid pressure, valve flow coefficient, as well as inherent, installed, and linear flow characteristics. Various flow characteristics of sleeve valves can typically be determined or controlled by a number of factors, including the size and shape or contour of the upstream end of the valve plug, the shape of the plug body beyond or downstream of the upstream end, and the passageway or orifice size and contour surrounding the valve plug. Other valve features can be designed and shaped to affect valve flow or performance characteristics as well, including contours of the valve sleeve outlet opening or the like. Along these lines, designing a particular valve plug shape is an often used means to achieve a desired valve performance or flow characteristic. However, as a result, a typical sleeve valve for a given system often has a unique, non-replaceable valve sleeve and plug. Thus, if a different valve flow characteristic is desired for a particular valve or system, or if a valve seat or plug is damaged within a valve or system, it is often necessary to remove and replace the entire valve assembly within the system. In this regard, to change the load characteristics or the valve plug, it has typically been necessary in the prior art to swap the entire sleeve valve with a newer replacement valve.
The axial drag valve constructed in accordance with the present invention is adapted to overcome many of the deficiencies highlighted above in relation to known rotary, sliding stem, and sleeve valve designs. Various novel features of the present invention will be discussed in more detail below.
BRIEF SUMMARY OF THE INVENTION
In accordance with the present invention, there is provided multiple embodiments of an axial drag control valve which includes an internal disk stack trim and an internal actuator. The fluid inlet and outlet of the valve are disposed along a common axis, which is further shared with both the actuator and a plug of the valve. The plug and actuator move along this particular axis to control the fluid flow rate, pressure, or temperature of the system. In certain embodiments of the present invention, the valve actuator may be powered by an operating fluid from an external source, exemplary operating fluids including seven (7) bar air or eighty (80) bar air. A special, two-part packing with a lantern ring and leak-off port provides protection and safety for the actuator.
The present invention is best understood by reference to the following detailed description when read in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
These, as well as other features of the present invention, will become more apparent upon reference to the drawings wherein:
FIG. 1 is a cross-sectional view of an axial drag valve constructed in accordance with a first embodiment of the present invention as residing in its closed position;
FIG. 2 is a cross-sectional view of the axial drag valve of the first embodiment as residing in its open position;
FIG. 3 is a perspective view of the plug assembly of the axial drag valve of the first embodiment shown in FIGS. 1 and 2 ;
FIG. 3A is a cross-sectional, perspective view of the plug assembly of the axial drag valve of the first embodiment shown in FIGS. 1 and 2 taken along line 3 A- 3 A of FIG. 3 ;
FIG. 4 is a cross-sectional view of an axial drag valve constructed in accordance with a second embodiment of the present invention;
FIG. 4A is a cross-sectional view of a first potential variant of the axial drag valve of the second embodiment shown in FIG. 4 ;
FIG. 4B is a cross-sectional view of a second potential variant of the axial drag valve of the second embodiment shown in FIG. 4 ;
FIG. 5 is a cross-sectional view of an axial drag valve constructed in accordance with a third embodiment of the present invention; and
FIG. 6 is a cross-sectional view of an axial drag valve constructed in accordance with a fourth embodiment of the present invention.
Common reference numerals are used throughout the drawings and detailed description to indicate like elements.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the drawings wherein the showings are for purposes of illustrating preferred embodiments of the present invention only, and not for purposes of limiting the same, FIGS. 1 and 2 depict an axial drag valve 10 constructed in accordance with a first embodiment of the present invention. In FIG. 1 , the valve 10 is depicted in a closed position, while in FIG. 2 , the valve 10 is depicted in a fully open position.
The valve 10 comprises a housing 12 . The housing 12 itself comprises an inlet section 14 which defines an inlet passage 16 . In addition to the inlet section 14 , the housing 12 includes an outlet section 18 which defines an outlet passage 20 . The inlet and outlet sections 14 , 18 of the housing 12 are rigidly attached to each other. As seen in FIGS. 1 and 2 , the attachment of the inlet and outlet sections 14 , 18 to each other is facilitated by the use of fasteners 22 , such as bolts. However, those of ordinary skill in the art will recognize that a wide variety of different attachment methods may be used to effectuate the rigid attachment of the inlet and outlet sections 14 , 18 to each other. However, in the valve 10 , it is contemplated that any attachment method used to facilitate the attachment of the inlet and outlet sections 14 , 18 to each other will be adapted to allow for the periodic separation of the inlet section 14 from the outlet section 18 as may be needed to access the interior of the housing 12 to allow for maintenance on other parts and components of the valve 10 which will be described in more detail below.
In the outlet section 18 of the housing 12 , the outlet passage 20 defines three separate regions. More particularly, the outlet passage 20 defines an enlarged inlet region 20 a which is in direct fluid communication with the inlet passage 16 . The inlet region 20 a transitions into an arcuate central region 20 b , which itself transitions into an enlarged, generally cylindrical outlet region 20 c . Those of ordinary skill in the art will recognize that the configuration of the outlet passage 20 as shown in FIGS. 1 and 2 is exemplary only, and that alternative configurations for the outlet passage 20 are contemplated to be within the spirit and scope of the present invention. Indeed, certain exemplary alternative embodiments of the outlet passage 20 will be described below in relation to other embodiments of the valve 10 .
Disposed within the interior of the housing 12 and rigidly attached thereto is a hub cap 24 . The hub cap 24 defines an annular shoulder 26 which is abutted against an interior portion of the outlet section 18 of the housing 12 . That portion of the hub cap 24 extending between the shoulder 26 and the inlet passage 16 resides within the inlet region 20 a of the outlet passage 20 . In addition to defining the shoulder 26 , the hub cap 24 also defines a central bore 28 which extends axially therethrough. Additionally, formed in that end of the hub cap 24 facing the inlet passage 16 is an annular channel 30 which extends to a prescribed depth within the hub cap 24 . The bore 28 and channel 30 are sized and configured to accommodate respective portions of an internal actuator of the valve 10 , such as a plug assembly 32 (shown in FIGS. 3 and 3A ) which will be described in more detail below.
In the valve 10 , the end or face of the hub cap 24 facing the outlet region 20 c of the outlet passage 20 is abutted against one end or rim of a cylindrical, tubular piston sleeve 33 . The opposite end and the outer surface of the piston sleeve 33 are abutted against an interior portion of the outlet section 18 of the housing 12 . The end of the hub cap 24 facing the outlet region 20 c , the inner surface of the piston sleeve 33 , and a portion of the interior of the outlet section 18 collectively define a generally cylindrical, internal piston chamber 34 of the valve 10 . The piston chamber 34 is placeable into fluid communication with an external regulating device such as a spool valve via first and second air passages 36 , 38 which each fluidly communicate with the piston chamber 34 . The first air passage 36 includes a first segment 36 a which extends through the outlet section 18 , and a second segment 36 b which extends through the hub cap 24 in a generally L-shaped configuration. In this regard, one end of the second segment 36 b fluidly communicates with the piston chamber 34 , with the opposite end thereof fluidly communicating with the first segment 36 a . The second air passage 38 extends exclusively through the outlet section 18 of the housing 12 . The first and second air passages 36 , 38 are adapted to selectively supply air to, or exhaust air from, the piston chamber 34 in a manner which will be described in more detail below.
As is also seen in FIGS. 1 and 2 , the hub cap 24 may be provided with one or more annular grooves 40 within the exterior surface thereof. The groove(s) 40 may include a sealing element such as an O-ring disposed therein for purposes of defining a sealed engagement between the hub cap 24 and other parts of the valve 10 . For example, as seen in FIGS. 1 and 2 , the O-rings within two of the grooves 40 are used to create seals between the outer surface of the hub cap 24 and the interior of the outlet section 18 of the housing 12 , with the O-ring within the remaining one of the grooves 40 being used to create a seal between the hub cap 24 and one end of the piston sleeve 33 .
As indicated above, the bore 28 and channel 30 of the hub cap 24 are sized and configured to accommodate respective portions of a plug assembly 32 of the valve 10 . As seen in FIGS. 3 and 3A , the plug assembly 32 comprises an elongate piston rod 42 defining opposed ends. Attached to the piston rod 42 in relative close proximity to one of the opposed ends thereof is a circularly configured piston head 44 . The piston head 44 defines a peripheral side surface 46 having a continuous groove 48 disposed therein. Disposed within the groove 48 is a sealing member such as an O-ring 50 . Also attached to the piston rod 42 in relative close proximity to the remaining end thereof is a hollow balanced plug 52 . The plug 52 defines an end portion 52 a which transitions into an annular, generally cylindrical sidewall portion 52 b . Disposed in and extending through the end portion 52 a between the inner and outer surfaces thereof is at least one, and preferably a plurality of balance holes 54 , the use of which will be described in more detail below. Additionally, formed in the inner surface of the sidewall portion 52 b is an anti-rotation groove 56 , the use of which will also be described in more detail below. As best seen in FIG. 3A , the anti-rotation groove 56 extends to the distal rim defined by the sidewall portion 52 b , and terminates a prescribed distance inwardly from the inner surface of the end portion 52 a . The groove 56 also extends in generally parallel relation to the axis of the piston rod 42 . As also seen in FIG. 3A , extending axially through a portion of the length of the piston rod 42 is an elongate probe bore 58 . The probe bore 58 has a generally circular cross-sectional configuration, and extends from that end of the piston rod 42 disposed closest to the piston head 44 to a prescribed depth within the piston rod 42 . The use of the probe bore 58 will also be described in more detail below.
In the valve 10 , the piston rod 42 of the plug assembly 32 is advanced through and reciprocally moveable axially within the central bore 28 defined by the hub cap 24 . Additionally, the interface of the plug assembly 32 to the hub cap 24 is such that the piston head 44 resides and is reciprocally moveable within the piston chamber 34 collectively defined by the outlet section 18 , hub cap 24 and the piston sleeve 33 . More particularly, the piston head 44 is moveable along the axis defined by the piston sleeve 33 (which is coaxially aligned with the axis of the piston rod 42 ), with the O-ring 50 being slidably moveable along the inner surface of the piston sleeve 33 .
The valve 10 further comprises a generally cylindrical, tubular flow control element 60 which is disposed within the inlet region 20 a of the outlet passage 20 . As seen in FIGS. 1 and 2 , one end or annular rim defined by flow control element 60 is abutted against that end or annular rim of the hub cap 24 which faces the inlet passage 16 . The opposite, remaining end or annular rim of the flow control element 60 is abutted against an annular sealing member 62 which is itself abutted against an interior surface portion defined by the inlet section 14 of the housing 12 . Thus, the sealing member 62 is effectively captured and compressed between the flow control element 60 and the inlet section 14 of the housing 12 , with the flow control element 60 itself being captured and compressed between the hub cap 24 and the sealing member 62 . The positioning of the hub cap 24 , flow control element 60 and sealing member 62 relative to each other is such that the axis of the bore 28 , the axis of the flow control element 60 , and the axis of the sealing member 62 are all coaxially aligned with each other, and hence the axis of the piston rod 42 which is advanced through and reciprocally moveable within the bore 28 as indicated above. The sealing member 62 defines an annular sealing surface 64 which is disposed slightly radially inward of the inner surface of the flow control element 60 . In the valve 10 , it is contemplated that the flow control element 60 may comprise a stack of annular discs that collectively define a series of substantially radially directed passageways extending between the inner and outer radial surfaces or edges of the discs. Each of the radially directed passageways has a plurality of turns formed therewithin in order to reduce the velocity of fluid that is flowing through the flow control element 60 . An exemplary flow control element 60 is disclosed in commonly owned U.S. Pat. No. 5,687,763, the disclosure of which is incorporated herein by reference.
As previously explained, FIG. 1 depicts the valve 10 in its closed position, with FIG. 2 depicting the valve 10 in its fully open position. As also indicated above, the interface of the plug assembly 32 to the hub cap 34 is such that the piston head 44 resides and is reciprocally moveable within the piston chamber 34 . In the valve 10 , the plug 52 is likewise reciprocally moveable axially within the interior of the flow control element 60 in a manner effectively facilitating the opening or closure of the valve 10 . More particularly, when the valve 10 is in its closed position as shown in FIG. 1 , a peripheral portion of the outer surface of the end portion 52 a of the plug 52 is abutted and effectively sealed against the sealing surface 64 defined by the sealing member 62 . When the plug 52 is in this particular orientation, the sidewall portion 52 b thereof is aligned with but substantially removed from within the complimentary shaped channel 30 within the hub cap 24 . At the same time, the piston head 44 is oriented within the piston chamber 34 so as to be disposed proximate the hub cap 24 , with only a small gap being defined between the piston head 44 and the end of the hub cap 24 facing the outlet region 20 c of the outlet passage 20 , as shown in FIG. 1 . Conversely, when the valve 10 is moved to the fully open position as shown in FIG. 2 , the plug 52 is moved axially away from the sealing member 62 , with the sidewall portion 52 b of the plug 52 being drawn into the complimentary channel 30 and the end portion 52 a of the plug 52 being effectively separated from the sealing surface 64 defined by the sealing member 62 . At the same time, the piston head 44 is oriented within the piston chamber 34 so as to reside in close proximity to that end of the piston sleeve 33 opposite that abutted against the hub cap 24 .
As will be recognized by those of ordinary skill in the art, the plug assembly 32 , and in particular the plug 52 thereof, is effectively moved between closed and fully open positions relative to the sealing member 62 as a result of the reciprocal axial movement of the piston rod 42 of the plug assembly 32 relative to the hub cap 24 . Such reciprocal axial movement of the piston rod 42 , and hence the plug 52 , is facilitated by the selective application of air pressure to either side of the piston head 44 within the piston chamber 34 . More particularly, to facilitate the movement of the plug 52 to the closed position shown in FIG. 1 , pressurized air is input into the piston chamber 34 via the second air passage 38 , such pressurized air acting against the piston head 44 in a manner effectively forcing it toward the hub cap 24 , the movement of the piston head 44 toward the hub cap 24 being discontinued as a result of the abutment of the plug 52 against the sealing surface 64 of the sealing member 62 . As will be recognized, when the second air passage 38 is pressurized as occurs to facilitate the actuation of the plug 52 to the closed position, the first air passage 36 acts as an exhaust port so that air captured in the piston chamber 34 between the piston head 44 and the hub cap 24 does not impede the movement of the piston head 44 toward the hub cap 24 .
Conversely, to facilitate the movement of the plug 52 to the fully open position shown in FIG. 2 , the first air passage 36 is pressurized so as to facilitate the input of air into the piston chamber 34 in a manner acting against the piston head 44 as results in its movement away from the hub cap 24 toward the outlet region 20 c of the outlet passage 20 . Such movement of the piston head 44 effectively draws the plug 52 away from the sealing member 62 and into its nested orientation within the hub cap 24 as shown in FIG. 2 . As will be recognized, when the first air passage 36 is pressurized to facilitate the movement of the plug 52 toward the fully open position, the second air passage 38 effectively functions as an exhaust port so that any air trapped between the piston head 44 and the outlet section 18 of the housing 12 does not impede the movement of the piston head 44 away from the hub cap 24 . Within the piston chamber 34 , pressurized air is prevented from migrating between the peripheral edge of the piston head 44 and the inner surface of the piston sleeve 33 by the sliding, sealed engagement effectuated by the above-described O-ring 50 .
In the valve configuration shown in FIGS. 1 and 2 , fluid normally enters the valve 10 via the inlet passage 16 in the direction designated by the arrow A in FIG. 1 . When the plug 52 is in the closed position, the fluid within the inlet passage 16 is effectively prevented from entering the outlet passage 20 . When the plug 52 is moved from the closed position shown in FIG. 1 toward the fully open position shown in FIG. 2 , the fluid is able to flow through the sealing member 62 and thereafter radially outwardly through the flow control element 60 and into the outlet passage 20 . Since the fluid must flow through the flow control element 60 to reach the outlet passage 20 , the energy of the fluid is effectively reduced due to the above-described functional attributes of the flow control element 60 .
The opening of the valve 10 may be effectuated without necessarily actuating the plug 52 to the fully open position shown in FIG. 2 . In this regard, in the valve 10 , the axial movement of the plug 52 away from the sealing member 62 may be regulated or controlled depending on the desired level of fluid energy dissipation. Along these lines, as will be recognized, the greater the amount of axial movement of the plug 52 away from the sealing member 62 , the greater the number of energy dissipating flow passageways of the flow control element 60 that will be exposed to the incoming fluid flow via the inlet passage 16 . In this regard, maximum energy dissipation of the inlet fluid is achieved when the plug 52 is moved to the fully open position shown in FIG. 2 .
In order to monitor and thus tightly regulate or control the position of the plug 52 relative to the sealing member 62 , the valve 10 is provided with a position feedback device 66 which is oriented between the piston chamber 34 and the outlet region 20 c of the outlet passage 20 , and is accommodated within a complimentary internal recess defined by the outlet section 18 of the housing 12 . The feedback device 66 includes an elongate, generally cylindrical probe portion 68 which is coaxially aligned with and slideably advanced into the probe bore 58 of the piston rod 42 . The probe bore 58 and probe portion 68 of the feedback device 66 have complimentary configurations, with the advancement of the probe portion 68 into the probe bore 58 being operative to allow the feedback device 66 to effectively monitor the relative position of the piston rod 42 , and hence the plug 52 . As is apparent from FIGS. 1 and 2 , the piston rod 42 is moveable relative to the probe portion 68 which remains stationary, with at least some segment of the probe portion 68 always remaining within the interior of the probe bore 58 throughout the movement of the plug 52 between the closed and fully open extremes.
In the valve 10 , the feedback device 66 is effectively sealed within its complimentary recess defined by the outlet section 18 by a sealing cap 70 which is rigidly attached to the outlet section 18 . The sealing cap 70 defines a continuous groove which accommodates a sealing member such as an O-ring 72 . The abutment of the O-ring 72 against the outlet section 18 as occurs when the sealing cap 70 is rigidly attached to the outlet section 18 effectively prevents fluid flowing through the outlet passage 20 from reaching and possibly affecting the performance of the feedback device 66 . A hard wired connection to the feedback device 66 to facilitate the electrical connection thereof to an external control device may be obtained via a probe outlet passage 74 which extends through the outlet section 18 of the housing 12 and into communication with the internal recess accommodating the feedback device 66 . The detachment of the sealing cap 70 from the outlet section 20 provides access to the feedback device 66 as may be needed for the periodic maintenance thereof.
As the plug 52 moves between the fully open and closed positions during operation of the valve 10 , it is desirable to effectively prevent any rotation of the plug 52 relative to the hub cap 24 . Such anti-rotation is accomplished in the valve 10 by the inclusion of an anti-rotation member 76 which is partially embedded within the hub cap 24 , and protrudes into the channel 30 defined thereby. As is most apparent from FIG. 2 , the exposed portion of the anti-rotation member 76 has a configuration which is complimentary to the anti-rotation groove 56 included in the inner surface of the sidewall portion 52 b of the plug 52 . When the plug 52 is in any position other than its closed position, at least a portion of the anti-rotation member 76 is slidably received into the complimentary anti-rotation groove 56 , thus effectively preventing any rotation of the plug 52 relative to the hub cap 24 .
As indicated above, the plug 52 integrated into the valve 10 is “balanced” as a result of the inclusion of the balance holes 54 within the end portion 52 a thereof. As a result of the inclusion of the balance holes 54 therein, when the plug 52 is in its closed position, high pressure fluid flowing through the inlet passage 16 in the direction of the arrow A is able to pass through the balance holes 54 and into the interior chamber 78 collectively defined by the inner surfaces of the end and sidewall portions 52 a , 52 b of the plug 52 , the outer surface of the piston rod 42 , and a portion of the hub cap 24 . The placement of the plug 52 into a balanced condition as a result of the inclusion of the balance holes 54 therein gives rise to greater ease in the movement of the plug 52 between the fully open and closed positions. Despite fluid flowing into the interior chamber 78 when the plug 52 is in the closed position, such fluid is still effectively prevented from flowing through the flow control element 60 and hence into the outlet passage 20 .
As will be recognized by those of ordinary skill in the art, the proper operation of the valve 10 could be compromised if fluid flowing into the interior chamber 78 when the plug 52 is in the closed position is able to migrate between the outer surface of the piston rod 42 and that surface of the hub cap 24 defining the bore 28 into the piston chamber 34 . To prevent the flow of fluid from the interior chamber 78 into the piston chamber 34 , a live load packing is preferably interposed between the piston rod 42 and the hub cap 24 . As seen in FIGS. 1 and 2 , the live load packing comprises annular first and second packing elements 80 , 82 which reside within the central bore 28 in spaced relation to each other. Captured between the first and second packing elements 80 , 82 is an annular lantern ring 84 . The piston rod 42 is slidably advanced through the first and second packing elements 80 , 82 and the lantern ring 84 . The first and second packing elements 80 , 82 and the lantern ring 84 , as well as ancillary packing elements disposed adjacent respective ones of the first and second packing elements 80 , 82 , are all maintained in a compressive state by an annular packing bushing 86 which is rigidly attached to the hub cap 24 and partially resides within the interior chamber 78 . The piston rod 42 is also slidably advanced axially through the packing bushing 86 .
The sealing arrangement provided by the first and second packing elements 80 , 82 and intermediate lantern ring 84 is effective in preventing any fluid migration from the interior chamber 78 to the piston chamber 34 . However, in the event that such seal degrades over time as a result of the axial movement of the piston rod 42 , any fluid reaching the lantern ring 84 from the interior chamber 78 may be effectively bled off by a leak off passage 88 of the valve 10 . As seen in FIGS. 1 and 2 , the leak off passage 88 includes a first segment 88 a which extends through the outlet section 18 , and a second segment 88 b which extends through the hub cap 24 . In this regard, one end of the second segment 88 b fluidly communicates with that portion of the bore 28 adjacent the lantern ring 84 , with the opposite end thereof fluidly communicating with the first segment 88 a.
Referring now to FIG. 4 , there is shown an axial drag valve 100 constructed in accordance with a second embodiment of the present invention. The axial drag valve 100 is substantially similar in structure and function to the axial drag valve 10 described above. Accordingly, only the distinctions between the valves 10 , 100 will be highlighted below.
The primary distinction between the valve 100 and the above-described valve 10 lies in the configuration of the housing 112 of the valve 100 in comparison to the housing 12 of the valve 10 . More particularly, the housing 112 of the valve 100 comprises an inlet section 114 and an outlet section 118 which are rigidly attached to each other. As seen in FIG. 4 , the attachment of the inlet and outlet sections 114 , 118 to each other is facilitated by the use of fasteners 122 , such as bolts. In the valve 100 , it is contemplated that any attachment method used to facilitate the attachment of the inlet and outlet sections 114 , 118 to each other will be adapted to allow for the periodic separation of the inlet section 114 from the outlet section 118 as may be needed to access the interior of the housing 112 to allow for maintenance on other parts and components of the valve 100 .
In the valve 100 , the inlet section 114 defines an inlet passage 116 . Additionally, the inlet and outlet sections 114 , 118 collectively define an outlet passage 120 . In this regard, an inlet region 120 a of the outlet passage 120 is defined by the inlet section 114 . The inlet region 120 a transitions into a central region 120 b , which itself transitions into an enlarged outlet region 120 c . The central and outlet regions 120 b , 120 c are each defined by the outlet section 118 of the housing 112 . As further seen in FIG. 4 , the outlet region 120 c is formed to have a prescribed diameter D, which in many applications may be approximately twelve (12) inches.
A further distinction between the valves 10 , 100 lies in the configuration of the sealing cap 170 of the valve 100 in comparison to the sealing cap 70 of the valve 10 . In this regard, due to the alternative configuration of the outlet passage 120 in comparison to the outlet passage 20 , the sealing cap 170 is formed to have a more cone-like configuration in comparison to the sealing cap 70 of the valve 10 . The cone-like configuration of the sealing cap 170 in the valve 100 promotes a smoother transition for fluid flowing from the central region 120 b of the outlet passage 120 into the outlet region 120 c thereof.
Referring now to FIG. 4A , there is shown an axial drag valve 100 a which comprises a first potential variant of the valve 100 described above in relation to FIG. 4 . More particularly, the sole distinction between the valves 100 , 100 a lies in the outlet region 120 c of the outlet passage 120 in the valve 100 a being defined by an outlet flange 190 a which is rigidly attached to that end of the outlet section 118 opposite the end which is rigidly attached to the inlet section 114 . The attachment of the outlet flange 190 a to the outlet section 118 in the valve 100 a is preferably facilitated by the use of fasteners 192 a such as bolts. However, those of ordinary skill in the art will recognize that a wide variety of different attachment methods may be used to effectuate the rigid attachment of the outlet flange 190 a to the outlet section 118 . However, in the valve 100 a , it is contemplated that any attachment method used to facilitate the attachment of the outlet flange 190 a to the outlet section 118 will be adapted to allow for the optional detachment of the outlet flange 190 a from the outlet section 118 for potential replacement with an alternatively configured outlet flange. In the outlet flange 190 a shown in FIG. 4A , the outlet region 120 c of the outlet passage 120 defined thereby is of a diameter D which in certain applications may be approximately twelve (12) inches.
Referring now to FIG. 4B , there is shown an axial drag valve 100 b which comprises a second potential variant of the valve 100 described above in relation to FIG. 4 . More particularly, the sole distinction between the valves 100 , 100 b lies in the outlet region 120 c of the outlet passage 120 in the valve 100 a being defined by an outlet flange 190 b which is rigidly attached to that end of the outlet section 118 opposite the end which is rigidly attached to the inlet section 114 . The attachment of the outlet flange 190 b to the outlet section 118 in the valve 100 a is preferably facilitated by the use of fasteners 192 b such as bolts. However, those of ordinary skill in the art will recognize that a wide variety of different attachment methods may be used to effectuate the rigid attachment of the outlet flange 190 b to the outlet section 118 . However, in the valve 100 a , it is contemplated that any attachment method used to facilitate the attachment of the outlet flange 190 b to the outlet section 118 will be adapted to allow for the optional detachment of the outlet flange 190 b from the outlet section 118 for potential replacement with an alternatively configured outlet flange. In the outlet flange 190 b shown in FIG. 4A , the outlet region 120 c of the outlet passage 120 defined thereby is effectively reduced to a diameter D which in certain applications may be approximately six (6) inches. Those of ordinary skill in the art will recognize that the outlet flange 190 b may be optionally replaced with the outlet flange 190 a described above in relation to FIG. 4A .
Referring now to FIG. 5 , there is shown an axial drag valve 200 constructed in accordance with a third embodiment of the present invention. The axial drag valve 200 is substantially similar in structure and function to the axial drag valve 100 described above. Accordingly, only the distinctions between the valves 100 , 200 will be highlighted below.
The primary distinction between the valve 200 and the above-described valve 100 lies in the configuration of the housing 212 of the valve 200 in comparison to the housing 112 of the valve 100 . More particularly, the housing 212 of the valve 200 comprises an inlet section 214 , and intermediate section 215 , and an outlet section 218 which are rigidly attached to each other. As seen in FIG. 5 , the attachment of the inlet and intermediate sections 214 , 215 to each other is facilitated by the use of fasteners 222 , such as bolts. In the valve 200 , it is contemplated that any attachment method used to facilitate the attachment of the inlet and intermediate sections 214 , 215 to each other will be adapted to allow for the periodic separation of the inlet section 214 from the intermediate section 215 as may be needed to access the interior of the housing 212 to allow for maintenance on other parts and components of the valve 200 . As is apparent from FIG. 5 , it is contemplated that the outlet section 218 will be rigidly attached to the intermediate section 215 through the use of an attachment means other than the above-described fasteners 222 .
In the valve 200 , the inlet section 214 defines an inlet passage 216 . Additionally, the inlet, intermediate and outlet sections 214 , 215 , 218 collectively define an outlet passage 220 . In this regard, an inlet region 220 a of the outlet passage 220 is defined by the inlet section 214 . The inlet region 220 a transitions into a central region 220 b of the outlet passage 220 which is defined by the intermediate section 215 . The central region 220 b itself transitions into an outlet region 220 c of the outlet passage 220 which is defined by the outlet section 218 of the housing 212 . As further seen in FIG. 5 , the outlet region 220 c of the outlet passage 220 is effectively reduced to a diameter D which in many applications may be approximately six (6) inches.
Referring now to FIG. 6 , there is shown an axial drag valve 300 constructed in accordance with a fourth embodiment of the present invention. The valve 300 comprises a housing 312 . The housing 312 itself comprises an inlet section 314 and an outlet section 318 which are rigidly attached to each other. The attachment of the inlet and outlet sections 314 , 318 to each other is facilitated through the use of fasteners 322 , such as bolts. However, those of ordinary skill in the art will recognize that a wide variety of different attachment methods may be used to effectuate the rigid attachment of the inlet and outlet sections 314 , 318 to each other. However, in the valve 300 , it is contemplated that any attachment method used to facilitate the attachment of the inlet and outlet sections 314 , 318 to each other will be adapted to allow for the periodic separation of the inlet section 314 from the outlet section 318 as may be needed to access the interior of the housing 312 to allow for maintenance on other parts and components of the valve 300 which will be described in more detail below.
The inlet section 314 of the housing 312 defines an inlet passage 316 . Additionally, the inlet and outlet sections 314 , 318 , when rigidly attached to each other, collectively define an outlet passage 320 . The outlet passage 320 includes a first region 320 a which is defined by the inlet section 314 , and a second region 320 b which is defined by the outlet section 318 . As seen in FIG. 6 , the second region 320 b of the outlet passage 320 is configured to be effectively reduced to a diameter D which in many applications may be approximately six (6) inches. Those of ordinary skill in the art will recognize that the configuration of the outlet passage 320 as shown in FIG. 6 is exemplary only, and that alternative configurations for the outlet passage 320 are contemplated to be with the spirit and scope of the present invention.
Disposed within the interior of the housing 312 and rigidly attached thereto is a plug sleeve 333 . The plug sleeve 333 defines an end portion 333 a which transitions into an annular, generally cylindrical side wall portion 333 b . Abutted against the distal end or rim defined by the sidewall portion 333 b is an annular guide bushing 324 . Whereas the plug sleeve 333 resides within both the first and second regions 320 a , 320 b of the outlet passage 320 (though extending predominantly within the second region 320 b ), the guide bushing 324 resides exclusively in the first region 320 a of the outlet passage 320 .
The valve 300 further comprises a generally cylindrical, tubular flow control element 360 which also resides within the first region 320 a of the outlet passage 320 . As seen in FIG. 6 , one end or annular rim defined by the flow control element 360 is abutted against the annular guide bushing 324 . The opposite, remaining end or annular rim of the flow control element 360 is abutted against an annular sealing member 362 which is itself abutted against an interior surface portion defined by the inlet section 314 of the housing 312 . Thus, the sealing member 362 is effectively captured and compressed between the flow control element 360 and the inlet section 314 of the housing 312 , with the flow control element 360 itself being captured and compressed between the guide bushing 324 and the sealing member 362 . The positioning of the plug sleeve 333 , guide bushing 324 , flow control element 360 and sealing member 362 relative to each other is such that the axes thereof are coaxially aligned with each other. The sealing member 362 defines an annular sealing surface 364 which is disposed slightly radially inward of the inner surface of the flow control element 360 . In the valve 300 , it is contemplated that the flow control element 360 may comprise a stack of annular discs having the structural and functional attributes described above in relation to the flow control element 60 of the valve 10 . As further seen in FIG. 6 , captured between a portion of the guide bushing 324 and a portion of the rim of the flow control element 360 abutted against the guide bushing 324 is an annular seal 325 , the use of which will be discussed in more detail below.
The valve 300 further comprises a plug 352 which is reciprocally moveable axially relative the plug sleeve 333 between a closed position as shown in FIG. 6 and a fully open position. The plug 352 has a generally cylindrical configuration, and defines a first portion 352 a which is of a first diameter, and a second portion 352 b which is of a second diameter exceeding the first diameter of the first portion 352 a . As a result, a continuous, annular shoulder 354 is defined between the outer surfaces of the first and second portions 352 a , 352 b . Disposed within the peripheral side surface defined by the second portion 352 b is a spaced pair of continuous grooves 356 . Each of the grooves 356 is adapted to accommodate a sealing element (not shown) such as an O-ring. Extending axially through a portion of the plug 352 is an elongate probe bore 358 which has a generally circular cross-sectional configuration. The probe bore 358 extends from the end or face of the plug 352 defined by the second portion 352 b thereof and terminates approximately midway within the first portion 352 a , as shown in FIG. 6 . The use of the probe bore 358 will be described in more detail below.
As previously explained, FIG. 6 depicts the valve 300 in its closed position. The interface of the plug 352 to the plug sleeve 333 is such that the plug 352 is reciprocally moveable within the interior of the piston sleeve 333 , as well as the interior of the flow control element 360 , in a manner effectively facilitating the opening or closure of the valve 300 . More particularly, when the valve 300 is in its closed position as shown in FIG. 6 , a peripheral portion of the outer surface of the first portion 352 a of the plug 352 is abutted and effectively sealed against the sealing surface 364 defined by the sealing member 362 . At the same time, the second portion 352 b is oriented within the plug sleeve 333 such that the shoulder 354 is substantially aligned with the distal end or annular rim defined by the sidewall portion 333 b of the plug sleeve 333 . Conversely, when the valve 300 is moved to its fully opened position, the plug 352 is moved axially away from the sealing member 362 , with the plug 352 being drawn into the interior of the plug sleeve 333 to an orientation wherein only a small portion, if any, of the plug 352 protrudes into the interior of the flow control element 360 .
As will be recognized by those of ordinary skill in the art, the plug 352 is effectively moved between closed and fully open positions relative to the sealing member 362 as a result of the reciprocal axial movement of the plug 352 relative to the plug sleeve 333 and flow control element 360 . Such reciprocal axial movement of the plug 352 is facilitated by the selective application of air pressure to the end or face of the plug 352 defined by the enlarged second portion 352 b thereof. More particularly, to facilitate the movement of the plug 352 to the closed position shown in FIG. 6 , an operating fluid such as pressurized air is input into the interior of the plug sleeve 333 via an air passage 338 . The air passage 338 includes a first segment 338 a which extends through the outlet section 318 of the housing 312 , and a second segment 338 b which extends through the plug sleeve 333 . More particularly, one end of the second segment 338 b fluidly communicates with the first segment 338 a , with the opposed, remaining end of the second segment 338 b extending to the inner surface of the sidewall portion 333 b of the plug sleeve 333 , thus fluidly communicating with the hollow interior of the plug sleeve 333 . Such pressurized air or other operating fluid acts against the plug 352 in a manner effectively forcing it toward the sealing member 362 . In this regard, the axial movement of the plug 352 is discontinued as a result of the abutment of the plug 352 against the sealing surface 364 of the sealing member 362 .
Conversely, to facilitate the movement of the plug 352 to the fully open position, the air passage 338 is converted to an exhaust port. In this regard, high pressure fluid entering the inlet passage 316 in the direction designated by the arrow A in FIG. 6 acts against the plug 352 , and in particular the distal end or face defined by the first portion 352 a thereof, in a manner effectively forcing the plug 352 toward the end portion 333 a of the plug sleeve 333 . Since the air passage 338 effectively functions as an exhaust port, any air or other operating fluid trapped between the plug 352 and the end portion 333 a of the plug sleeve 333 does not impede the movement of the plug 352 away from the sealing member 362 . As such movement occurs, high pressure fluid entering the valve 300 via the inlet passage 316 in the direction of the arrow A is effectively prevented from migrating beyond the guide bushing 324 by the sliding seal created between the seal 325 and the outer surface of the first portion 352 a of the plug 352 . To the extent that any high pressure fluid migrates between the seal 325 and the plug 352 , such fluid is still effectively prevented from migrating between the peripheral edge of the second portion 352 b and the inner surface of the sidewall portion 333 b of the plug sleeve 333 by the sliding, sealed engagement effectuated by the O-rings disposed within the grooves 356 within the second portion 352 b of the plug 352 .
In the valve configuration shown in FIG. 6 , when the plug 352 is in the closed position, the fluid within the inlet passage 316 is effectively prevented from entering the outlet passage 320 . When the plug 352 is moved from the closed position shown in FIG. 6 toward the fully open position, the fluid is able to flow through the sealing member 362 and thereafter radially outwardly through the flow control element 360 and into the outlet passage 320 . Since the fluid must flow through the flow control element 360 to reach the outlet passage 320 , the energy of the fluid is effectively reduced due to the above-described functional attributes of the flow control element 360 .
The opening of the valve 300 may be effectuated without necessarily actuating the plug 352 to the fully opened position. In this regard, in the valve 300 , the axial movement of the plug 352 away from the sealing member 362 may be regulated or controlled depending on the desired level of fluid energy dissipation. Along these lines, as will be recognized, the greater the amount of axial movement of the plug 352 away from the sealing member 362 , the greater the number of energy dissipating flow passageways of the flow control element 360 that will be exposed to the incoming fluid flow via the inlet passage 316 . In this regard, maximum energy dissipation of the inlet fluid is achieved when the plug 352 is moved to the fully opened position. The degree to which the plug 352 is moved away from the closed position may be controlled by regulating the manner in which air is exhausted from between the plug 352 and the plug sleeve 333 via the air passage 338 .
In order to monitor and thus regulate or control the position of the plug 352 relative to the sealing member 362 , the valve 300 is provided with a position feedback device 366 which is accommodated within a complimentary recess defined by the end portion 333 a of the plug sleeve 333 . The feedback device 366 includes an elongate, generally cylindrical probe portion 368 which is coaxially aligned with and slidably advanced into the probe bore 358 of the plug 352 . The probe bore 358 and probe portion 366 have complimentary configurations, with the advancement of the probe portion 368 into the probe bore 358 being operative to allow the feedback device 366 to effectively monitor the relative position of the plug 352 . The plug 352 is moveable relative to the probe portion 368 which remains stationary, with at least some segment of the probe portion 368 always remaining within the interior of the probe bore 358 throughout the movement of the plug 352 between the closed and fully open extremes.
In the valve 300 , the feedback device 366 is effectively sealed within its complimentary recess defined by the plug sleeve 333 by a sealing cap 370 which is rigidly attached to the end portion 333 a of the plug sleeve 333 . The sealing cap 370 defines a continuous groove 372 which accommodates a sealing member such as an O-ring. The abutment of the O-ring against the plug sleeve 333 effectively prevents fluid flowing through the outlet passage 320 from reaching and possibly affecting the performance of the feedback device 366 . A hard wired connection to the feedback device 366 to facilitate the electrical connection thereof to an external control device may be obtained via a probe outlet passage 374 which extends through the outlet section 318 of the housing 312 , through the end portion 333 a of the plug sleeve 333 , and through the sealing cap 370 , as shown in FIG. 6 . The detachment of the sealing cap 370 from the plug sleeve 333 provides access to the feedback device 366 as may be needed for the periodic maintenance thereof.
As indicated above, as the plug 352 moves between the closed and fully open positions during operation of the valve 300 , high pressure fluid entering the valve 300 via the inlet passage 316 in the direction of the arrow A is effectively prevented from migrating beyond the guide bushing 324 by the sliding seal created between the seal 325 and the outer surface of the first portion 352 a of the plug 352 . To the extent that any high pressure fluid migrates between the seal 325 and the plug 352 , such fluid is still effectively prevented from entering into any open area defined between the plug 352 and the end portion 333 a of the piston sleeve 333 by the O-rings disposed within the grooves 356 .
As is further seen in FIG. 6 , the inlet section 314 of the housing 312 preferably includes a fluid passage 326 formed therein and communicating with the inlet passage 316 . The fluid passage 326 allows for the effective monitoring of the inlet pressure of the high pressure fluid entering the valve 300 via the inlet passage 316 . Similarly, the outlet section 318 of the housing 312 preferably includes a fluid passage 328 which is formed therein and fluidly communicates with the outlet passage 320 . Similar to the functionality of the fluid passage 326 , the fluid passage 328 allows for the monitoring of the fluid pressure of the fluid flowing through the outlet passage 320 and out of the valve 300 . Further, the sidewall portion 333 b of the plug sleeve 333 is preferably formed to include a fluid passage 330 , one end of which fluidly communicates with the outlet passage 320 . The fluid passage 330 is used to communicate the pressure of the fluid flowing into the outlet passage 320 into a space or region which is defined between the shoulder 354 and the guide bushing 324 when the plug 352 is actuated out of its closed position.
The valve 10 discussed above and constructed in accordance with the present invention may be packless or sealess to atmosphere, thus avoiding potential risks related to outside leaks. Leak susceptibility is also reduced as a result of the feedback device 66 being internally located within the valve 10 , thus facilitating the full closure of all the internal movements of the valve 10 . The valve 10 also provides the additional benefit of optimizing the process pressure ratio factor which refers to the situation in which the valve 10 is fully open to allow for the maximum flow rate at a minimum pressure drop as required by most new processes for energy saving to maximize differential pressure across the valve 10 when the valve 10 is going to close. In this regard, the valve 10 can reach the highest value of [ΔP min. at max. flow/ΔP max. when going to close], thereby resulting in the aforementioned energy savings. Further benefits include keeping the center of gravity within the pipeline center to provide additional safety when the valve 10 is used in a seismically active environment, and optimizing the flow control element 60 by adding the inherent outlet area expansion, which is particularly important for large mass-flow and high pressure drop or compressible fluids such as gas or vapor.
This disclosure provides exemplary embodiments of the present invention. The scope of the present invention is not limited by these exemplary embodiments. Numerous variations, whether explicitly provided for by the specification or implied by the specification, such as variations in structure, dimension, type of material and manufacturing process may be implemented by one of skill in the art in view of this disclosure. | In accordance with the present invention, there is provided an axial drag control valve which includes an internal disk stack trim and an internal actuator. The fluid inlet and outlet of the valve are disclosed along a common axis, which is further shared with both the plug and the actuator. The plug and actuator move along this particular axis to control the fluid flow rate, pressure, or temperature of the system. The valve actuator may be powered by an operating fluid such as air supplied from an external source. A special, two-part packing with a lantern ring and leak-off port provides protection and safety for the actuator. | 8 |
BACKGROUND OF THE INVENTION
Much of the current spinal cord regeneration research is focused on manipulating the function of neurons or glia, in order to promote axon growth or remove the inhibition of axon growth. These studies are increasingly designed to specifically alter the function of a particular gene or genes. Usually, the procedure is to introduce a genetic element into the cells of interest, and either block or enhance the expression of an important gene product. Up to this time, almost all such efforts have been concentrated on cells in vitro, where it is possible to treat the entire dish as a single population of cells, and then assay for the desired effect in the cells of interest. The long term goal of many of these studies is to provide a remedy for paralysis in humans. Unfortunately, the "shotgun" approach of transforming cells nonspecifically with a therapeutic gene will never be a viable way of treating this problem in vivo. In fact, such attempts could have potentially devastating effects on the function of the nervous system of the recipient. It is clear that for the potentially important gene therapy studies now being conducted in vitro to have application in the treatment of paralysis in vivo, a method must be devised to selectively deliver such genes (or other therapeutic agents) to specific cell types within the CNS.
Encapsulation of therapeutic pharmaceutical and genetic products by a targetable vehicle has been a goal for many investigators for years. Many problems have been encountered along the way regarding the specificity, mode of action, and physiological response to the varied therapies tested. The natural occurrence of the components of a liposome, a microscopic hollow sphere or "balloon" made of two layers of specific combinations of lipid or fatty molecules, make it an ideal carrier for delivery of therapeutic molecules. It has been shown that both drugs and genes are able to be delivered specifically to cells in vitro and in vivo with the desired specific effect. (P. R. Cullis and B. Dekruijff, Biochim. Biophy. Acta, 559, 339 (1979); J. Connor and L. Huang, Cancer Res., 46, 3431 (1986); and D. Collins and L. Huang, Cancer Res., 47, 735 (1987)).
The delivery of the liposome is facilitated by the chemical coupling of a specific monoclonal antibody to the outside of the liposome so that it will only bind to the specific site that it is intended to bind to. Such constructs are called immunoliposomes. Since the first success with liposome therapies a series of advancements and setbacks have occurred. The targeting ability of liposomes to carry the intra-liposome contents to a specific site has been increased by a factor of >10 by the development of a series of techniques and antibody combinations used by Holmberg et al. (B. J. Hughes and S. Kennel, R. Lee and L. Huang, Cancer Res., 49, 6214 (1989); K. Maruyama, E. Homberg, S. Kennel, A. Klibanov, V. Torchillin, and L. Huang, J. Pharm. Sci., 79(11), 978 (1990); E. Holmberg, K. Maruyama, D. Litzinger, S. Wright, M. Davis, G. Kabalka, S. Kennel, and L. Huang, Biochem. Biophys. Res. Comm., 165(3), 1271 (1989)).
A series of synthetic lipids have been synthesized to facilitate the intracellular delivery of the liposome's contents after the cell has engulfed the liposome. The normal endocytic pathway that a cell utilizes to engulf external particles will cause the digestion and destruction of the particle. In the case of an immunoliposome the liposome and the contents will be destroyed. The natural endocytic pathway involves a pH change in the endocytic particle, the endosome, by the addition of naturally occurring proton pumps after the cell has internalized the particle. This causes a drop in the pH of the internal portion of the endosome. This occurrence can be used to the advantage of the liposome engineer in that liposomes have been developed that "disrupt" when the pH is lowered to a certain point. The point at which a pH-sensitive immunoliposome "disrupts" can be controlled by the addition, to the components of the liposome, of a variety of lipids. (S. Wright and L. Huang, Adv. Drug Delivery Rev., 3, 343-389 (1989); D. Collins, D. C. Litzinger, and L. Huang, Bichim. Biophys. Acta, 1025(2), 234-242 (1990)). The proper combination of components will allow the successful delivery of the liposomes contents to the cell in an intact fashion such that they are biologically active and effective.
Huang (U.S. Pat. No. 4,957,735) discloses target-sensitive immunoliposomes which bind to the cell surface for the delivery of cytotoxic drugs. However, Huang '735 does not disclose the use of pH-sensitive immunoliposomes for the delivery of genetic material to the interior of the cell, in order to transfect the cell. Furthermore, Huang '735 does not disclose target-sensitive immunoliposomes which are sensitive to cells of the mammalian CNS.
Huang (U.S. Pat. No. 4,925,661) discloses target-specific cytotoxic liposomes which are also pH-sensitive. However, Huang '661 does not disclose the delivery of genetic material by such liposomes, nor the targeting of such liposomes to the mammalian CNS.
Huang et.al. (U.S. Pat. No. 4,789,633) discloses pH-sensitive liposomes and their use for introducing DNA into the cells of animals by intravenous injection. However, this is a non-specific targeting by liposomes without a conjugated antibody. Huang '633 does not disclose the use of pH-sensitive immunoliposomes to specifically target cells of the mammalian CNS in vitro or in vivo.
Immunoliposome therapy has not achieved the success that was initially predicted. The major obstacles have been nonspecific uptake of lipids by the liver and the destruction of liposomes by the immune system. Both of these major problems are unique to the peripheral circulation and do not exist within the central nervous system. Therefore, although some important technical questions will still need to be addressed, there is a much greater probability that immunoliposome therapy can provide an excellent method for delivery of active agents to specific cell types via direct injection into the CNS.
There is a need for a pH-sensitive immunoliposome for the delivery of genetic material to the mammalian central nervous system (CNS). The immunoliposomes must be usable for gene delivery both in vitro and in vivo by direct injection into the CNS, in order to avoid the obstacles associated with the peripheral circulation.
SUMMARY OF THE INVENTION
This invention relates to pH-sensitive immunoliposomes with a conjugated antibody sensitive to cells of the mammalian CNS, a method for introducing genetic material into the cells of the mammalian CNS in vitro through these liposomes, and a method of introducing genetic material into the cells of the mammalian CNS through direct injection of the liposomes into the CNS.
A principal object and advantage of the present invention is that it allows the encapsulation of biologically-active agents into a delivery vehicle which achieves specific delivery to cells of the mammalian CNS, i.e., glia and neurons.
A second object and advantage of the present invention is that it allows specific transfection of mammalian CNS cells by exogenous genes.
A third object and advantage of the present invention is that it allows transfection of cells of the mammalian CNS by direct injection into the CNS of liposome-encapsulated genetic material. This has important implications for gene therapy of human paralysis.
A fourth object and advantage of the invention is that the liposomes may be targeted specifically at neurons or specifically at glia by conjugating the liposomes with an antibody specific to neurons or an antibody specific to glia.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1: 15 ul of liposomes (1 mg/ml total lipid, 0.25 mg/ml antibody, 0.025 mg/ml plasmid DNA) were added to C6 glioma cells at 75% confluence. After exposure to immunoliposomes cells were fixed and assayed for expression of B-galactosidase. Transformed cells were counted and are expressed as a function of the percent total cell population±S.D. (n=3). (BL) bare liposomes, (113) 5-113 immunoliposomes, (1321) 13-21 immunoliposomes, (LF) lipofectin, (FREE) free plasmid. Free plasmid transfection had less than 1% transfection.
FIG. 2: 15 ul of liposomes (1 mg/ml total lipid, 0.25 mg/ml antibody, 0.025 mg/ml plasmid DNA) were added to NIH 3T3 cells at 75% confluence. After exposure to immunoliposomes cells were fixed and assayed for expression of B-Galactosidase. Transformed cells were counted and are expressed as a function of the percent total cell population±S.D. (n=3). (BL) bare liposomes, (113) 5-113 immunoliposomes, (1321) 13-21 immunoliposomes, (LF) lipofectin, (FREE) free plasmid. 113 and free plasmid transfection had less than 1% transfection.
FIG. 3: C6 glioma cells were presaturated with antibodies 5-113 (113), 13-21 (1321), and control buffer (-) at 4° C. prior to exposure to bare liposomes (BL), 5-113 immunoliposomes (113), and 13-21 immunoliposomes at 37° C. to block specific binding sites located on the cell surface prior to transfection. Blockers are smaller case and transfection liposomes are large case characters. Transformed cells were counted and are expressed as a function of the percent total cell population±S.D. (n=3).
FIG. 4: A drawing of a photomicrograph taken from injections of 5-113 immunoliposomes into a cannula-implanted brain lesion shows heavy labeling of the ependyma and glial scar. Most labeled cells appear to have an astrocyte morphology.
FIG. 5: Drawing of a low magnification photomicrograph of a longitudinal section of the spinal cord of a rat injected with THY 1.1 immunoliposomes. Dark colored cells are cells that react positively to the X-gal reaction indicating the expression of beta-galactosidase.
FIG. 6: Drawing of a high magnification photomicrograph of the section described in FIG. 5.
FIG. 7: Drawing of a high magnification photomicrograph similar to FIG. 6 with the exception of additional staining by TuJ1, an indicator of neuronal tubulin. Cells that contain both brown and blue colorings indicate neurons that have been successfully transfected via THY 1.1 immunoliposomes.
FIG. 8: Drawing of a photomicrograph of a section of white matter after transfection using THY 1.1 immunoliposomes. Blue cells indicate cells that have been successfully transfected via immunoliposomes and brown counter staining arises from the addition of glial fibrillary acid protein to indicate astrocytic cells. There appears to be very little cross-transfection between cell types.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Materials: Lipids were obtained from Avanti Polar Lipids, Inc. (Alabaster, Ala.). 1-Ethyl-3 (3-dimethylaminopropyl) carbodiimide (EDC) and N-hydroxysulfosuccinimide (S-NHS) were obtained from Pierce (Rockford, Ill.). Cholesterol, oleic acid, and all other chemicals were obtained from Sigma Chemical Co. (St. Louis, Mo.). Lipofectin and Transfectase were obtained from Gibco Laboratories. (Grand Island, N.Y.).
Antibodies: The monoclonal antibody 13-21 was generated from a fusion of lymph nodes in which two mice were immunized with a preparation of external membrane and associated proteins produced from mixed primary cultures of rat cerebral cortex. Cells from the neonatal rat cortex were cultured using methods previously described (E.G. Holmberg and L. Huang, Liposomes in the Therapy of Infectious Diseases and Cancer, Alan R. Liss, Inc., 25-34 (1989)). Fragments of the external membrane of the cultured cells were prepared following the procedure described by Neff et al. (N. T. Neff, C. Lowery, C. Decker, A. Tovar, C. Damsky, Buck, and A. F. Horwitz, J. Cell Biol, 654-666 (1982)). Antibodies were tested using an immunoblot analysis. Two subclasses of antibodies were determined, 5-113 was IgM subclass and 13-21 was IgG subclass, and both were used as targeting ligands. Both monoclonal antibodies were determined to be glia specific via indirect immunofluorescence staining. THY 1.1 monoclonal antibody was produced using a cell line purchased from American Type Culture Collection (ATTC TIB 100). Non-immune IgM was purchased from ICN (Irvine, Calif.).
Immunoliposome Preparation: N-glutaryl-phosphatidylethanolamine (NGPE) dissolved in CHCl 3 was dried with N 2 gas, and solubilized with octylglucoside in MES Buffer to a final concentration of 824 mg/ml (NGPE to octylglucoside molar ratio=0.07). Forty ul 1-ethyl-3-(3-dimethylaminopropyl) carbodiimide (0.25M in MES buffer) and 40 ul N-hydroxysulfosuccinimide (0.1M in MES buffer) were added to 200 ul of above NGPE solution and then incubated for 10 min. at room temperature. The mixture was neutralized by adding HEPES buffer (100 mM, pH 7.5) and 1N NaOH to pH 7.5. Monoclonal antibody 34A and a trace amount of 128 I-labeled antibody were then added, and incubated for 8 hr. at 4° C. with gentle stirring. Lipid mixtures and trace amounts of 111 In-DTPA-SA were mixed and evaporated free of organic solvent with N 2 gas. The dried lipid film was vacuum desiccated and solubilized with octylglucoside (100 mM in PBS (pH 7.4), lipid:octylglucoside=1:5, m/m). The resultant solution was mixed vigorously with the antibody conjugated with NGPE, and then the detergent was removed by dialysis in PBS for 12-18 hr at 4° C. The immunoliposomes were extruded 4 times through a 0.4 um nucleopore membrane. The size of liposomes was measured using a Coulter N4SD sub-micron particle size analyzer (Hialeah, Fla.). The immunoliposomes were separated from the unbound antibody on a Bio-Gel A 1.5M (Bio-Rad) column. Peak liposome fractions were collected and diluted to 1 mg lipid/ml PBS (pH 7.4). Plasmid DNA was added and the entire mixture was dialyzed for 48 hours at 4° C. in the final step. After dialysis, liposomes were sized four times through a 0.4 um Nuclepore membrane. Liposomes were separated from free plasmid DNA and unconjugated antibody on a BioGel A 1.5M (Bio-Rad) column. Liposomes were diluted to a concentration of 1 mg/ml total lipid. Plasmid DNA and antibody concentrations were determined to be 0.025 mg/ml and 0.25 mg/ml, respectively, in the standard 1 mg/ml total lipid immunoliposome solution.
Plasmid Preparation: A DNA plasmid containing the marker gene B-galactosidase was obtained from Promega Corp. (Madison, Wis.). The plasmid expression was under the control of either the SV40 early promotor or the cytomegalovirus promotor. The plasmid DNA was amplified in E. coli DH5-alph cells and recovered by alkaline extraction. (H. C. Bimboim and J. Doly, Nuc. Acids Res., 7, 1513 (1979)). Plasmid was purified by passage through Quiagen columns. (Quiagen Inc., Chatsworth, Calif.). Cell Culture Assay: NIH 3T3 fibroblasts and C6 glioma cells were seeded in six well plates and allowed to grow 50%-75% confluency. Cells were rinsed with serum free media and allowed to equilibrate. Liposomes were added to the cells and gently rocked for 1 hour. Experiments designed to test the specificity of the liposomes transfection necessitated the addition of free antibody to the cell cultures prior to the addition of the immunoliposomes. After 1 hour of exposure to the free antibody, the cells were rinsed and immunoliposomes were added in serum free media with mild agitation. After rocking, the cells were rinsed and serum-containing media was added and cells were incubated at 37° C. in 5% CO 2 for 48 hours. Treated cells were rinsed and lightly fixed in 3% paraformaldehyde. Fixed cells were treated with X-gal as previously described. (K. Lin and C. B. Chai, Biotechniques, 7:576 (1989)). Cells expressing B-galactosidase appear blue after the addition of X-gal. Cells were microscopically examined and counted with transformed cells expressed as a percent of the total cell population. Data were determined to be statistically significant using a students' t-test.
Immunoliposomes were constructed using antibodies 5-113 and 13-21, which bind specifically to glial cells, and containing a B-galactosidase expressing gene. Bare liposomes, containing plasmid but with no attached targeting antibody, were constructed as a control for immunoliposomes. To compare the efficiency of immunoliposome transfection with other commercially available methods, cells were transfected using lipofectin and transfectase. Cells were also exposed to an aliquot of free plasmid.
FIG. 1 illustrates the percent of transfected cells versus the transfection method for C6 glioma cells. Results in FIG. 1 indicate that maximal transfection occurred when cells were exposed to immunoliposomes with conjugated antibody 5-113 when identical concentrations (10 ug lipid/well of cells, 75% confluent) of immunoliposomes were added to the cells. The transfection rate was 43.7±4.2% (n=3) as determined by differential cell counting. A smaller percentage of cells were transfected when exposed to 13-21 conjugated immunoliposomes, 18.1±1.5% (n=3) of the cells were transformed. Background transfection via liposomes is quantified by the addition of bare liposomes. The transfection efficiency for bare liposomes was 10.2±0.9% (n=3).
C6 Glioma cells were transfected via two commercially available methods and by the addition of free plasmid. Results indicate a transfection rate of 4.3±2.1% (n=3) with lipofectin. No detectable transfection was observed when cells were transfected with Transfectase or free plasmid. (Data not shown for Transfectase)
To examine the transfection specificity to cell type of 5-113 and 13-21 immunoliposomes, NIH 3T3 fibroblasts were exposed via the above mentioned transfection methods. FIG. 2 illustrates the percentage of cells transfected versus the transfection method. Maximal transfection occurred when lipofectin was used as a transfection carrier, 17.4±2.6% (n=3) transfection efficiency was observed. Results with bare liposomes indicate a transfection frequency of 10.1±1.5% (n=3), a rate nearly identical to that of the C6 glioma cells. No detectable transfection was observed when cells were exposed to transfectase (data not shown), free plasmid, or 5-113 immunoliposomes. A very low transfection rate, 3.1±1.7% (n=3) was observed when 3T3 cells were exposed to 13-21 immunoliposomes.
To test the specificity of transfection, via immunoliposomes, cells were presaturated with free antibody prior to exposure to the immunoliposomes. Presaturation of the cell-surface antigens should block specific sites and reduce the specific binding to approximately background levels. FIG. 3 illustrates the percent of transformed C6 glioma cells versus transfection vehicle when cells were presaturated by either specific antibody or with the addition of no antibody. Little variation in background transfection levels was observed for the addition of plasmid containing bare liposomes with or without the prior addition of free antibody.
Antibody 5-113 immunoliposomes were added to C6 glioma cells in culture with and without the presaturation by either antibody. A transfection level of 42.8±4.2% (n=3) was observed with the addition of 5-113 immunoliposomes. Transfection levels were reduced three fold with the prior addition of 5-13 free antibody (13.2±2.2%, n=3) to the cells. Transfection levels were reduced approximately twofold with the prior addition of antibody 13-21 (22.1±3.91%, n=3) when 5-113 immunoliposomes were added to the cells. 13-21 immunoliposomes were added to C6 glioma cells and had a transfection efficiency of 31.7±5.39% (n=3). 13-21 immunoliposomes were added to C6 glioma with and without prior treatment of antibodies 13-21 and 5-113. Prior saturation of the cells with antibody 5113 resulted in a slight, but insignificant (P<0.50), increase in transfection 34.7±5.91% (n=3). Presaturation of the cells with antibody 13-21 prior to addition of 13-21 immunoliposomes resulted in an approximate 40% decrease in transfection efficiency to 17.1±2.7% (n=3).
In vivo experiments
In Vivo experiments were conducted using four different types of immunoliposomes. Plasmid containing 5-113 immunoliposomes were directed at glia, plasmid containing THY 1.1 were directed to neuronal cells, and plasmid containing non-immune IgM immunoliposomes and bare liposomes acted as control vehicles. Two different experimental models were used to demonstrate the effectiveness of In Vivo gene delivery by injection directly into the CNS. The first model was composed of rats previously injured by a scalpel blade wound through the cerebral cortex, the internal capsule and the fimbria, to test delivery to the brain. The lesion was implanted with a cannula for future liposome delivery. Injections directly into the spinal cord of uninjured, healthy Sprague-Dawley rats composed the second model.
Injections into the brain
5-113 immunoliposomes and non-immune IgM immunoliposomes were tested in chronically injured rat brains. As shown in FIG. 4, 5-113 immunoliposomes caused intense labeling of the gliotic scar 20 and the surrounding tissue 22 of the injection site. Most of these cells 24 observed to have color had astrocytic morphology, indicating that they are glia. In contrast, non-immune IgM immunoliposomes caused only light and diffuse labeling. This intense labeling of 5-113 immunoliposomes in comparison to non-immune IgM immunoliposomes indicates an increased transfection rate, due to the presence of the 5-113 antibody.
There was some non-specific labeling of pericytes and cells of choroid plexus observed with all injections. Light and diffuse labeling of ependymal cells was observed with non-immune IgM immunoliposomes along with some of the tissue adjacent to the ventricular system. However, this background labeling was of significantly less intensity than that observed with the 5-113 immunoliposomes.
Tissues taken from animals injected with non-immune IgG immunoliposomes or bare liposomes showed weak labeling of the cells at the injection site. Small numbers of both neurons and glia were observed as being labeled at this site. This observation was not seen in sham injected control animals, indicating that some minimal transfection occurs through liposomes without antibody.
Injections into the spinal cord
THY 1.1 immunoliposomes, which contain an antibody specific to an antigen expressed on the surface of neurons, were tested in the spinal cords of normal rats. As shown in FIGS. 5 and 6, the highest level of transfection was observed when THY 1.1 immunoliposomes were injected. The distinguishing feature of the THY 1.1 immunoliposomes was the increased number of transfected neurons 26 within the gray matter of the spinal cord 28, as compared to control experiments.
In all cases the heaviest labeling was observed at the injection site. Specificity of transfection was low at the injection site in that both cells of astrocytic and neuronal morphology were positive to the X-gal reaction. This is thought to be caused by the high concentration of liposomes and high hydrostatic pressure at the injection site. However, with the non-immune liposomes, the labeling of glial-like cells faded within a centimeter of the injection site and neurons were only labeled within 2 to 3 mm of the injection site. In contrast, with the THY 1.1 immunoliposomes, neurons 26 over the entire length of the spinal cord 28 were transfected. The intensity of the X-gal reaction product was the highest within 5 mm of the injection site; however, the neurons 26 within the spinal chord 28 were labeled from the sacral through the cervical levels of the chord. This indicates that the immunoliposomes were not destroyed by the immune system at the site of injection, but rather were able to transfect CNS cells at considerable distances from the injection site.
In order to examine the specific morphology of the transfected cells, tissue sections were cross-stained with markers for both glia and neurons. Spinal cords were injected with THY 1.1 immunoliposomes containing a beta-galactosidase plasmid. Tissue sections were examined for labeling from X-gal. A large number of cells were observed to be X-gal positive in these sections. In order to determine the specific cell type of these cells similar sections were examined for their reactivity with TuJ1, a label for neuronal tubulin. As can be seen in FIG. 7, the cell bodies of the cells 30 positive for TuJ1 (shown by brown staining) are also positive for the X-gal reaction (shown by blue staining). This indicates that neurons are transfected by THY 1.1 immunoliposomes. A similar section was cross-stained with glial fibrillary acidic protein, GFAP. As can be seen in FIG. 8, the cell bodies of the cells 32 positive for GFAP (shown by brown staining) were not also positive for the X-gal reaction, and the cells 34 positive for the X-gal reaction (shown by blue staining) are not also positive for GFAP. The indications are that there is a heightened degree of transfection of neurons using the THY 1.1 immunoliposomes, and that the transfection can be used to transfect neurons without simultaneously transfecting glia.
The present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof, and it is therefore desired that the present embodiment be considered in all respects as illustrative and not restrictive, reference being made to the appended claims rather than to the foregoing description to indicate the scope of the invention. | This invention relates to pH-sensitive immunoliposomes with a conjugated antibody sensitive to cells of the mammalian CNS, a method for introducing genetic material into the cells of the mammalian CNS in vitro through these liposomes, and a method of introducing genetic material into the cells of the mammalian CNS through direct injection of the liposomes into the CNS. | 2 |
CROSS REFERENCE TO A RELATED APPLICATION
This is a CIP of application Ser. No. 10/122,876 filed on Apr. 12, 2002, the teaching of which is incorporated herein by reference.
Copending U.S. application Ser. No. 09/793,646 filed on Feb. 26, 2001 entitled “Attenuated Embedded Phase Shift Photomask Blanks, the teaching of which is incorporated herein by reference.
FIELD OF THE INVENTION
The present invention is directed to attenuated embedded phase shift photomask blanks and in particular to attenuated phase shift mask (APSM) materials and processes.
BACKGROUND OF INVENTION
Phase shift masks are gaining attention as the next generation lithographic technique for microelectronic fabrication due to their capability to produce higher resolution images compared to the conventional binary photomasks. Among the several phase shifting schemes, the attenuating embedded phase shifter proposed by Burn J. Lin, Solid State Technology, January issue, page 43 (1992), the teaching of which is incorporated herein by reference, is gaining wider acceptance because of its ease of fabrication and the associated cost savings. There have been a number of variations associated with this scheme to improve the optical properties of the photomask, i.e. tunability of the optical transmission and resistance against photon irradiation and chemical treatments.
157 nm lithography is being considered as a post 193 nm lithography scheme. Currently, there are no mature APSM materials for 157 nm that exhibit appropriate optical properties, tunability, radiation and chemical durability, etch selectivity, low defects, and ease of manufacturability. Previously in U.S. application Ser. No. 9/793,646 filed on Feb. 26, 2001, we disclosed an APSM Material and process based on SiTiN,SiTiON system for 193 nm lithography—the teachings of which are incorporated herein by reference.
Herein we describe compositions of matter and methods of fabricating 157 nm APSM materials in particular a stacked bi-layer structure and methods of fabricating a phase shift photomask that has tunable optical transmission, coupled with stable optical properties during usage (photon exposure and chemical treatments) of the photomask, and a superior etch selectivity. The composition consists of SiM x O y N z materials with an etch stop layer, where element M represents a metal as described in the claims.
SUMMARY OF THE INVENTION
A broad aspect of the present invention comprises an attenuating embedded phase shift photomask blank capable of producing a phase shift of 180° with an optical transmission of at least 0.001% at a selected lithographic wavelength, having chemical and optical durability and flexible optical transmission tunability.
In another aspect, the invention comprises a process of making an attenuating embedded phase shift photomask, which process comprises the steps of depositing a bi-layer of thin film phase shifting materials.
In another aspect, the invention comprises a phase shifting composition of matter consisting of a phase shifting layer and an etch stop.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other objects, features and advantages of the present invention will become apparent upon a consideration of the following detailed description and the invention when read in conjunction with the drawing Figures, in which:
FIG. 1 shows two schematics of APSM. (a)single layer approach and (b)bi-layer approach.
FIG. 2 is a Transmission curve as a function of wavelength for a single layer approach, in particular SiTiON.
FIG. 3 is a table of the atomic composition, optical constants n and k, thickness required to give 180 degree phase shift and the corresponding transmission at 157 nm. The atomic composition was measured by Xray photoelectron spectroscopy and Rutherford back scattering. The optical constants were measured with the VESA Woollam Ellipsometer. The thickness and transmission were calculated using the optical constants.
FIG. 4 show Transmission curves as a function of wavelength for a bi-layer APSM. (a)The top layer is the phase shifting layer SiTiO and the bottom layer is the etch stop layer Ti. (b)The top layer is the phase shifting layer SiTiO and the bottom layer is the etch stop layer Ta.
FIG. 5 shows the optical constants (n and k), thickness of the thin films and corresponding transmission at 157 nm. The optical constants are measured with the VESA Woollam ellipsometer and the thickness corresponding to 180 degree phase shift and transmission is calculated from the optical constants.
FIG. 6 is a graph of the Transmission versus the cleaning time for the phase shifting layer SiTiO in a mixture of hot sulfuric acid and hydrogen peroxide solution at 90 C (H 2 SO 4 :H 2 O 2 =3:1).
FIG. 7 is a graph of the Transmission versus the cleaning time for the bi-layer SiTiO/Ta in a mixture of hot sulfuric acid and hydrogen peroxide solution at 90 C (H 2 SO 4 :H 2 O 2 =3:1).
FIG. 8 is a table of the RIE etch selectivity of SiTiO, Ti, Ta and quartz with the corresponding etch gas.
FIG. 9 is a graph of the laser durability of the APSM SiTiO on Ti. The Transmission change is plotted as a function of laser dose. The fluence of the 157 nm laser beam is 2.5 mJ/cm 2 /pulse and the repetition rate is 50 Hz. The total laser dose is 5 kJ/cm 2 .
FIG. 10 is a graph of the laser durability of the APSM SiTiO on Ta. The Transmission change is plotted as a function of laser dose. The fluence of the 157 nm laser beam is 2.5 mJ/cm 2 /pulse and the repetition rate is 50 Hz. The total laser dose is 5 kJ/cm 2 .
FIG. 11 illustrates a comparison of two graphs, a first graph depicting the transmission versus the cleaning time for the bi-layer SiTiO/Ta in a mixture of hot sulfuric acid and hydrogen peroxide solution, and a second graph depicting the transmission change plotted as a function of laser dose to illustrate durability of the APSM SiTiO on Ta.
DETAILED DESCRIPTION
A composition of matter and process is invented for fabricating photomask blanks that produces phase shifting films having tunable optical characteristics (%T,n and k) (T is the transmission; n is the index of refraction; and k is the extinction coefficient) with 180° phase shift at 157 nm and with good stability against laser irradiation and chemical treatment, as well as a good etch selectivity. The phase shifting films comprise of a bi-layer structure. The layer adjacent to the substrate controls the %T and also acts as an etch stop layer while the other layer on top acts as the phase shifting layer. The first layer comprises a metal or metal based film. An example will be given for titanium and tantalum. The phase shifting films comprise silicon and a metal and nitrogen and/or oxygen. The metal can be an element from the groups II, IV, V, transition metals, lanthanides and actinides. An example will be given for titanium as the metal. The invention comprises a phase shifting layer (Si w Ti x N y O z , where w is in the range 0.1 to 0.6, x is in the range 0 to 0.2, y is in the range 0 to 0.6, z is in the range 0 to 0.7) on top of a etch stop layer (metal or metal based layer) which is deposited on a substrate (quartz, fluorinated quartz, CaF 2 , or Al 2 O 3 , etc), the methods for forming the layers.
1. Deposition
The thin film can be deposited by sputter deposition (RF, DC magnetron, AC magnetron, pulsed bipolar DC magnetron, RF diode sputtering, or other sputter deposition methods familiar to those skilled in the art) from either a single target of a composite material (for example, Si 1−x M x , with x in the range 0 to 0.5 and M representing an element from either groups II,IV,V, transition metals, lanthanides and actinides) or two or more targets of different compositions (for example, SiO 2 and M targets, or Si 1−x M x and M targets). Variation in composition of the composite targets or individual variation of power and deposition time of the pure targets produces changes in film composition. Reactive sputtering with nitrogen and oxygen provides further capability to adjust the relative compositions of Si, M, and N and O, and thus the optical characteristics of the film. The substrate stage can be either stationary or planetary for the single target, and planetary for the multitarget with rotation speed adjusted accordingly.
Specifically, a RF magnetron sputtering was used for a single target (Si 0.7 (TiSi 2 ) 0.1 ) deposition for the phase shifting layer SiTiO (Ti as the element M) and a DC magnetron deposition was used for the etch stop layer (Ta and Ti) deposition. To obtain a thin film stable against chemical treatment used in photomask cleaning, the deposition condition needs to be optimized. We identified the preferred deposition conditions needed for chemical resistance.
2. Optical Properties
The optical properties (index of refraction (n), and extinction coefficient (k)) of both the phase shifting layer and etch stop layers were determined using a multi-angle VESA Woollam Ellipsometer in the range of 150 to 700 nm. Then, the preferred film thickness to obtain a 180 degree phase shift was calculated by using those optical constants. The transmission at 180° phase shift was measured in the transmission mode of the ellipsometer and compared with the calculated transmission value. The transmission change during the laser irradiation was monitored in real time by monitoring the laser intensity change as it irradiates onto the APSM sample. The laser measurement set up is similar to the one described by Liberman et al. (1999).
3. Examples
(A) Si w Ti x N y O z Single Layer
1) Processing Gas Ar/O 2 /N 2
Thin films composed of Si w Ti x N y O z by using a Si 0.7 (TiSi 2 ) 0.1 target were deposited, with the substrate in a rotating holder with planetary motion or positioned under the target without planetary motion. Sputtering was carried out in an argon/nitrogen/oxygen mixture with 1.0 mT Ar partial pressure. Ultra high purity gases were used for Ar, N 2 and O 2 (99.999%) and the background pressure of the chamber was <9.0×10 −7 torr. The thin film was deposited by RF magnetron sputtering from a five inch diameter target with a power of 450 W. Under the above conditions, the deposition rate was typically 0.3 to 1.6 Å/sec.
Prior to sputtering, the target was presputtered in 5 mT Ar for 5 min at 450 W. Then 5 min of presputtering was performed under the deposition condition of the thin film to precondition the surface of the target. After presputtering, the substrates were preferably immediately loaded through a load lock chamber into the deposition chamber and deposition was carried out. The film thickness ranged between 400 to 2000 Å depending on the deposition conditions. FIG. 2 shows the optical transmission as a function of wavelength. The film has a refractive index k of 2.10 and the absorption constant k of 0.467. The corresponding film thickness of the film is 745 Å which gives a transmission of 5.26% at 157 nm. According to calculation, the film with the same optical constants requires a thickness of 711 Å to obtain a 180 degree phase shift at 157 nm resulting in a transmission of 5.9%. By adjusting the oxygen to nitrogen, transmission as high as 18% can be achieved at 157 nm. FIG. 3 is a table of the atomic composition of the films with varying concentration of oxygen as measured by Xray photoelectron spectroscopy and Rutherford Back Scattering. The optical constants n and k are measured with the VESA Woollam ellipsometer and the optical transmission at 157 nm for a film thickness corresponding to 180 degree phase shift is calculated. As the oxygen concentration increases, the refractive index n decreases. As a result, the thickness required for 180 phase shift increases as well as the optical transmission at 157 nm.
While this single layer APSM satisfies the optical properties, the etch selectivity against quartz was poor, with etch selectivity of less than 1.7 under CF 4 plasma. This is due to the fact that a fairly high oxygen concentration (>35%) is required to give a suitable transmission and this high oxygen concentration results in less selectivity versus the quartz substrate. As an effort to improve the etch selectivity, a bi-layer APSM which utilizes an etch stop is developed.
(B) Si w Ti x O z /metal Bi-layer
For the bi-layer APSM, a metal etch stop layer is deposited on the fluorinated quartz substrate.(FIG. 1) Here we show examples with Titanium etch stop and Tantalum etch stop. After the metal etch stop layer, a phase shifting layer, composed of Si w Ti x N y O z by using a Si 0.7 (TiSi 2 ) 0.1 target is deposited. The example given here utilizes the composition with maximum transparency (y=0) for a given ratio of Si to Ti.
Sputtering for the metal layer is carried out in argon processing gas with 1.0 mT Ar partial pressure, with DC magnetron sputtering. Prior to the actual film deposition, the target was pre-sputtered for 10 min while the substrate was isolated in the load lock chamber. The thin film is deposited from a five inch diameter target with power ranging from 150 to 300 W. Under the above conditions, the deposition rate was typically 2.3 to 4.5 Å/sec. Typically, the etch stop layer thickness ranges from 10 Å to 400 Å. After the metal etch stop layer deposition, the substrate is transferred to the load lock chamber while the pre-sputter cleaning for the phase shifting layer takes place. The phase shifting layer is deposited by RF sputter deposition from a five inch diameter target. For this example, a SiTiO film is deposited under argon/oxygen mixture processing gas with 1.0 mT Ar partial pressure (Ar flow at 15 sccm). Oxygen is leaked in with a Gransville-Phillips precision leak valve to maintain a constant O 2 partial pressure ranging from 0.10 to 0.70 mT. The RF power ranges from 450 W to 900 W. Under the above conditions, the deposition rate is typically 0.75 to 1.7 Å/sec. The phase shifting layer thickness ranges between 400 to 2000 Å depending on the deposition conditions.
The best optical and chemical durability was achieved with the following conditions for the phase shifting layer SiTiO. The RF power is set to 900 W, the Ar partial pressure 1.0 mT and Oxygen partial pressure 0.55 mT. For films with oxygen partial pressure less than 0.35 mT, the optical transmission was too low for practical usage due to the low incorporation of the oxygen in the film. Also, the low power depositions (450 W) gave inferior chemical durability, likely as a result of higher porosity (less density) of the film. Prior to loading the substrates, the substrates are pre-cleaned with an oxygen asher to eliminate hydrocarbons that can reduce the transmission at 157 nm.
FIG. 4 is the transmission curve as a function of wavelength for SiTiO/Ti and SiTiO/Ta. The transmission at the inspection wavelength 248 nm are less than 30% for both APSM. This is another advantage over the single layer APSM. The atomic composition of the phase shifting layer SiTiO is shown in the table of FIG. 3 . The optical constants (n and k) and the film thicknesses were measured by the Woollam ellipsometer. The values are shown in FIG. 5 together with the corresponding transmission at 157 nm. The advantage of a bi-layer scheme is that the optical transmission is easier to adjust compared to the single layer. Instead of changing the concentration of the oxygen, simply by adjusting the etch stop layer the transmission can be adjusted. For example, SiTiO of 1150 Å with Ti of 149 Å will give a 180 degree phase shift with transmission of 5.9%. By reducing the Ti to 60 Å(and SiTiO to 1175 Å) the transmission becomes 12%. Similarly, for SiTiO of 1170 Å with Ta of 106 Å will give a 180 degree phase shift with transmission of 5.9%. By reducing the Ta to 50 Å(and SiTiO to 1183 Å) the transmission becomes 10.6%.
FIG. 6 summarizes the change of %T of the phase shifting layer SiTiO at 157 nm as a function of immersion time in a cleaning solution of sulfuric acid and hydrogen peroxide(H 2 SO 4 :H 2 O 2 =3:1, 90° C.), this solution is typically used for stripping photoresists in manufacturing line, also known as piranha solution. The total change of %T is 0.3% over 115 min of immersion. This excellent stability ensures a compatibility of the material with the standard photomask manufacturing process. For comparison, the deposition with lower power(450 W) is shown together. The chemical durability of the bi-layer SiTiO/Ta also shows extremely stable %T as a function of piranha cleaning. FIG. 7 summarizes the change of %T of the bi-layer SiTiO/Ta at 157 nm as a function of immersion time in a cleaning solution of sulfuric acid and hydrogen peroxide. An increase of the T%, from 6.07% to 6.27%, occurs after the initial clean, however, the subsequent cleaning over a period of 90 min gave a T% of 0.02%. This demonstrates that the bi-layer SiTiO/Ta has an excellent chemical stability against repeated cleanings.
FIG. 8 is a summary of the etch selectivity of the single layer scheme and the bi-layer scheme. The SiTiO/Ti and SiTiO/Ta are comparable, both a major improvement over the single layer scheme. However, the Ti/quartz shows a better etch selectivity over the Ta/quartz combination under identical etch conditions.
Both SiTiO/Ta and SiTiO/Ti bi-layers showed excellent stabilities against 157 nm laser irradiation. FIG. 9 summarizes the change of %T for the SiTiO/Ti APSM at 157 nm as a function of irradiation at 157 nm (using a Lambda Physik LPX 120 F2 laser). The film was irradiated with laser power density of 2.5 mJ/cm 2 /pulse at 50 Hz frequency. The total transmission change at a dose of 5.0 kJ/cm 2 is 0.50%. The sample was irradiated in a nitrogen atmosphere with less than 2 ppm oxygen. The SiTiO/Ti APSM gives a total increase of 0.5%.(5.94% to 6.44%). Also, the SiTiO/Ta bi-layer test is comparable to the SiTiO/Ti bi-layer. FIG. 10 summarizes the change of %T for the SiTiO/Ta at 157 nm as a function of irradiation at 157 nm (using a Lambda Physik LPX 120 laser). The film was irradiated with laser power density of 2.5 mJ/cm 2 /pulse at 50 Hz frequency. The total transmission change at a dose of 5.0 kJ/cm 2 is 0.55%. The sample was irradiated in a nitrogen atmosphere with less than 2 ppm oxygen. The SiTiO/Ta APSM gives a total increase of 0.55% (5.71% to 6.26%).
While this invention has been described in terms of certain embodiment thereof, it is not intended that it be limited to the above description, but rather only to the extent set forth in the following claims. The embodiments of the invention in which an exclusive property or privilege is claimed are defined in the appended claims. The teaching of all references cited herein, are incorporated herein by reference. | An attenuating embedded phase shift photomask blank that produces a phase shift of the transmitted light is formed with an optically translucent film made of metal, silicon, nitrogen and oxygen. An etch stop layer is added to improve the etch selectivity of the phase shifting layer. A wide range of optical transmission (0.001% up to 15% at 157 nm) is obtained by this process. | 2 |
FIELD OF THE INVENTION
This invention relates to a squeeze bottle metering dispenser with a child resistant, tightly sealing closure.
DESCRIPTION OF THE PRIOR ART
Metering dispensers utilizing a cup-like fitment having a dip tube extended upwardly through the bottom wall for insertion into the mouth of a squeeze bottle have been suggested in the prior art, for example, in Greene U.S. Pat. No. 259,446. The closure of the metering chamber of this type by means of a cap having a simple annular friction seal has also been heretofore suggested in Greene U.S. Pat. No. 2,714,975.
Push and turn type child resistant closures utilizing interengaging camming type lugs to provide the locking action have also been heretofore suggested, for example, in Hedgewick Re-Issue U.S. Pat. No. Re. 27,156 and Bauer U.S. Pat. No. 3,623,623.
The aforesaid Hedgewick Re-Issue U.S. Pat. No. Re. 27,156 discloses a safety cap and container wherein a plurality of container-locking elements or lugs are spaced peripherally from each other on the outer wall of the mouth portion of the container for engagement with complementary cap locking elements or lugs on the inner wall of a peripheral skirt which projects axially from the base of the cap. The cap and container locking elements are of the type wherein the cap must be engaged with and disengaged from the container by combined axial and rotative motion of the cap relative the container. When the cap is mounted on the container, the cap locking elements are biased against disengagement from the container locking elements by a spring member in the form of an integral annular web formed in the cap.
In the aforesaid Bauer U.S. Pat. No. 3,623,623 a similar cap locking arrangement is provided but the biasing means comprises a separate domed element carried by the container for resiliently maintaining the cap in interlocked engagement with the container.
In both the Hedgewick Re-Issue U.S. Pat. No. Re. 27,156 and the Bauer U.S. Pat. No. 3,623,623 the sealing of the container is achieved by means of the engagement between the annular spring element of the cap against the container mouth and of the dome spring element against the cap, respectively. Hence, in each of these prior art patents the spring member provides both biasing of the locking elements and sealing of the container mouth. The optimum biasing forces for each of these two functions are not identical and, therefore, these arrangements require that the resilience of the spring element be selected by compromise between the desired optimums for sealing and biasing of the locking members.
OBJECTS OF THE INVENTION
Bearing in mind the foregoing, it is a primary object of the present invention to provide a novel and improved metering dispenser with a child resistant, tightly sealing closure.
Another primary object of the present invention, in addition to the foregoing object, is the provision of such novel and improved apparatus utilizing biasing means integral with the metering dispenser and sealing means separate and independent thereof.
Another primary object of the present invention, in addition to each of the foregoing objects, is the provision of such apparatus wherein the closure is of integral, one-piece molded construction.
Yet another primary object of the present invention, in addition to each of the foregoing objects, is the provision of such apparatus wherein the closure may be made of a relatively rigid material such as polypropylene, or the like, and the metering dispenser may comprise a fitment made of a relatively less rigid material such as polyethylene, or the like.
Still another primary object of the present invention, in addition to each of the foregoing objects, is the provision of novel sealing closures for metering dispensers.
Yet still another primary object of the present invention, in addition to each of the foregoing objects, is the provision of a child resistant closure for a metering dispenser of the type herein disclosed.
The invention resides in the combination, construction, arrangement and disposition of the various component parts and elements incorporated in new and improved metering dispensers with child resistant, tightly sealing closures constructed in accordance with the principles of this invention. The present invention will be better understood and objects and important features other than those specifically enumerated above will become apparent when consideration is given to the following details and description which, when taken in conjunction with the annexed drawing describes, discloses, illustrates and shows a preferred embodiment or modification of the present invention and what is presently considered and believed to be the best mode of practicing the principles thereof. Other embodiments or modifications may be suggested to those having the benefit of teachings herein, and such other embodiments or modifications are intended to be expressly reserved, especially as they fall within the scope and spirit of the subjoined claims.
SUMMARY OF THE INVENTION
Metering fitment inserted into the mouth of a squeeze bottle for dispensing measured quantities of a liquid therefrom and child resistant, tightly sealing closure cooperating therewith. The metering insert comprises an open top cup with a dip tube extending axially upwardly through the bottom wall less than the depth of the cup. Upon squeezing of the bottle, liquid content is forced upwardly through the dip tube into the cup and upon release of squeeze pressure, part of the liquid in the cup automatically drains back through the dip tube to retain a measured quantity of liquid in the cup defined by the height of the dip tube and the diameter of the cup. The metering insert may be molded of a soft material such as polyethylene or may be of such a design that it flexes vertically upon engagement with a stem being integrally molded therewith defining the upper end of the dip tube and the child resistant closure is of the push and turn type cooperating with the metering fitment and the bottle finish. The closure comprises a circular base and a depending skirt with the interior of the skirt and the exterior of the bottle finish being provided with cooperating locking lugs. The closure provides sealing by means of two annular axially extending seals, an inner seal that engages the top portion of the dip tube and an outer seal that engages inside the metering cup rim. In addition, the inner seal engagement with the upper end portion of the dip tube flexes the bottom wall of the metering cup to provide spring action for the locking lugs. The closure cap can be made of a relatively rigid material, such as polypropylene, or the like, and be of one-piece molded construction. The fitment can also be of one-piece molded construction of a relatively resilient material such as low density polyethylene, or the like, with the dip tube separately assembled therewith. The materials of the various component parts and elements need not necessarily be critical.
DESCRIPTION OF THE DRAWING
While the specification concludes with the claims particularly pointing and distinctly claiming the subject matter which is regarded as forming the present invention, it is believed the invention will be better understood from the following detailed description when taken in conjunction with the annexed drawing which discloses, illustrates and shows a preferred embodiment or modification of the present invention and what is presently considered and believed to be the best most of practicing the principles thereof and wherein:
FIG. 1 is an elevational view, partially in section of a squeeze wall bottle provided with the metering dispensing and child resistant, tightly sealing closure of the present invention;
FIG. 2 is a plan view, viewed from the bottom, of the closure cap;
FIG. 3 is an elevational view of the squeeze bottle having the metering fitment positioned therein; and
FIG. 4 is a top plan view of the squeeze bottle and metering fitment.
DETAILED DESCRIPTION OF THE INVENTION
With reference now to the drawing, there is shown and illustrated a safety and metering package constructed in accordance with the principles of this invention designated generally by the reference character 10. The package 10 defines a metering dispenser for a liquid product with a child resistant, tight sealing closure. The package 10 comprises a squeeze bottle 12 having a flexible side wall 14 and a finish portion 16 connected therewith and having a generally open and unobstructed mouth portion 18; a metering fitment or insert 20 disposed within the mouth opening 18 of the finish 16 and a closure or cap 22 sealing engaging the metering fitment 20, as will be described hereinafter, and complementary locking elements provided on the closure 22 and bottle finish 16, respectively, as will also be hereinafter described.
The container or squeeze bottle 12 may be of substantially any desired shape or configuration and is herein shown, for exemplary purposes only, with the side wall 14 being of generally cylindrical configuration and connected with the bottle finish 16 by means of a sloped frusto-conical connecting wall portion 24, a generally cylindrical connecting wall portion 26 and a generally annular radially extending flange portion 28. The squeeze bottle or container 12 further comprises a generally circular bottom wall 30.
A plurality of container locking elements 32 are spaced peripherally from each other and are located at a fixed axial position around the bottle finish 16. The container locking elements 32 are of the type shown in the above-mentioned Hedgewick Re-Issue U.S. Pat. No. Re. 27,156 and each includes a radially outwardly extending projection formed with a notch 34 formed between a stop portion 36 and a cam portion 38 (FIG. 3).
The cap or closure 22 comprises an end wall 40 of generally circular configuration having a peripheral skirt 42 projecting axially therefrom for receiving the bottle finish 16 therewithin. Spaced peripherally from each other on the inner surface of the skirt portion 42 are a plurality of cap locking elements 44 in the form of radially inwardly projecting lugs. The cap locking elements 44 are engageable with and disengageable from the container locking elements 32 by an axial motion of the cap or closure 22 relative the container or squeeze bottle 12 followed successively by a rotative motion of the cap or closure 22 relative the container or squeeze bottle 12. To apply the cap or closure 22 to the container or squeeze bottle 12, the cap-locking elements 44 are aligned with the spaces between the container locking elements 32 so that the locking lugs 44 engage the cam surface of the cam portion 38 of the locking elements 32. Upon rotation of the cap or closure 22 in the direction to move the cap locking elements or lugs 44 toward the left in FIG. 3, the cap-locking elements or lugs 44 are cammed downwardly by the cam portion 48 until they engage the respective stop portion 36, at which point the lugs 44 come into alignment with the respective notches 34. Subsequent upward movement engages each cap locking element or lug 44 in a notch 34 to prevent relative rotation between the cap and container. The upward movement is provided by a biasing spring action developed by the metering insert or fitment 20 in cooperation with the closure or cap 22, as will be described hereafter.
The metering insert or fitment 20 is of generally cup shaped configuration having a generally cylindrical side wall portion 46 and provided at the upper end portion thereof with a generally radially outwardly extending flange portion or lip 48. The wall portion 46 generally adjacent the flange or lip 48 comprises a generally thickened annular shoulder 50 which fits tightly within the mouth opening 18 of the bottle finish 16 with the flange portion or lip 48 positioning the insert or fitment within the mouth portion 18 of the bottle finish 16 (FIG. 1).
The metering insert or fitment 20 further comprises a generally annular bottom wall portion of generally upwardly belled or frusto-conical configuration through which a dip tube 54 generally axially extends from the bottom of the container or bottle 12 to within the fitment 20 to some distance below the rim of the outer wall 46. The upper end portion of the dip tube 54 may be engaged within a stem portion 56 integrally formed with the bottom wall 52 of the fitment or insert 20. The upper end portion of the stem 56 may be provided with a top wall 58 and a plurality of sideways or radially directed orifices 60 arranged, for example, at 120° intervals around the distal end portion of the stem 56 so that liquid passing upwardly through the dip tube 54 and the stem 56 will be directed radially outwardly therethrough and precluded from squirting upwardly out of the mouth opening of the squeeze bottle 12.
The metering function of the package 10 operates as follows. Squeezing of the side wall 14 of the squeeze bottle 12 compresses the liquid contained therein and forces it upwardly through the dip tube 54 and radially outwardly through the orifices 60 into the generally annular well or cup formed by the metering insert or fitment 20. The bottle 12 is squeezed until the level of liquid within the cup or well defined by the insert or fitment 20 rises to or above the level of the orifices 60. Upon release of squeeze pressure from the squeeze bottle 12, the excess of liquid within the cup above the orifices 60 will drain downwardly through the dip tube 54 to retain a measured quantity of liquid within the fitment cup defined by the cup diameter and the depth of the cup beneath the orifices 60. The measured quantity of the liquid then contained within the fitment cup can be dispensed by tilting and inverting of the bottle 12 to pour the measured quantity of the liquid from the cup. Upon such inversion, the lower end portion of the dip tube 54 will be withdrawn from the liquid within the squeeze bottle 12 and lack of a separate vent to the bottle precludes dispensing of additional quantity of product outwardly through the dip tube 54.
The closure or cap 22 further comprises a generally centrally disposed generally axially depending stem 62 of generally cylindrical configuration depending from the top wall 40 generally coaxial the skirt portion 42 for engaging the stem portion 56 of the metering insert or fitment 20. The lower or distal end portion of the cap stem 62 is provided with a counterbore 64 extending to a shoulder or step 66. The counterbore 64 fits around the distal end portion of the fitment stem 56 and, in cooperation with a generally annular sealing ring or flange 68 extending generally circumferentially around the fitment stem 56 generally beneath the openings 60, that is, between the openings 60 and the fitment bottom wall 52, provides priming of inner sealing for closure of the openings 60 and the distal end of the fitment stem 56 when the cap or closure 22 is assembled with the bottle 12 with the cap locking elements 44 engaged within the notches 34 of the container locking elements 32.
The cap or closure 22 is further provided with secondary or outer sealing means defined by a sealing ring 70 depending from the face 40 of the cap or closure 22 generally coaxially with the cap stem 62 and cap skirt 42. The secondary sealing ring 70 extends into the metering cup or fitment 22 and slidably sealingly engages an inwardly directed and annular sealing rim ring 72 integrally formed with the metering fitment or insert adjacent the mouth thereof and opposite the locating flange 48.
As heretofore pointed out, biasing means are required for resiliently retaining the cap or closure 22 in interlocked engagement with the container finish 16. In accordance with the present invention such biasing means is integrally provided by the metering fitment or insert 20, independent of the sealing means 64 and 70. In accordance with the present invention the bottom wall 52 of the metering insert or fitment 20 is resilient and upwardly cupped or beveled to define a frusto-conical or belleville type spring carrying the fitment stem 56 at its inner edge. As has been heretofore pointed out, the upper end or distal wall 58 of the fitment stem 56 engages the shoulder 66 of the closure stem 62. Hence, upon depression of the closure cap 22 from the latched position, shown in solid lines in FIG. 1, wherein the closure lugs 44 are engaged within the notches 34 of the container lugs 32 to the unlatched position, shown in phantom lines in FIG. 1, whereat the closure lugs 44 clear the camming surface 38 of the container lugs 32, the bottom wall 52 of the metering fitment 20 flexes downwardly to the position shown in phantom lines in FIG. 1 and thereby provides the biasing force for the closure cap 22.
Accordingly, the metering cup or fitment 20 may be integrally molded as one-piece from a relatively resilient material cup such as low density polyethylene. The cap or closure 22, since it does not require any resilience or resilient elements, may be integrally molded from a relatively nonresilient material, such as polypropylene. Each of the primary and secondary sealing means tightly seals independent of the spring action by the engagement of the relatively resilient sealing rings 68 and 72 integrally molded with the metering fitment or insert 20 engaging against the relatively less resilient sealing surfaces of the cap stem 62 and seal ring 70.
While the invention has been described, disclosed, illustrated and shown in terms of a preferred embodiment or modification which it has assumed in practice, such other embodiments or modifications as may be suggested to those having the benefit of the teachings herein are intended to be expressly reserved especially as they fall within the scope and breadth of the claims here appended. | Fitment and closure for the mouth of a bottle comprising an open top cup with a tube extending axially upwardly through the bottom wall less than the depth of the cup and molded of a soft material such as polyethylene and comprising a circular base and a depending skirt with the interior of the skirt and the exterior of the bottle finish being provided with cooperating locking lugs, the cap sealing the fitment by means of an inner seal that engages the top portion of the tube and an outer seal that engages inside the cup rim with the inner seal engagement depressing the tube to flex the bottom wall of the cup to bias the locking lugs to provide push and turn child resistance and enabling the closure cap to be made of integral one-piece molded construction of a relatively rigid material, such as polypropylene. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of and claims priority of PCT/SE02/01183, filed 19 Jun. 2002, as well as of both Swedish Patent Application No. 0104409-8, filed 21 Dec. 2001, and U.S. Provisional Patent Application No. 60/304,872, filed 12 Jul. 2001, both of which PCT/SE02/01183 also claims priority from.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention relates to solenoid control, especially in the context of solenoid-controlled fuel injection systems in vehicle engines.
BACKGROUND ART
[0004] In order to minimize the exhaust of particles and nitrous oxide (NOx), as well as to achieve the highest possible efficiency in a diesel engine, the crank angle position at which fuel-injection into a cylinder of a vehicle engine is initiated is critical. Because such fuel injection is typically controlled by a solenoid valve, it is not enough to ensure that the control signal occurs at the correct position; rather one must also know when the valve itself has reached its fully opened position. One known method for determining this involves measuring the current in the driving stage of the solenoid and therefrom detecting the change in inductance that arises when the valve cone is seated.
[0005] This method is usually referred to as BIP-detection, where BIP stands for “Beginning of Injection Pulse.” FIG. 1 is a diagram of current and voltage as functions of time as used in the conventional BIP technique. In principle, the solenoid is controlled by applying a voltage pulse U until the current in the solenoid winding reaches a predetermined level known as the “pull-in” current, which is the current level that must be achieved in the circuit in order to be able to move the solenoid armature.
[0006] Thereafter, the control voltage U is pulsed so that the winding current remains approximately at this level until the valve is fully opened. Once the valve is fully open, however, a significantly lower current—the so-called “hold” current—is needed in order to keep the valve open. This hold current is also maintained by pulsing the control voltage U. The hold current is maintained until it is once again time to close the valve, which is determined by the amount of fuel that is to be injected.
[0007] Detecting the BIP signal at the same time as the pull-in current is being regulated is very difficult because the BIP signal is typically obscured by the noise that arises when using such pure current regulation. The application of the pull-in current is therefore usually turned off immediately before the time when the BIP signal is expected to arise, which can be estimated using known methods. The BIP signal (which appears as a “bump” in the current curve) then occurs in the period during which the current discharges through a freewheel diode D connected to the solenoid winding. This period of current “decay” is known as the BIP “window.” The minimum width of the BIP window needed for reliable detection of the BIP using standard equipment is typically about 600 μs.
[0008] “Freewheeling” refers to the remaining current that circulates within the solenoid circuit after the applied voltage has been shut off. If there were no resistive losses in this circuit, the freewheeling could theoretically continue forever. Components such as a freewheeling diode D and at least one resistive shunt are usually included in the solenoid circuitry, however. It has, moreover, also been shown that the time it takes for the solenoid current to decrease from the pull-in level to the hold level can vary greatly in practice, primarily because of resistances in the network of conductors (such as cables) and connectors used to connect the various components in the circuitry involved in operating the solenoid. These conductor resistances vary not only from application to application, but even among different valves in the same engine. The time for BIP detection may therefore be too short, such that it may become impossible to detect the occurrence of the BIP with certainty—the BIP pulse may fall outside the BIP window and disappear in the noise created by the current regulation.
[0009] The main components of a typical prior art circuit that implements current-only control are shown in FIG. 3. The injection solenoid S (represented in the figures as its inductive winding) is usually connected to a system power supply V via a resistive shunt Rs, in parallel with a freewheel diode D. A conventional circuit 100 is included to measure current through the solenoid, the result of which is applied to a differencing component (shown as an operational amplifier 202 ) in a current-regulating circuit 200 .
[0010] Usually, this circuit 200 will have two inputs, namely, one to set the desired current level and another to turn the current on and off completely. The difference between measured current and desired current is then “added” into the circuit using a power transistor Q 1 . The On/Off signal is similarly applied via a corresponding transistor Q 2 , which acts essentially as a switch.
[0011] The source of the input signals for current level and current ON/OFF will typically be a supervisory processor that calculates desired values and times and generates the input signals in digital form, which are the converted into analog form using a conventional digital-to-analog converter.
[0012] The reason that the voltage U to the solenoid circuit is pulsed ON/OFF in the prior art, instead of being controlled over a continuous range is that the power that develops in the control electronics becomes too high. The problem to be solved is therefore how to ensure a sufficiently large BIP window, thereby allowing reliable BIP detection, without too much power being developed in the circuitry. One known attempted solution to this problem is to include additional circuitry that adds voltage directly to the free-wheeling circuit. The difficulties and complications associated with this solution are well known.
SUMMARY OF THE INVENTION
[0013] A circuit arrangement for controlling a solenoid, which actuates a valve in a fuel-injection system, in which the solenoid is connected in parallel with a freewheel element, comprises a current-control circuit operable to switch current through the solenoid between a pull-in level and a hold level. A voltage-control circuit applies a continuously adjustable voltage at a connection point between the solenoid and the current-control circuit such that the time it takes the current through the solenoid to drop from the pull-in level to the hold level is adjustable above a minimum time.
[0014] In an illustrated embodiment of the invention, the current-control circuit includes an output transistor; the solenoid is connected to ground over the output transistor of the current-control circuit; and the connection point is electrically connected to an output point of the output transistor.
[0015] A current-measuring circuit is preferably also included such that it has an output signal indicating the current through the solenoid. The current-measuring circuit includes a resistive shunt connected electrically in series with the solenoid.
[0016] In the illustrated embodiment, the output signal of the current-measuring circuit forms a first input to a differencing element in the current-control circuit; a desired current level signal forms a second input to the differencing element in the current-control circuit; and the output of the differencing element in the current-control circuit corresponds to the difference between its first and second inputs and is applied as a driving input to the output element of the current-control circuit. Similarly, the voltage-control circuit includes an output transistor over which the solenoid is also connected to ground. An output signal of the voltage-measuring circuit, which is also the signal applied at the connection point, then forms a first input to a differencing element in the voltage-control circuit; a desired voltage level signal forms a second input to the differencing element in the voltage-control circuit; and the output of the differencing element in the voltage-control circuit corresponds to the difference between its first and second inputs and is applied as a driving input to the output element of the voltage-control circuit.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] [0017]FIG. 1 illustrates the current and voltage sequence used to control a solenoid in a fuel-injection system according to the prior art.
[0018] [0018]FIG. 2 illustrates the current and voltage sequence used to control the solenoid using the invention.
[0019] [0019]FIG. 3 shows the main components of a circuit for regulating current to control the solenoid in the prior art.
[0020] [0020]FIG. 4 shows the main components of a circuit for regulating current to control the solenoid according to the invention.
DETAILED DESCRIPTION
[0021] [0021]FIGS. 2 and 4 illustrate the main idea, and circuit, respectively, of the invention: Instead of simply pulsing the control voltage U either ON (Umax) or OFF (0) using the current control circuit 200 , additional voltage Uw that may lie and vary anywhere between Umax and 0, inclusive, is added into the solenoid circuit at the beginning of and maintained during the BIP window by a voltage-control circuit 300 .
[0022] As FIG. 4 shows, the voltage-control circuit 300 has a structure similar to that of the current control circuit 200 , but taps the solenoid circuit directly (at the connection of the freewheeling diode D and the solenoid) as an input to the differencing component 302 .
[0023] The input signals to the control circuit 300 are then the desired voltage level and voltage On/Off, which may also be generated by existing supervisory processing circuitry.
[0024] The “window voltage” Uw is shown in FIG. 2 as being a constant voltage only by way of example. As will become clearer from the description below, the voltage control circuit may be used to generate any voltage profile during the BIP window. A constant additional voltage Uw, will, however, usually be sufficient to adjust the duration of the BIP window. The regulation of the current in the transition range between pull-in and hold is referred to here as “linear” regulation. In this context, linear regulation means that the voltage applied by the voltage-regulating circuit 300 according to the invention may take any value between 0 and the maximum supply voltage. This contrasts with the conventional ON/OFF (switched) regulation used it the prior art, which is illustrated in FIG. 1.
[0025] As FIG. 2 shows, applying the window voltage across the solenoid after the pull-in current has been shut off allows the circuit to control the rate at which the current decreases substantially arbitrarily. Because this added current during the BIP window may be controlled smoothly, there is no concern that the BIP pulse itself will disappear in the noise created by the regulation of the current. Furthermore, although the power developed in the control electronics may become relatively high during the phase of linear regulation, it will be so only briefly, so that the average power developed will still be low.
[0026] In order to ensure the ability to detect BIP with respect to all external circuits, there should be a certain minimum width of the BIP window. FIG. 2 illustrates how the invention solves this problem using voltage-controlled linear regulation. One effect of the application of the invention is apparent from FIG. 2, namely, the BIP window is lengthened. The voltage level that is applied during the current decay period (the BIP window) may also be determined in such a way that the time it takes for the current to decrease from the pull-in level to the hold level remains essentially constant, regardless of the resistances within the network of conductor or other factors that might otherwise affect it.
[0027] As is mentioned above, if there were no resistive losses in the solenoid circuit, freewheeling could theoretically continue forever. In order to compensate for the voltage drop caused by the free-wheel current, multiplied by the inherent resistances, the invention thus makes it possible to add volts to the circuit.
[0028] Note that the figures principally show the principle of regulation—in actual implementation, both of the control circuits 200 , 300 may share the same power transistors and do not necessarily need separate ones. In such case, only a few small and simple components will be needed, which makes for a compact and inexpensive solution.
[0029] The voltage regulation according to the invention is shown here relative to ground. In those cases where the supply voltage varies greatly, however, the regulation preferably takes place relative to the supply voltage instead.
[0030] There are several main advantages of the invention: It ensures that one, using existing equipment, may determine with certainty when the solenoid core is being moved; in other words, one can determine exactly when fuel injection begins in a cylinder. This solution according to the invention means that one may in all cases achieve a well-defined window within which to detect the BIP substantially free of interference.
[0031] Movement of the solenoid armature may then be detected accurately by the “bump” on the current curve, which is easy to detect using known techniques given the time made available by the invention for detection. This is in turn a prerequisite for exactly controlling and regulating a motor in order to minimize exhaust. The invention thus makes it possible to exactly control and regulate the fuel-injection time in a simple and cost-effective manner. The invention also makes it possible to allow greater resistances within the freewheel circuit, which means in turn that one can use cables of smaller gauge, which are less expensive. | In a vehicle fuel-injection system, additional voltage is applied to an otherwise current-controlled valve solenoid so as to increase the time window over which freewheeling current in the solenoid decreases from a pull-in level to a hold level. The time during which the Beginning of Injection Pulse (BIP) signal is detected is thereby increased. | 5 |
TECHNICAL FIELD
[0001] The present invention relates to a twisting machine capable of independently controlling the twisting speed of a thread or plurality of threads, i.e. the twisting density in a certain length and the winding speed of twisted thread.
[0002] The twisting of threads defined in a commercial context typically comprises either: covering a thread or a plurality of threads by rotating one or more threads around the thread; or alternatively, twisting a thread or a plurality of threads by twisting one or more threads around each other.
[0003] Most textile articles including both knitted and woven fabrics, clothing etc. are inherently produced from twisted threads. One remarkable advantage of utilizing twisted threads in producing textile articles is surprisingly their strength, particularly their tensile strength, such that it is more difficult to break off the thread compared to a single untwisted thread in the same thickness. Likewise, a twisted thread is capable of extending in its longitudinal direction much more than an untwisted thread. In addition to these sound mechanical properties, twisted threads are often used by textile designers for creating cutting-edge fashion designs when for instance the threads to be twisted are selected from a group of various colors and formations. These advantageous properties lead the twisted threads to be widely utilized in producing textile products.
BACKGROUND OF THE INVENTION
[0004] Thread twisting technology generally comprises three known methods: the hollow spindle method, the two-for-one method; and the ring twisting method. Various twisting configurations can be obtained by employing these known methods. The twisting configurations can be classified according to the twisting direction as either “S-twisting”, or “Z-twisting” and according to the twisting technique as one or more of “covering”, “fantasy twisting”, and “false twisting”.
[0005] In the hollow spindle method, a first bobbin which is rotated around its longitudinal axis by a motor and another bobbin which is stationary are provided. A first thread released from the stationary bobbin is introduced through an aperture extending along the axis of the rotated bobbin and another thread released from the rotated bobbin is simultaneously introduced through the aperture. The threads taken up from the separate bobbins are combined together in the aperture and twisting of the threads is accomplished by wrapping the thread released from the rotated bobbin around the thread released from the stationary bobbin so as to cover the thread released from the stationary bobbin.
[0006] In a subsequent step, the twisted thread is wound onto another bobbin for dispatching. Notwithstanding the fact that the number of stationary bobbins must be increased to introduce a plurality of threads into the aperture for covering thereof by the thread released from the rotated bobbin, the major disadvantage of the hollow spindle method is that the thread on the rotated bobbin must be prepared in advance for the resultant twisting configuration i.e. S-twisting, Z-twisting etc. Furthermore, the thread must be homogenously and tightly wound on the rotated bobbin prior to use which is a labor-intensive task. Another disadvantage of the hollow spindle method is that the entire bobbin is rotated, potentially causing excessive centrifugal forces depending on the rotation speed. This is why the hollow spindle method is preferred for covering but not for twisting threads together.
[0007] The two-for-one method equipment comprises a spindle having an aperture extending through its axis, a rotor rotating with the spindle, a bobbin having threads thereon and a casing surrounding the bobbin. The reason that this method is called “two-for-one” is that two turns are formed in the threads as the spindle performs one turn.
[0008] The two-for-one effect is achieved only if the casing and the bobbin are held stationary as the spindle rotates even though the casing is coaxially mounted with respect to the spindle. Holding the casing stationary is accomplished by providing s a magnet couple between the casing and the body covering the casing. In other words, opposite poled magnets are fixed to the casing and to the body respectively.
[0009] In the two-for-one method, the threads are directed through the aperture of the spindle so that the threads perform one turn in the aperture of the spindle as the spindle performs one turn. In this manner, the threads are twisted and the first step of the two-for-one method is completed.
[0010] Once the twisted threads have passed through the aperture in the spindle, they are advanced over the rotor to a thread guide which is stationary as it is immovably secured to the machine body. Since the twisted threads are advanced to the thread guide, they perform one more turn between the rotor and the guide meaning that two turns are formed in the threads as the spindle performs one turn. In a subsequent step, the twisted threads are wound on a bobbin for dispatching.
[0011] Although both S-twisting and Z-twisting configurations can be achieved by the two-for-one method, the maximum number of threads provided on the bobbin is generally two. In practice employing more than two threads would not exploit the two-for-one method efficiently, since the threads are knotted or even broken off when released from the bobbin. Furthermore, even using two threads may cause knotting or even breaking off when the threads are slippery. Moreover, the threads to be twisted are wound on the bobbin before the two-for-one twisting begins which involves extra effort. Further, it is not possible to cover threads by the two-for-one method.
[0012] The ring twisting method equipment comprises a plurality of bobbins having untwisted threads provided thereon, speed-controlled rotating cylinders through which the threads released from the bobbins are passed, a ring through which the threads are passed, a thread guide and a spool.
[0013] The threads provided from the bobbins are passed through the ring thus bunching the threads together. The bunch of threads is further advanced through the guide and wound onto the spool as it is rotating. The threads are therefore twisted before winding on the spool.
[0014] The immediate disadvantage of the ring twisting method is the failure to wind the twisted threads directly onto a bobbin, which will be dispatched to the end user. The ring twisting requires a further step to wind the twisted threads onto a bobbin independent from the spool. Moreover, the twisted thread is wound on the spool during use and the spool is rotated as the twisting is performed. As twisted threads accumulates on the spool, the centrifugal forces increase and so the spool must be changed regularly and the spool cannot be rotated at high speeds. Finally, as in two-for-one twisting, covering of threads is not possible by the ring twisting method.
[0015] The most frequently practiced twisting method over the years has been the two-for-one method and accordingly literature shows various studies for improving the two-for-one technology. For instance, U.S. Pat. No. 3,406,511 discloses a spindle having a rotor rotatable with the spindle and a cylinder having a bobbin on which twisted threads are wound. In the cylinder, there is provided a rail element extending parallel to the axis of the cylinder. A thread guide mounted transversely to the rail element and being displaceable in the longitudinal direction of the rail element is provided for winding the twisted threads on the bobbin.
[0016] The bobbin in U.S. Pat. No. 3,406,511, is engaged to a mandrel from its bottom end and said mandrel is associated with a head rotating eccentrically with respect to the axis of the spindle. The head is connected to a platform rotated by the spindle through a spring element. The cylinder is held stationary by an opposite poled magnet couple, one provided to the cylinder and one provided to the body.
[0017] As the spindle and the platform connected thereto are rotated, the bobbin rotates around the axis of the spindle. The thread guide is continuously moved in upper and lower directions and continuously provides twisted threads onto the bobbin so that the twisted threads are wound thereon. As the construction disclosed in U.S. Pat. No. 3,406,511 comprises various eccentrically mounted masses i.e. machine parts including the bobbin, rail element, spring element and so on, the centrifugal forces induced by this eccentricity can not be balanced by the machine configuration. This failure is a major obstacle to the spindle speed and the winding speed of the twisting machine in the U.S. Pat. No. 3,406,511 being set to higher values which leads to inefficiency in twisting of threads.
[0018] U.S. Pat. No. 3,368,336 discloses a version of the machine of U.S. Pat. No. 3,406,511 and includes substantially identical machine parts to the latter. The distinction in U.S. Pat. No. 3,368,336 is that the thread guide can be driven in a vertical direction through magnetic force. Achievement of this movement is performed by an opposite poled magnet couple (one magnet movably provided on the outer surface of the body and one magnet provided on an engagement element engaging the thread guide to the rail). However, the same disadvantages apply to this version, i.e. the incapability of operating the machine at high speeds due to the extreme centrifugal forces induced.
[0019] U.S. Pat. No. 3,834,146 discloses a twisting machine comprising a rotatable spindle having an aperture extending along the axis thereof in which a plurality of threads taken from a plurality of bobbins and incorporated together are provided. The spindle has an opening radially extending therefrom and the threads are taken out through the opening and advanced further via the outer surface of a rotor to a winding drum for winding onto a bobbin.
[0020] The rotation of the spindle and the rotor connected to it in U.S. Pat. No. 3,834,146 is provided by a motor transmitting rotational movement through a belt pulley and a gear reduction mechanism. The rotational movement of the winding drum for winding the twisted threads onto the bobbin is achieved by another gear reduction mechanism. The winding speed of the twisted threads (i.e. the rotation speed of the winding drum) is dependent upon the gear reduction mechanism or any other power transmitting means that would be replaced with the gear mechanism. The only way to change the rotation speed, independently from the spindle speed, of the winding drum is to change the dimensions of the gear reduction mechanism, which suggests an extremely inflexible arrangement.
[0021] EP 0 867 541 discloses a twisting method operated according to the two-for-one method on a machine having first and second centering points. The method comprises introducing twisted threads into a balloon formation zone from the second centering point and then winding the twisted threads onto a bobbin. The arrangement introduced in EP 0 867 541 is substantially identical to that of U.S. Pat. No. 3,406,511 and U.S. Pat. No. 3,368,336 and has the same disadvantages set forth above.
[0022] U.S. Pat. No. 6,047,535 discloses an arrangement providing energy and signal transmission between a first stationary zone and a second zone. The energy transmission is provided by a transformer and the energy is transmitted to movable machine parts including a spindle. The signal generated and modulated by a control unit controls various functional outputs including thread winding breaking, spindle rotation etc.
[0023] JP 59-106527 discloses a twisting machine comprising a spindle, a rotor mounted on the spindle, a gear mounted to an end of the spindle, another gear mounted on a winding drum for matching the gear on the spindle, and a bobbin on which twisted threads from the winding drum are wound.
[0024] As in the above mentioned references, in JP 59-106527, the casing having the bobbin on which twisted threads are wound is kept stationary by a magnet couple. The winding drum speed is set through the gear couple, i.e. the gear on one end of the spindle and the matching gear on the winding drum, so that the winding speed and the rotor speed can be held at different respective values while the twisting machine is operated. However, among the most readily identifiable disadvantages of JP 59-106527, is the fact that the winding drum speed cannot be adjusted while the twisting machine is operating, as the dimensions of the gears on the spindle and on the winding drum cannot be changed simultaneously.
[0025] Since the winding drum speed can only be changed by the replacement of the gear couple with a gear couple of different dimensions, this would lead to an infinite number of gear couple configurations in theory. Furthermore, the arrangement in JP 59-106527 induces extreme centrifugal forces while the twisting machine is in operation, as the machine comprises various masses mounted eccentrically from the spindle rotation axis.
[0026] In the light of the disadvantages pointed out above, there is a need to provide a way of setting spindle speed and winding drum speed independently while a twisting machine is in operation.
DESCRIPTION OF INVENTION
[0027] It is an object of the present invention to enhance the efficiency of thread twisting by independently controlling and altering the speed of thread twisting (i.e. the number of twists per meter) and the winding speed of the twisted threads onto a bobbin as desired.
[0028] Another object of the present invention is to minimize the centrifugal forces and vibrations experienced in a twisting machine to extend the operation life cycle of twisting machines.
[0029] From a first aspect, the present invention provides a twisting machine comprising: a spindle to which a thread or a plurality of threads is/are introduced in use and from which the thread or the plurality of threads is/are taken out in use, the spindle being driven by a spindle driving motor ; a rotor being associated with the spindle and being in contact with the thread or plurality of threads taken out of the spindle while rotating in use; a winding drum for winding the thread or the plurality of threads, which advance from the rotor and are conveyed via a thread guide, onto a bobbin in use; and a stationary carrier carrying the bobbin, characterized in that the machine comprises means for independently moving the spindle and winding drum.
[0030] From a further aspect, the present invention provides a method for twisting threads; comprising introducing a thread or plurality of threads into a spindle having an aperture extending along the axis thereof, said spindle being driven by a motor; taking out the twisted thread or the plurality of threads from the spindle and s advancing the threads from the outer surface of a rotor; and further advancing the twisted threads to a winding drum for winding the twisted threads onto a bobbin, characterized in that the method comprises the steps of;
transmitting the movement of a secondary motor to a primary power transmission means rotatable independently from the spindle, said primary power transmission means being arranged coaxially with the spindle, transmitting the movement provided by the primary power transmission means to a secondary power transmission means capable of performing planetary movement with respect to the spindle axis, transmitting the movement provided by the secondary power transmission means to a tertiary power transmission means rotatable independently from the spindle and said tertiary power transmission means being arranged coaxially with the spindle.
[0034] The preferred method and machine of the present invention further comprises a step for holding the carrier carrying the bobbin onto which twisted threads are wound stationary without using magnets. In order to hold the carrier, a mechanism for performing a planetary movement with respect to the axis of the spindle and dissipating the power transmission in its own arrangement for preventing carrier rotation is provided.
DESCRIPTION OF FIGURES
[0035] Preferred embodiments of the invention will now be described, by way of example only, and with reference to the accompanying drawings in which:
[0036] FIG. 1 is a perspective view of a twisting machine according to the invention;
[0037] FIG. 2 is a perspective view of the motion transmission mechanism of the twisting machine of FIG. 1 ;
[0038] FIG. 3 is a cross-sectional view of the motion transmission mechanism of FIG. 2 ;
[0039] FIG. 4 is a perspective view of an alternative motion transmission mechanism of to a twisting machine according to the invention;
[0040] FIG. 5 is a perspective view of another alternative motion transmission mechanism of a twisting machine according to the invention;
[0041] FIG. 6 is a schematic representation of the mechanism for keeping the carrier of a twisting machine according to the invention stationary;
[0042] FIG. 7 is a schematic representation of the mechanism for keeping the carrier stationary and the motion transmission mechanism of a twisting machine according to the invention;
[0043] FIG. 8 is a schematic representation of an alternative mechanism for keeping the carrier of a twisting machine according to the invention stationary;
[0044] FIG. 9 is a schematic representation of an alternative mechanism for keeping the carrier stationary and the motion transmission mechanism of a twisting machine according to the invention;
[0045] FIG. 10 is a schematic representation of an alternative mechanism for keeping the carrier of a twisting machine according to the invention stationary;
[0046] FIG. 11 is a schematic representation of an alternative mechanism for keeping the carrier stationary and the motion transmission mechanism of a twisting machine according to the invention;
[0047] FIG. 12 is a perspective view of the covering process being carried out by the twisting machine of FIG. 1 ;
[0048] FIG. 13 is a perspective view of the lubricant housing of a twisting machine according to the invention;
[0049] FIG. 14 illustrates the driving mechanism of the winding drum and yarn feeder of a twisting machine according to the invention;
[0050] FIG. 15 illustrates the motion transmission from the yarn feeder to the thread waxing mechanism of a twisting machine according to the invention;
[0051] FIG. 16 illustrates the twisted thread winding termination mechanism for measuring when the bobbin has a predetermined thickness according to the invention;
[0052] FIG. 17 illustrates an alternative twisted thread winding termination mechanism for measuring when the bobbin has a predetermined thickness according to the invention; and
[0053] FIG. 18 illustrates an alternative twisted thread winding termination mechanism for measuring when the bobbin has a predetermined thickness according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0054] In FIG. 1 , a general perspective view of a twisting machine according to the invention is illustrated.
[0055] In general terms, the twisting machine comprises a base portion including a hollow spindle 1 adapted to rotate about its axis and a substantially cylindrical rotor 12 positioned coaxially with the spindle at the upper end thereof and having a greater diameter than that of the spindle as will be described in further detail below. As s shown in FIG. 2 , an aperture 100 is provided in the spindle 1 to extend perpendicular to the axis thereof at a level just below the rotor 12 to link the interior of the hollow spindle to the exterior thereof. A thread guide head 43 is provided a desired distance above the rotor 12 and coaxial with the spindle 1 .
[0056] In the twisting machine according to the invention when being used in a twisting configuration, the thread or plurality of threads 70 to be twisted is/are fed into the machine through the lower end of the spindle 1 . The threads pass along the spindle, out through the aperture 100 and over the radially outer surface of rotor 12 . The twisted threads 44 are then directed to a thread guide head 43 secured is above an upper table 56 and through which the threads 44 are introduced to extend downwardly. The threads extending from the edge of rotor 12 to thread guide head 43 rotate around the spindle 1 axis in use as the rotor 12 rotates and so form a balloon shape around the twisting machine. The height of the balloon can be modified by altering the height of the thread guide head 43 above the upper table 56 .
[0057] The twisted threads 44 are then passed through a pig tail 42 and further advanced to a yarn feeder pulley 49 secured to the upper table 56 . Afterwards the twisted threads are directed to a wax 50 for waxing thereof and then fed to a winding drum 46 for winding the twisted threads onto a bobbin 45 . In the particular embodiment shown in FIG. 1 , 4 threads are being twisted together. It will be appreciated however that the machine could be used to twist a different number of threads of from 2 to 8 or more.
[0058] In FIG. 2 , the motion transmission mechanism is illustrated in perspective view and the same mechanism is illustrated in cross-sectional view in FIG. 3 . The spindle 1 is driven by a driving motor 27 for rotating thereof, and a rotor 12 connected coaxially to the spindle 1 is rotated with the same rotation speed of the spindle 1 .
[0059] A planetary pulley mechanism 4 is coaxially provided) on the spindle 1 , and this pulley 4 is rotated by a winding drum driving motor 28 independently from the spindle driving motor 27 . The actuation provided by the winding drum driving motor 28 is preferably transmitted to the planetary pulley mechanism 4 by a winding drum driving belt 30 . A ball bearing is provided between the planetary pulley mechanism 4 and the spindle 1 so that the outer ring of the ball bearing rotates with the planetary pulley mechanism 4 and the inner ring of the ball bearing rotates with the spindle 1 .
[0060] The planetary pulley mechanism 4 is fixed to a lower collar 33 having a rotatable gear 10 (a lower rotatable gear) at one end thereof and the lower collar 33 being coaxially arranged on the spindle 1 . Thus as the planetary pulley mechanism 4 is rotated, the gear 10 is rotated accordingly with the same rotational speed. The rotatable gear 10 transmits its rotational motion to a primary planetary gear 6 , capable of performing planetary motion around the spindle 1 axis, by a lower rotatable gear belt 35 . A primary power transmission spindle 21 is provided, preferably by tight engagement, in an opening extending along the axis of the primary planetary gear 6 so that the primary power transmission spindle 21 can transmit its motion along its axis. As the primary power transmission spindle 21 passes through the rotor 12 and a rotor lower piece 11 , the primary power transmission spindle 21 is rotatably housed to a primary bearing housing 23 in which bearings are mounted. The primary power transmission spindle 21 has a secondary planetary gear 8 mounted at the other end being at the upper side of the rotor 12 . As the secondary planetary gear 8 is preferably tightly engaged to the primary power transmission spindle 21 , the secondary planetary gear 8 , capable of performing planetary motion around the spindle 1 axis, rotates with the same rotational speed as the primary planetary gear 6 .
[0061] Furthermore, since the primary power transmission spindle 21 is associated with the rotor 12 , which is rotated by the spindle 1 , the primary power transmission spindle 21 has a certain linear velocity with respect to the spindle 1 axis. Consequently, both the primary and secondary planetary gears 6 , 8 rotate both about the power transmission spindle 21 axis and about the spindle 1 axis, so performing planetary motions.
[0062] The secondary planetary gear 8 transmits its rotational motion to a rotatable gear 17 , an upper rotatable gear, mounted to one end of an upper collar 38 being coaxially arranged on the spindle 1 by an upper rotatable gear belt 36 . A ball bearing is provided between the upper rotatable gear 17 and the spindle 1 so that the outer ring of the ball bearing rotates with the upper rotatable gear 17 and the inner ring of the ball bearing rotates with the spindle 1 . The upper collar 38 has a yarn feeder pulley 14 and a winding drum driving pulley 15 at its other end, both being arranged coaxially with the spindle 1 axis. The pulleys 14 , 15 preferably rotate with the same rotation speed as the upper collar 38 .
[0063] Consequently, on the same machine axis, i.e. on the spindle axis, the thread twisting speed and winding speed of the twisted thread are independently adjusted.
[0064] The speeds of the spindle driving motor 27 and the winding drum driving motor 28 can be adjusted as desired through a control unit or independently without employing a control unit.
[0065] In FIG. 2 and FIG. 3 , the mechanism used to keep the carrier carrying the winding drum 46 , and the bobbin 45 on which twisted threads are wound, stationary without employing magnetic means is also shown.
[0066] A lower stationary gear 9 is provided on the outer surface of the lower collar 33 , so the lower stationary gear 9 is coaxially mounted to the spindle 1 axis with the collar 33 . The lower stationary gear 9 is fixed to a fixing platform 26 by attaching means 25 and the fixing platform 26 is immovably connected to a sheet metal plate 24 attached to the body of the twisting machine. A ball bearing is provided between the lower stationary gear 9 and the lower collar 33 and while the inner ring of the ball bearing is rotatable with the lower collar 33 , the outer ring is kept stationary.
[0067] A lower stationary gear belt 34 is mounted between the lower stationary gear 9 and a tertiary planetary gear 5 for performing planetary motion around the spindle 1 axis. A first end of secondary planetary spindle 20 is provided in an opening extending along the axis of the tertiary planetary gear 5 . The secondary planetary spindle 20 has a quaternary planetary gear 7 provided at the other end thereof in a substantially identical manner to the mechanism described above for FIGS. 2 and 3 . The secondary planetary spindle performs planetary rotation around the spindle 1 axis. Since the secondary planetary spindle 20 passes through the rotor 12 , which is rotated by the spindle 1 , the secondary planetary spindle 20 has a certain linear velocity with respect to the spindle 1 axis. Consequently, both the tertiary and quaternary planetary gears 5 , 7 rotate both about the secondary planetary spindle 20 axis and about the spindle 1 axis, so performing planetary motions around the spindle 1 axis. An upper stationary gear belt 37 is mounted between the quaternary planetary gear 7 and an upper stationary gear 16 mounted on the outer surface of the upper collar 38 . A ball bearing is provided between the upper stationary gear 16 and the upper collar 38 , and while the inner ring of the ball bearing is rotatable with the upper collar 38 , the outer ring is kept stationary. The upper stationary gear 16 keeps its stationary position, i.e. does not rotate, for the reasons to be explained with reference to FIGS. 6 to 11 . Since the carrier 13 carrying the winding drum 46 and the bobbin 45 is fixed to the upper stationary gear 16 , the carrier also keeps its stationary position, i.e. it does not rotate around the spindle 1 axis.
[0068] The embodiment described above is a preferred construction of the device of the invention and preferably, the number of teeth and/or the diameters of the lower stationery gear 9 and the upper stationary gear 16 are identical.
[0069] However, if the number of teeth and/or the diameters of the lower stationery gear 9 and the upper stationary gear 16 are different from each other then the carrier might have a slight turning motion depending on the difference in the number of teeth and/or the respective diameters. This situation would apply when the belts 34 , 37 used are the trigger or toothed kind as in the best mode of the invention, the belts having more or less teeth to match with the gears 9 , 5 , 7 , 16 .
[0070] In the preferred embodiment of the present invention, the elements 6 , 8 ; 5 , 7 performing planetary motion around the spindle 1 and the elements 10 , 17 ; 9 , 16 associated with those 6 , 8 ; 5 , 7 performing planetary motion are preferably gears and the motion transmission belts 34 , 35 , 36 , 37 between these gears 6 , 8 ; 5 , 7 , 10 , 17 ; 9 , 16 are trigger belts.
[0071] An alternative mechanism providing independent adjustment of the twisting speed and the thread winding speed without employing belts is illustrated in FIG. 4 . According to the figure, the gears 6 , 8 performing planetary motion around the spindle 1 directly match the rotatable gears 10 , 17 coaxially mounted on the spindle 1 axis.
[0072] In this alternative, similarly, the gears 5 , 7 performing planetary motion around the spindle 1 axis for preventing rotation of the carrier without employing magnets, directly match the gears 9 , 16 coaxially mounted on the spindle axis 1 .
[0073] In FIG. 5 , an alternative mechanism comprising a bevel gear group providing independent adjustment of the twisting speed and the thread winding speed is illustrated. In this alternative, the lower rotatable gear 10 and the upper rotatable gear 17 are replaced with bevel gears. Furthermore, motion transmission between the lower rotatable gear 10 and the upper rotatable gear 17 is provided by primary and secondary bevel gears 6 , 8 matching the lower rotatable gear 10 and the upper rotatable gear 17 and mounted substantially radially—perpendicularly—to the spindle 1 axis. The primary and secondary bevel gears 6 , 8 perform planetary motion around the spindle 1 axis. In this alternative, the number of gears performing planetary motion is at least one, and selected as two preferably.
[0074] The alternative embodiment shown in FIG. 5 comprises a magnet couple 68 , one of which is provided on the body of the twisting machine and has an opposite pole with respect to the other which is provided on the carrier 13 for keeping the carrier 13 stationary, while the spindle speed and the twisted thread winding speed are adjusted independently.
[0075] As another alternative for adjusting the thread twisting speed and twisted thread winding speed independently, the motion transmission between the lower rotatable gear 10 and primary planetary gear 6 ; and similarly the motion transmission between the secondary planetary gear 8 and the upper rotatable gear 17 can be provided, without a mechanical connection, by magnetic gear couples or magnetic cylindrical means. The same motion transmission can be employed for keeping the carrier 13 stationary. In this case, the lower stationary gear 9 and tertiary planetary gear 5 ; and similarly the quaternary planetary gear 7 and upper stationary gear become magnetic gear couples or magnetic cylindrical means.
[0076] Alternatively, the lower rotatable gear 10 , the primary planetary gear 6 , the secondary planetary gear 8 and the upper rotatable gear 17 could be selected as pulley gears or chain gears. In this latter case, the motion transfer between the chain gears is provided by chains. Furthermore, all of the above-mentioned alternatives set forth e.g. magnetic gear couples, chain gears etc. for independently adjusting the twisting speed, i.e. the spindle speed, and the thread winding speed, i.e. winding drum speed, apply also to the motion transmission mechanism provided to keep the carrier 13 stationary.
[0077] FIG. 6 schematically illustrates the mechanism for keeping the carrier of the twisting machine of FIGS. 1 to 3 stationary. This figure is intended to describe the way in which the upper stationary gear 16 and the carrier 13 connected thereto are prevented from rotating without an attachment to the body of the twisting machine.
[0078] The relative velocities of the component parts are defined as follows, where:
[0079] w 0 =spindle angular velocity
[0080] w 1 =lower stationary gear angular velocity
[0081] w 2 =angular velocity of the tertiary planetary gear around the secondary planetary spindle axis
[0082] m=number of teeth of the lower stationary gear
[0083] n=number of teeth of the tertiary planetary gear
[0084] l=number of teeth of the quaternary planetary gear
[0085] k=number of teeth of the upper stationary gear
[0000] w 2 =( w 0 +w 1 )* m/n and from the similarity;
[0000] w 2 =( w 0 +w 3 )* k/l
[0087] In this case;
[0000] ( w 0 +w 1 )* m/n =( w 0 +w 3 )* k/l
[0088] So, if m/n=k/l then w 1 =w 3 .
[0089] As seen from the FIG. 3 , since the lower stationary gear 9 is fixed to the body, w 1 =0, so the angular velocity of the upper stationary gear becomes w 3 =0.
[0090] FIG. 7 schematically illustrates the mechanism for keeping the carrier of FIG. 6 stationary and the motion transmission mechanism of the twisting machine according to the invention.
[0091] FIG. 8 schematically illustrates an alternative mechanism for keeping the carrier of the twisting machine according to the invention stationary. The theory discussed above for FIG. 6 also applies to this mechanism. As shown, in this alternative mechanism each of the lower stationary gear 9 , the tertiary planetary gear 5 , the quatemary planetary gear 7 and the upper stationary gear 16 comprise toothed gear wheels which interengage in respective pairs such that no belts need to be used. The remaining parts of FIG. 8 correspond to those of FIG. 6 . FIG. 9 shows the mechanism of FIG. 8 for keeping the carrier stationary combined with an equivalent motion transmission mechanism.
[0092] FIG. 10 schematically illustrates an alternative mechanism for keeping the carrier of the twisting machine according to the invention stationary. In this embodiment, the lower stationary gear 9 and the upper stationary gear 16 comprise ring gears having teeth on the inner surface thereof which engage with the tertiary and quatemary planetary gears respectively (those gears comprising toothed gear wheels). Again, the remaining parts of this Figure correspond to those of FIG. 6 . Again, the theory mentioned for FIG. 6 applies to this mechanism.
[0093] FIG. 11 shows the mechanism of FIG. 10 for keeping the carrier stationary combined with an equivalent motion transmission mechanism.
[0094] FIG. 12 is a perspective view of a twisting machine according to the invention being used in a covering process. In use, a thread or plurality of threads 70 are passed through the thread guide head 43 from above, are covered by a thread 71 which is passed through an opening at the lower end of the spindle 1 , out of the spindle, over the rotor 12 and upwardly to enter the thread guide head 43 with the other threads 70 . Through this process, covering twisting is performed. In the particular embodiment shown, 5 threads are being covered using a single thread. It will be appreciated however that one or more threads could be covered by either a single thread, a plurality of threads twisted together or a plurality of threads extending parallel to one another.
[0095] FIG. 13 illustrates the lubricant housing having ball bearings of a twisting machine according to the invention. When the spindle 1 is rotated at high speeds, centrifugal forces arise, causing the lubricant to move to the outer most walls in the bearing housings 22 , 23 in which the ball bearings of the primary and secondary planetary spindles 20 , 21 are mounted. In order to prevent the lubricant leakage from the bearing housings 22 , 23 , lids 54 are mounted to the bearing housings 22 , 23 .
[0096] FIG. 14 illustrates the driving mechanism of the winding drum and yarn feeder of a twisting machine according to the invention. The winding drum driving pulley 15 transmits its motion received from the upper collar 38 to a winding drum pulley 51 coupled with the winding drum 46 by a winding drum driving belt 40 . Similarly, yarn feeder pulley 14 transmits its motion to a yarn feeder spindle 41 by a yarn feeder belt 39 . The yarn feeder belt 39 transmits its motion to a yarn feeder spindle pulley 48 mounted on the yarn feeder spindle 41 . A yarn feeder roller 49 is provided on the yarn feeder spindle 41 and the twisted threads are passed around the yarn feeder roller 49 for drawing the twisted threads by the winding drum 46 for winding thereof on the bobbin 45 .
[0097] to The winding drum 46 is secured to the carrier 13 by fixation means and the winding drum 46 , rotated by the actuation provided by the winding drum driving pulley 15 , winds the twisted thread onto the bobbin. Rotation direction of the winding drum driving pulley 15 is altered by a middle pulley 52 on which the winding drum driving belt 40 is connected.
[0098] FIG. 15 illustrates the motion transmission from the yarn feeder to the thread waxing mechanism of a twisting machine according to the invention when used for twisting. The twisted thread passing through the thread guide head 43 is further passed through the pig tail 42 and advanced to the wax 50 for waxing thereof. The wax 50 can be rotated around its own axis without driving by another means as seen in FIG. 1 . Alternatively, the wax 50 can be associated with the yarn feeder spindle 41 by a driving belt 57 for driving the wax 50 . The twisted and waxed thread is directed to the winding drum 46 through an opening 47 in the upper table 56 without utilizing another directing means. So, channels 53 grooved on the winding drum 46 can directly wind the twisted thread conveyed from the upper table 56 onto the bobbin 45 .
[0099] FIGS. 16 to 18 illustrate the mechanisms for terminating winding of the twisted thread when the bobbin has a predetermined thickness.
[0100] In FIG. 16 , a sensor operated according to a radio frequency sensing method is illustrated. As the twisted threads are wound onto the bobbin 45 the thickness thereof increases, a bobbin arm 58 securing the bobbin 45 to the carrier 13 slightly rotates and a switch 59 mounted close to a tip of the bobbin arm 58 is forced to move so that the radio frequency generator 61 is actuated. The radio frequency 60 generated is received by a receiver 62 and once the radio frequency 60 rises to a predetermined level then the receiver 62 controls the motors to terminate the thread winding operation.
[0101] In FIG. 17 , a signal supplier 63 and a signal receiver 64 mutually positioned opposite each other are illustrated. The signal 65 permanently supplied by the signal supplier 63 to the signal receiver 64 is interrupted when the thickness of the bobbin increases to a certain level by the twisted threads and then the signal receiver 64 generates a signal for controlling the motors to terminate the thread winding operation.
[0102] In FIG. 18 , a sensor mechanism having a beam supplier-receiver and a reflector is illustrated. The reflector 66 is mounted at a tip of the bobbin arm 58 . As the thickness of the bobbin increases by the wound twisted threads, the bobbin arm 58 in contact with the increased thickness of the bobbin slightly rotates and the beam 67 supplied by the beam supplier-receiver 68 alters its reflected direction so that it corresponds to the receiver section of the beam supplier-receiver 68 . The receiver then generates a signal to control the motors to terminate the thread winding operation. | The invention relates to a twisting machine capable of independently controlling the twisting speed of a thread or plurality of threads and the winding speed of the twisted threads i.e. the twisting density in a certain length and the method of the same. Thus, a twisting machined is provided comprising: a spindle ( 1 ) extending in an axial direction from a first end to a second end thereof; drive means for rotatably driving the spindle ( 1 ); a rotor coaxially mounted to the spindle adjacent the second end thereof; winding means for winding thread onto a bobbin; a stationary carrier supported over the rotor on the opposite side thereof from the spindle, the carrier supporting the bobbin thereon; and thread guide means spaced in the axial direction from the carrier, wherein in use, thread extends from the spindle via the radially outer edge of the rotor to the thread guide means, characterized in that the machine comprises means for independently moving the spindle and the winding means. | 3 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Not applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable.
BACKGROUND OF THE INVENTION
FIELD OF THE INVENTION
[0003] The present invention relates generally to vehicle hubcaps or wheel center caps that spin. More particularly, the present invention relates to spinning vehicle hubcaps that are attached to the outer ends of the central hubs of wire spoke vehicle wheels, such as the 30-spoke wire wheels offered and sold by Texan Wire Wheels, LLC. (texanwirewheels.com).
[0004] BRIEF SUMMARY OF INVENTION
[0005] In one embodiment of the present invention there is described a spinning hub cap assembly, for use on the end face of a center hub of a wheel (such as, for example, a wire wheel, or a 30-spoke wire wheel), the wheel having an axis of rotation, comprising: a base section connectable on its inside to the end face of the wheel center hub and on its outside to an outer section; and an outer section rotatably connected to the base section, wherein the rotatable connection permits rotation of the outer section about the wheel axis of rotation. In another embodiment, the outer section may further comprise an outer face and an inner face, wherein the inner face further comprises a bearing (such as a sealed bearing) mounted thereon on a bearing mount; wherein the base section outside further comprises a receiving well for receiving the bearing in mated, attached relationship. The assembly may further comprise a retention shaft employed to retain together, in rotational relationship, the outer section and the base section. In another embodiment, the base section further comprises a rotational assembly on its outside which is fixably connectable to the cap outer section. The outer section may comprise a central section, and two or more spaced-apart winged sections. The outer section may also comprise a central section, and two opposed winged sections.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0006] FIG. 1A presents a perspective view of a 30 -spoke prior art wire wheel offered and sold by Texan Wire Wheels, LLC (texanwirewheels.com) containing a fixed, non-spinning hub cap, here shown with a 2-bar variety fixed (non-spinning) wheel center cap.
[0007] FIG. 1B presents a side view of a 30-spoke prior art wire wheel offered and sold by Texan Wire Wheels, LLC (texanwirewheels.com) containing a fixed, non-spinning hub cap, here shown with a 2-bar variety fixed (non-spinning) wheel center cap.
[0008] FIG. 1C presents a perspective, topside view of a prior art wire wheel center cap offered and sold by Texan Wire Wheels, LLC (texanwirewheels.com) (here, shown in the hexagonal shape) for attaching in a fixed, non-spinning relationship to the center hub extension of the wheel.
[0009] FIG. 1D presents a perspective, underside view of a prior art wire wheel center cap offered and sold by Texan Wire Wheels, LLC (texanwirewheels.com) (here, shown in the hexagonal shape) for attaching in a fixed, non-spinning relationship to the center hub extension of the wheel via the threaded post connection shown or other suitable attachment configuration. The hexagonal hub is shown resting on the wheel center hub end face.
[0010] FIG. 1E presents a perspective, topside view of a prior art wire wheel center cap offered and sold by Texan Wire Wheels, LLC (texanwirewheels.com) (here, shown in the 2-bar shape) for attaching in a fixed, non-spinning relationship to the center hub extension of the wheel.
[0011] FIG. 2 shows topside view of a spinning wheel center cap according to the present invention (here, shown in the 2-bar or wing shape, but other cap shapes are possible) for attaching to the center hub extension of the wheel in a manner that permits the outer portion of the cap to rotate freely relative to the wheel center hub.
[0012] FIG. 3A shows an underside perspective view of the spinning wheel center cap of FIG. 2 according to the present invention (here, shown in the 2-bar or wing shape, but other cap shapes are possible). The upper section of the cap is mounted to the lower section in a rotatable, spinnable relationship. The lower base section is fixably mounted to the center hub extension of the wheel via the threaded post connection shown or via other suitable attachment configuration.
[0013] FIG. 3B shows an underside perspective view of the spinning wheel center cap of FIG. 2 according to the present invention (here, shown in the 2-bar or wing shape, but other cap shapes are possible). The upper section of the cap is mounted to the lower section in a rotatable, spinnable relationship. The lower base section is fixably mounted to the center hub extension of the wheel via the threaded post connection shown or via other suitable attachment configuration.
[0014] FIG. 3C shows a side view close up of the spinning wheel center cap of FIG. 2 according to the present invention (here, shown in the 2-bar or wing shape, but other cap shapes are possible) for attaching in a rotatable, spinning relationship to the center hub extension of the wheel. The upper section of the cap is mounted to the lower section in a rotatable, spinnable relationship. The lower base section is fixably mounted to the center hub extension of the wheel via suitable attachment configuration.
[0015] FIG. 3D shows a side view of the spinning wheel center cap of FIG. 2 according to the present invention (here, shown in the 2-bar or wing shape, but other cap shapes are possible) for attaching in a rotatable, spinning relationship to the center hub extension of the wheel. The upper section of the cap is mounted to the lower section in a rotatable, spinnable relationship. The lower base section is fixably mounted to the center hub extension of the wheel via suitable attachment configuration.
[0016] FIG. 4A shows an underside view of the spinning wheel center cap of FIG. 2 according to the present invention (here, shown in the 2-bar or wing shape, but other cap shapes are possible). The underside of the lower or base section can be fixably attached to the center hub extension of the wheel via the threaded post connection on the connection member shown or other suitable attachment configuration. The connection member shown is mounted in a recessed fashion and secured with screws or other suitable securing mechanisms.
[0017] FIG. 4B shows a perspective underside view of the spinning wheel center cap of FIG. 4A according to the present invention. The underside of the lower or base section can be fixably attached to the center hub extension of the wheel via the threaded post connection member (shown partially removed and in topside perspective view) or via other suitable attachment configuration.
[0018] FIG. 4C shows a perspective underside view of the spinning wheel center cap of FIG. 4A according to the present invention. The underside of the lower or base section can be fixably attached to the center hub extension of the wheel via the threaded post connection member insert (shown removed from the recessed well and in underside perspective view) or via other suitable attachment configuration.
[0019] FIG. 4D shows an underside view of the spinning wheel center cap of FIG. 4A according to the present invention. The underside of the lower or base section can be fixably attached to the center hub extension of the wheel via the threaded post connection member (not shown, removed from the recessed well) or via other suitable attachment configuration. A recessed well for receiving the connection member is shown.
[0020] FIG. 4E shows a close up underside view of the spinning wheel center cap of FIG. 4D according to the present invention showing a securing bolt in the connection member recessed well.
[0021] FIG. 4F shows a perspective underside view of the spinning wheel center cap of FIGS. 4D and 4E according to the present invention showing the securing bolt partially removed.
[0022] FIG. 4G shows a close up underside view of the spinning wheel center cap of FIGS. 4D-F according to the present invention showing the securing bolt partially removed.
[0023] FIG. 4H shows a close up underside view of the spinning wheel center cap of FIG. 4G according to the present invention showing the securing bolt or retaining shaft removed.
[0024] FIG. 4I shows a close up underside view of the spinning wheel center cap of FIG. 4H according to the present invention showing the threaded post in the base for receiving the securing bolt, and showing the threaded apertures for receiving the screws that secure the connection member insert.
[0025] FIG. 4J shows a close up of the receiving well of FIG. 4I .
[0026] FIG. 4K shows another close up of the receiving well of FIG. 4I .
[0027] FIG. 5A shows a side view of the spinning wheel center cap of FIG. 4H according to the present invention wherein the upper section is shown partially removed from the lower base section.
[0028] FIG. 5B shows a perspective view of the upper section (on left) and the lower base section (on right) separated from each other. The upper section is shown in an underside perspective view and shows a sealed bearing mounted on a threaded post. The base section is shown in topside perspective to illustrate how the top and bottom sections fit together in mated fashion with the securing bolt.
[0029] FIG. 5C shows a perspective view of the upper section (on left) and the lower base section (on right) separated from each other. The upper section is shown in an underside perspective view and shows a sealed bearing mounted on a threaded post. The base section is shown in topside perspective to illustrate how the top and bottom sections fit together in mated fashion with the securing bolt (not shown).
[0030] FIG. 6A shows an underside view of the top section of the spinning wheel center cap of FIG. 2 according to the present invention.
[0031] FIG. 6B shows an underside perspective view of the top section of the spinning wheel center cap of FIG. 2 according to the present invention.
[0032] FIG. 6C shows an underside close up perspective view of the top section of the spinning wheel center cap of FIG. 2 according to the present invention.
[0033] FIG. 6D shows another underside perspective view of the top section of the spinning wheel center cap of FIG. 2 according to the present invention.
[0034] FIG. 6E shows another underside close up perspective view of the top section of the spinning wheel center cap of FIG. 2 according to the present invention showing here, for illustration purposes (and without the base in place), how the securing bolt secures to the threaded post.
[0035] FIG. 7A shows a topside perspective view of the bottom (base) section of the spinning wheel center cap of FIG. 2 according to the present invention.
[0036] FIG. 7B shows a side view of the bottom (base) section of the spinning wheel center cap of FIG. 7A according to the present invention.
[0037] FIG. 7C shows a topside view of the bottom (base) section of the spinning wheel center cap of FIG. 7A according to the present invention.
[0038] FIG. 7D shows an underside view of the bottom (base) section of the spinning wheel center cap of FIG. 7A according to the present invention.
[0039] FIG. 7E shows an underside perspective view of the bottom (base) section of the spinning wheel center cap of FIG. 7A according to the present invention.
[0040] FIG. 7F shows a side view of the bottom (base) section of the spinning wheel center cap of FIG. 7A according to the present invention where the base contains the hub connection insert shown without the top section in place.
[0041] FIG. 7G shows an underside perspective view of the bottom (base) section of the spinning wheel center cap of FIG. 7F according to the present invention where the base contains the hub connection insert shown without the top section in place.
[0042] FIG. 8A shows a topside view of the connection member insert of the bottom (base) section of the spinning wheel center cap of FIG. 2 according to the present invention.
[0043] FIG. 8B shows an underside view of the connection member insert of the bottom (base) section of the spinning wheel center cap of FIG. 2 according to the present invention.
[0044] FIG. 8C shows a side view of the connection member insert of the bottom (base) section of the spinning wheel center cap of FIG. 2 according to the present invention.
[0045] FIG. 9A shows a side view of the securing bolt (retaining shaft) of the spinning wheel center cap of FIG. 2 according to the present invention.
[0046] FIG. 9B shows a top view of the securing bolt of the spinning wheel center cap of FIG. 2 according to the present invention.
[0047] FIG. 9C shows an underside perspective view of the securing bolt of the spinning wheel center cap of FIG. 2 according to the present invention.
[0048] FIG. 9D shows another side view of the securing bolt of the spinning wheel center cap of FIG. 2 according to the present invention.
[0049] FIG. 10A shows an exploded view of the spinning wheel center cap of FIG. 2 according to the present invention.
[0050] FIG. 10B shows another exploded view of the spinning wheel center cap of FIG. 2 according to the present invention.
[0051] FIG. 10C shows another exploded view of the spinning wheel center cap of FIG. 2 according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0052] Referring to FIGS. 1A-1B , there is shown an exemplary 30-spoke prior art wire wheel 10 offered and sold by Texan Wire Wheels, LLC (texanwirewheels.com) containing a fixed, non-spinning hub cap, here shown with a 2-bar variety fixed (non-spinning) wheel center cap 30 . The fixed hub cap is mounted to the end face 22 of the wheel center hub 20 .
[0053] FIG. 1C presents a perspective, topside 35 a view of a prior art wire wheel center cap offered and sold by Texan Wire Wheels, LLC (texanwirewheels.com) (here, shown in the hexagonal shape) 35 for attaching in a fixed, non-spinning relationship to the end face 22 of the center hub extension 20 of the wheel 10 . FIG. 1D presents a perspective, underside 35 b view of a prior art wire wheel center cap offered and sold by Texan Wire Wheels, LLC (texanwirewheels.com) (here, shown in the hexagonal shape) 35 for attaching in a fixed, non-spinning relationship to the end face 22 of the center hub extension 22 of the wheel 10 via the post connection 36 shown (with threaded aperture 38 ) or other suitable attachment configuration. The hexagonal hub cap 34 is shown resting on the wheel center hub 20 end face 22 . These fixed caps 35 , have an underside lip 39 spanning a diameter 36 that permits the cap to fit over the outer diameter of the wheel center hub end face 22 to facilitate a clean, mated point of connection 40 between the fixed hub cap 30 and the wheel center hub 20 end face 22 .
[0054] FIG. 1E presents a perspective, topside view of a prior art wire wheel center cap offered and sold by Texan Wire Wheels, LLC (texanwirewheels.com) (here, shown in the 2-bar shape) 30 for attaching in a fixed, non-spinning relationship to the face 22 of the center hub extension 20 of the wheel 10 . This two-bar or winged cap has an outer side 110 , and underside 120 , and two or more wings or bars 32 . Many different configurations are available, the 2-bar variety and the hex cap variety are being shown here for illustration purposes.
[0055] FIG. 2 shows topside view of a spinning wheel center cap 50 according to the present invention (here, shown in the 2-bar or wing shape, but other cap shapes are possible) for attaching to the end face 22 of the center hub extension 20 of the wheel 10 in a manner that permits the outer or top portion 100 of the cap to rotate freely relative to the wheel center hub 20 . In this 2-bar variety spinning center cap 50 , the cap upper spinning section 100 may comprise wings 102 . In a preferred embodiment, the cap 50 comprises two opposed wings 102 that have aerodynamically designed edges to permit wind friction to cause the cap spinning section 100 to rotate. The cap upper (spinning) section 100 has an outer side 110 that may contain decorative elements visible when looking at the cap 50 mounted on the wheel 10 . The cap upper section 100 also has an underside 120 .
[0056] Referring also to FIGS. 3A-3D , there is shown various views of the spinning wheel center cap 50 of FIG. 2 . The upper section 100 of the cap 50 is mounted to the lower section 200 in a rotatable, spinnable relationship. The lower base section 200 is fixably mounted to the face 22 of the center hub extension 20 (not shown) of the wheel 10 (not shown) via the threaded post 310 of connection insert 300 shown or via other suitable attachment configuration. In a preferred embodiment, the lower base 200 comprises a lip 250 that fits snugly over the outer diameter of the end face 22 of the wheel center hub 20 . In this embodiment, the base is fitted with an insert connection 300 that is secured in place via screws 330 to the underside 220 of the base 200 . The insert connection 300 comprises a connection post 310 of desired height, and preferably includes threaded aperture 320 for receiving a connection bolt (not shown) used to secure the cap 50 to the wheel center hub end face 22 . The upper section 100 is permitted to rotate about the lower section 200 along axis of rotation 60 . The upper section 100 of the cap 50 is mounted to the lower section 200 in a rotatable, spinnable relationship in a manner that creates a gap 190 separating the lower edges 122 of the upper section 100 from the upper edges 212 of the base section 200 . The cap lower or base section 200 comprises a topside 210 and an underside 220 .
[0057] FIG. 4A shows an underside view of the spinning wheel center cap 50 of FIG. 2 . The underside 220 of the lower or base section 200 can be fixably attached to the face 22 of center hub extension of the wheel (not shown) via the threaded post connection 310 on the connection member 300 shown or via other suitable attachment configuration. The connection member 300 shown is mounted in a recessed fashion within base insert well 230 and secured with screws 330 or other suitable securing mechanisms. FIG. 4B shows a perspective underside view of the spinning wheel center cap 50 of FIG. 4A . The threaded post connection member 300 is shown partially removed and in topside perspective view. The connection insert 300 sits within receiving well 230 and is secured in place, for example, by screws 330 that are passed through the hub insert attachment apertures 340 and secured into the base insert well threaded apertures 236 .
[0058] Referring also to FIGS. 4C-4K , the base insert receiving well 230 has a diameter 235 that is adapted to receive the hub connection insert 300 having an outer diameter 350 . The connection member insert 300 is shown fully removed from the recessed well 230 and in underside perspective view. A retaining shaft 400 with external retaining ring 410 mounted in retaining ring groove 412 is employed to secure the cap upper section 100 to the cap lower section 200 in a manner that permits rotation of the upper section 100 about the axis 60 relative to the lower section 200 . In a preferred embodiment, the lower base 200 comprises a lip 250 having a diameter 260 that fits snugly over the outer diameter of the end face 22 of the wheel center hub 20 . FIGS. 4F-4G show the securing bolt or retaining shaft 400 partially removed. The securing bolt or retaining shaft 400 employs threads 420 that are mated to be received in the threaded aperture 142 in the bearing mount post 140 located in the center of the cap spinning section underside 120 (shown in later figures). FIG. 4H shows the securing bolt or retaining shaft 400 removed to reveal the threaded aperture 142 . The receiving well 230 has a depth 232 that in one preferred embodiment matches the height 306 of the insert 300 (see FIG. 8C ).
[0059] FIG. 5A shows a side view of the spinning wheel center cap of FIG. 4H according to the present invention wherein the upper section is shown partially removed from the lower base section. FIGS. 5B-5C show the upper section 100 and the lower base section 200 separated from each other. Referring also to FIGS. 6A-E , the upper section 100 has a sealed bearing 130 fixably mounted on bearing mount post 140 in a manner that permits free rotational movement of the bearing 130 (i.e., there is a gap 134 between bearing 130 and cap spinning section underside 120 ). The bearing can freely rotate about the bearing mount post about axis 60 . The bearing 130 is preferably a sealed bearing such as the rubber sealed variety sold by VXB.com under the model number 6202RS (15×35×11 mm) or the like. Other suitable bearing configurations known in the art may be employed. The upper side 210 of the base section 200 is configured with a base extension stem 240 of desired height. Within the base extension stem 240 is a bearing receiving well 270 having in inside diameter 272 capable of receiving in snug relationship the outside diameter 132 of bearing 130 so as to permit the cap upper section 100 to be secured to bearing 130 to permit the upper section 100 to rotate on the bearing 130 about axis 60 . The top 100 and bottom 200 sections fit together in mated fashion with the bearing 130 being received into the bearing receiving well 270 , and securing bolt or retaining shaft 400 being used to retain the top 100 and base 200 sections together. The securing bolt 400 fits through base retaining shaft aperture 280 .
[0060] FIG. 6E shows another underside close up perspective view of the top section of the spinning wheel center cap of FIG. 2 according to the present invention showing here, for illustration purposes (and without the base in place), how the securing bolt 400 secures via its threads 420 to the bearing mount post 140 threaded aperture 142 .
[0061] FIGS. 7A-7G show various views of the bottom (base) section 200 of the spinning wheel center cap 50 of FIG. 2 according to the present invention. FIGS. 7F-7G illustrate the mounted relationship of hub connection insert 300 with its connection post 310 shown (for illustration purposes) without the top section 100 in place.
[0062] FIGS. 8A-8C shows various views of the connection member insert 300 of the bottom (base) section 200 of the spinning wheel center cap 50 of FIG. 2 according to the present invention. The insert 300 has a topside 301 and a bottom side 302 . On the bottom side is located an insert underside well to permit clearance for the top of retaining shaft 400 .
[0063] FIGS. 9A-9C illustrate various views of a preferred securing bolt (retaining shaft) 400 . The bolt 400 is outfitted with a retaining ring groove 412 to receive an external retaining ring 410 such as those made by Rotor Clip Company (www.rotorclip.com) of the spinning wheel center cap of FIG. 2 according to the present invention. Other suitable retaining shaft configurations may be employed.
[0064] FIGS. 10A-10C shows an exploded view of the spinning wheel center cap of FIG. 2 according to the present invention. As will be understood from the above descriptions of a preferred embodiment, the spinning cap outer section 100 is outfitted with a bearing 130 . The bearing 130 is then mounted in fixed position within the base 200 to permit the upper section 100 to freely rotate (via bearing 130 ) about axis 60 relative to the base 200 . The retainer shaft or other suitable mechanism is employed to retain the upper 100 and lower 200 sections together while also permitting the upper section 100 to freely rotate. The retainer shaft is mounted within the base, and the connection insert 300 is then mounted over the retainer 400 . The cap 50 may then be attached, via attachment post 310 or via other suitable attachment configuration, to the wheel center hub end face 22 of a desired wheel.
[0065] The various components of the above-described spinning cap 50 invention may be manufactured out of materials known in the art for these purposes, such as, metals, plastics, composite materials, and the like, and combinations thereof. The various fastening mechanisms may be varied, and one of ordinary skill in the art, having the benefit of the present disclosure, would be able to engineer other suitable embodiments within the spirit and scope of the present invention and its pending claims. Additionally, although the present disclosure describes the use of a bearing that is mounted on the inside of the outer section 100 , one of ordinary skill in the art with the benefit of the present disclosure could mount the bearing assembly in other suitable locations on the device, or in connection with the attachment of the outer section 100 to the wheel hub face 22 .
[0066] All references referred to herein are incorporated herein by reference. While the apparatus, systems and methods of this invention have been described in terms of preferred or illustrative embodiments, it will be apparent to those of skill in the art that variations may be applied to the process and system described herein without departing from the concept and scope of the invention. All such similar substitutes and modifications apparent to those skilled in the art are deemed to be within the scope and concept of the invention. Those skilled in the art will recognize that the method and apparatus of the present invention has many applications, and that the present invention is not limited to the representative examples disclosed herein. Moreover, the scope of the present invention covers conventionally known variations and modifications to the system components described herein, as would be known by those skilled in the art. | There is described a spinning hub cap assembly comprising: a base section connectable on its inside to the end face of the wheel center hub and on its outside to an outer section; and an outer section rotatably connected to the base section, wherein the rotatable connection permits rotation of the outer section about the wheel axis of rotation. The outer section may further comprises an outer face and an inner face, wherein the inner face further comprises a bearing mounted thereon on a bearing mount; wherein the base section outside further comprises a receiving well for receiving the bearing in mated, attached relationship. The assembly may further comprise a retention shaft employed to retain together, in rotational relationship, the outer section and the base section. In another embodiment, the base section further comprises a rotational assembly on its outside which is fixably connectable to the cap outer section. | 1 |
[0001] This patent application is a CIP of Non Provisional application Ser. No. 11/809,957 filed 4 Jun. 2007 whose parent was application Ser. No. 11/208,565 filed Aug. 22, 2005 This application claims the benefit of provisional application No. 61/277,201 filed 22 Sep. 2009 and provisional application No. 61/275,411 filed on 28 Aug. 2009 and provisional application No. 61/203,830 filed on 30 Dec. 2008; and claims the benefits of provisional application No. 60/810,747 filed Jun. 5, 2006, and claims the benefits of provisional application No. 60/814,791 filed Jun. 20, 2006, and claims the benefits of provisional application No. 60/814,721 filed Jun. 20, 2006.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a compact mobile vacuum boring and excavation method having a power supply, generally being a combustion engine, a device which will create a vacuum condition within a vacuum container and having a vacuum conduit to air convey or transport solid particles and or liquids into the vacuum container. The vacuum container arrangement may also facilitate the separation of solids from the vacuumed air flow by producing a circular cyclone effect within the vacuum container.
[0004] 2. Description of the Prior Art
[0005] Current state of the art mobile vacuum boring, and excavation systems are large and cumbersome, having an engine, a vacuum pump, a stand alone air water separator tank, a stand alone large air bag house filter, a stand alone air cyclone apparatus, and a stand alone vacuum container all mounted individually on the surface of a trailer or truck bed with inter connecting vacuum hoses to each component. Basically, it is a large and unsightly spider web of hoses & equipment. Length and width of the packaged unit is important to access work areas in congested areas & cities. The vacuum container has the ability to be filled and store liquid and solid particles. Currently, vacuum containers capable of vacuuming mud and boring earth are operated as a batch process. The vacuum container is mounted horizontal and filled with solids or liquid. After it is full of solids or liquid a hydraulic jack inclines the tank for unloading. Because of inclining the vacuum container for unloading, even longer interconnecting vacuum hoses are used to connect stationary equipment to the inclinable vacuum container. An operator climbs up on the truck or trailer bed, drains water from the air/liquid separator and then vertically lifts the filter bag with it's dirt from it's housing, shakes & hand washes the dirt from the bag filter and then pushes it back down into the housing. This process is dirty, labor intensive & time consuming so the filter does not get proper maintenance.
[0006] An objective of the present invention is to provide a means to improve the efficiency of air/solids separation within the vacuum container, improve air filter cleanness by vibrating solids from the air filter during operation, reduce the quantity of component interconnecting conduits, provide user friendly access to the vacuum container and air filter clean out doors and end up with a compact, concentrated weight, vacuum boring and excavation package mounted on a mobile platform.
[0007] It is yet another objective of the present invention to provide a means of adjacently mounting an air filter housing above the vacuum container.
[0008] It is yet another objective of the present invention to provide a means of adjacently mounting an air filter housing above the vacuum container, and said vacuum container and said air filter housing have a connecting vacuum air flow conduit.
[0009] It is yet another objective of the present invention to provide a means of adjacently mounting an air filter housing above the vacuum container, and said vacuum container and said air filter housing having a connecting vacuum air flow conduit and said conduit being located near the rear of said vacuum container (the rear of said vacuum container being the end nearest to the vacuum container access door 12 ), and said height of said filter housing giving vertical space to extent said conduit a distance above the top of said vacuum container. There are several advantages to the conduits location near the back of said vacuum container: 1. When the mobile vehicle stops, liquid in the vacuum tank will be pushed away from the conduit instead of being sloshed up through the conduit and into the filter housing. 2. Solids and liquid being vacuumed into the vacuum tank from the rear of the vacuum tank will be propelled by vacuum air velocity past said conduit.
[0010] The advantage of the extra conduit height within the filter housing above the vacuum tank is to: 1. Serve as a stand pipe above the vacuum container liquid in order to reduce the risk of the liquid sloshing out through the conduit. 2. To allow the lower volume of the filter housing to serve as a liquid/air separator.
[0011] It is yet another objective of the present invention to provide a means of adjacently mounting an air filter housing above the vacuum container, and said vacuum container and said air filter housing have a connecting vertical vacuum air flow conduit and the lower end of said conduit having a seal and float ball to serve as a high liquid level shut off in order to stop the vacuum air flow to the filter housing when the vacuum container is full of liquid and or solids.
[0012] It is yet another objective of the present invention to provide a means of adjacently mounting an air filter housing above the vacuum container and said air filter housing and said vacuum container share a common connecting wall.
[0013] It is yet another objective of the present invention to provide a means of adjacently mounting an air filter housing near the vacuum container and said air filter have air filter disposed within it.
[0014] It is yet another objective of the present invention to provide a means of adjacently mounting an air filter housing above the vacuum container and said air filter housing having an air filter disposed within it and said filter housing having an access door adjacently mounted near to said vacuum container access door.
[0015] It is yet another objective of the present invention to provide a means of adjacently mounting an air filter housing near the vacuum container and said air filter having an air filter disposed within it and said filter housing having an access door to remove solids and to give access to wash said filters with a pressurized spray nozzle.
[0016] It is yet another objective of the present invention to provide a means of adjacently mounting an air filter housing above the vacuum container and said air filter have an air filter disposed within it and to have an air vacuum conduit connecting a vacuum producing devise to said air filter and a 4 way valve arrangement may be placed in said air vacuum conduit between the filter housing and the vacuum producing means for the purpose of reversing the direction of air flow temporally for the purpose of back flow cleaning of said air filters.
[0017] It is yet another objective of the present invention to provide an air compressor to provide a volume of pressurized air to be used in loosening dirt so that the earthen material will be more vacuum able.
[0018] It is yet another objective of the present invention to provide ample air solids separation in order to precipitate the solids into the vacuum container so that they may later be emptied from the vacuum container and be used to refill excavated holes with pack able dirt and earthen material.
[0019] It is yet another objective of the present invention to provide a means of adjacently mounting an air filter housing above the vacuum container and said air filter have an air filter disposed within it and to have an air vacuum conduit connecting a vacuum producing devise to said air filter and said air vacuum conduit have a sealed disconnect positioned so as to allow temporary disconnecting of said filter housing from said vacuum producing means for the purpose of tilting said vacuum container to remove solids.
[0020] It is yet another objective of the present invention to provide a means to accomplish a compact, concentrated weight, vacuum boring & excavation system by mounting a vacuum container at a sufficient incline to allow solids to be emptied out by gravity and to provide space beneath said vacuum container to locate a water storage container.
[0021] It is yet another objective of the invention to provide a means of separating the stored contents by predetermined category and dispensing them without stopping the vacuum fill and store operation or eliminating the vacuum environment within the vacuum container.
[0022] It is yet another objective of the present invention to provide a means of separating the stored contents by predetermined category and dispensing them without stopping the vacuum fill and store operation or eliminating the vacuum environment within the vacuum container.
[0023] It is yet another objective of the present invention to provide an articulated powered vacuum conduit boom with sufficient structural strength to allow an operator to move and control the location of the suction end of the vacuum conduit and said suction end of said vacuum conduit have an earth digging bucket mounted adjacent it, and said conduit boom with said earth digging bucket being mounted on a mobile vehicle, and a preferred vehicle being a powered zero turn radius vehicle having the ability to be converted into a tow able trailer configuration for the purpose of transporting from job to job.
[0024] It is yet another objective of the present invention to provide a vacuum conduit boom with sufficient structural strength, power and articulated movement to allow an operator to move and control the location of the suction end of the vacuum conduit into a manhole lateral line along with a jetter spray nozzle.
[0025] It is yet another objective of the present invention to provide a powered articulated boom with sufficient structural strength to allow an operator to remotely move, control and stabilize the location of a tool attachment end of said boom within one or more tools may be adjacently attached to the tool attachment end of said articulated boom and said tool is selected from the group consisting of an earth digging bucket, a telescoping vacuum conduit, a sensor to locate buried utilities, a monitors and controls for operating the attachments and their function, a water spray nozzle, a manhole cover remover, a cutting tool, a grinding tool, a saw, a blasting tool, a surface cleaning tool, a demolition tool, a torque wrench, a tractor to pull vacuum hose, a jetter nozzle, a hose reel, a cord reel, a cable reel, and a camera and power source to operate it.
[0026] It is yet another objective of the present invention to separate hydrocarbons from the contents vacuumed into the vacuum container.
[0027] It is yet another objective of the present invention to provide a means to purify or sterilize the contents vacuumed into the vacuum tank.
[0028] It is an objective of the present invention to provide a mobile equipment means for servicing and repairing in ground utilities wherein the mobile equipment means comprises a mobile platform which may be quick coupled to a front loader skid steer type vehicle wherein the mobile platform may have a vacuum excavator system, a water jetter system, an air excavator system, a fire hydrant tester to include a water presser dissipater and water diffuser which may also include a dechlorinator, or an articulated boom arm with utility servicing tools attached mounted on it.
[0029] It is yet another objective of the invention for the utility servicing and repair event to be documented. The mobile platform mounted systems may have sensors to measure the physical quantities of the service or repair operation. A data logger, a PLC, an RFID, a camera, a GPS, a utility mapping program, blue tooth transmitting technology, and wireless communication may be used for documenting, controlling, displaying and storing data related to a utility servicing or repair operation or the like. Graphs, pictures, graphics, and charts relative to the service event may be generated for persons with a need to know.
[0030] It is yet another objective of the invention to position an RFID means adjacent to an in ground utility valve, valve stem, tee, junction point, service area, access area, or the like for the purpose of locating, identifying data, verifying information, storing information, retrieving information, or the like, relative to a utility item, function, service or the like.
[0031] It is yet another objective of the invention to manufacture a valve stem adapter with an RFID means adjacently positioned on said valve stem adapter.
[0032] It is yet another objective of the invention to manufacture utility fittings such as a tee, an ell, a flange, a valve, or the like, having an RFID means adjacently positioned on said utility fitting.
[0033] It is yet another objective of the invention to position a valve stem adapter on the valve stem of a utility valve wherein said valve stem adapter contains an RFID means.
[0034] It is yet another objective of the invention to transmit and or receive data or information to or from an RFID means which has been positioned adjacent to a utility.
[0035] It is yet another objective of the invention to locate a air inlet hole near the suction end of the vacuum conduit for the purpose of insuring that air conveying does not stop when the suction end of the vacuum conduit is clogged. It is another objective to place a check valve over said hole which will open at a predetermined vacuum.
[0036] It is yet another objective of the invention to position a vibrator means adjacent to the suction end of a vacuum conduit for the purpose of loosening earthen material and improving it's vacuum ability. It is yet another objective to use the vibrator simultaneously with a pressurized air excavation nozzle, where both work in communication with the other to expedite the rate of excavation.
[0037] It is yet another objective of the invention to add water to pressurized air which is being used for air excavation. It is yet another objective of the invention for said water to add mass said air. It is yet another objective of the invention for the ratio of said water to said air to be regulated to a predetermined amount for establishing a predetermined excavation efficiency. It is yet another objective of the invention for said water to said air ratio to be regulated to accomplish a predetermined ratio of dust and mud.
[0038] It is an object of the present invention to provide a vehicle mounted vacuum excavation system with a vacuum hose reel pivot ably mounted adjacent to a vacuum container and the vacuum hose reel allowing the vacuum hose to be used for vacuuming up solids or liquid while the vacuum hose is still partially rolled up on the vacuum hose reel and the vacuum hose reel being able to retract or dispense a length of vacuum hose as needed in order for the suction end of the vacuum hose to be placed near vacuum able solids or liquids.
[0039] It is an object of the present invention to provide a vehicle mounted vacuum excavation system with a vacuum hose reel pivot ably mounted adjacent to a vacuum container and said vacuum container also adding structural support to said pivotably mounted vacuum hose reel and the pivot ably mounted vacuum hose reel having a means to rotate said hose reel in order to retract or dispense a length of vacuum hose as needed in order for the suction end of the vacuum hose to be placed near vacuum able solids or liquids and said means of rotating said hose reel being chose from a group consisting of a handle for manually rotating said hose reel, an electric motor, a hydraulic motor, an air motor, a vacuum motor, or the like.
[0040] It is an object of the present invention to provide a vehicle mounted vacuum excavation system with a vacuum hose reel pivot ably mounted adjacent to a vacuum container and the pivot ably mounted vacuum hose reel having a means to rotate said hose reel in order to retract or dispense lengths of vacuum hose as needed in order for the suction end of the vacuum hose to be placed near vacuum able solids or liquids and said means of pivot ably attaching said vacuum hose reel to said vacuum container being chosen from a shaft with a bearing plate, a hollow shaft with bearing and a seal, and a slewing ring gear drive such as a Model S-7 hourglass worm slew drive made by Kinematics Mfg. Inc.,
[0041] Another object of this invention is to have a pivot able mounted articulated boom means which will allow an operator to move a reel to a desired position within a three dimensional space adjacent to the base to which the articulated boom arm is attached and said reel being chosen from a group consisting of a conduit reel, hose reel, a power cord reel, a fiber optic reel, a rope reel, and a cable reel.
[0042] It is an object of the present invention to use a slewing ring gear drive as the bearing support and rotational axis means to articulate the boom arm in relation to the mounting base on the mobile vehicle. An example of a slewing ring gear drive could be a Model S-7 hourglass worm slew drive made by Kinematics Mfg. Inc.
[0043] It is an object of the present invention to power a slewing ring gear drive with a hydraulic motor or electric motor.
[0044] It is an object of the present invention to use a motor to wind the reel and it is an objective of the present invention to monitor and document the torque required to turn the reel.
[0045] It is an object of the present invention to have a sensor means to monitor the length of cable or hose that is dispensed from the reel. A sensor means can measure and count the feet or units lengths of cable or hose as it is being dispensed and rewound onto the reel.
[0046] It is an object of the present invention to position sensors and transmitters adjacent to the reel to allow wireless communication and control of data associated with the operation and interaction of equipment and the utilities.
[0047] It is an object of the present invention to provide a vehicle mounted vacuum excavation system and water jetter system, with a vacuum hose reel pivot ably mounted adjacent to a vacuum container and the pivot ably mounted vacuum hose reel having a means to rotate said hose reel in order to retract or dispense a length of vacuum hose as needed in order for the suction end of the vacuum hose to be placed near vacuum able solids or liquids and said vacuum hose having an articulated support means pivot ably mounted adjacent to a jetter hose reel.
SUMMARY OF THE INVENTION
[0048] The above described objectives and others are met by a method having a vacuum container arrangement which may also facilitate the separation of solids from the vacuumed air flow by producing a circular cyclone effect within the vacuum container. The circular cyclone affect is generated by an inlet vacuum conduit entering the vacuum tank on the same end as the solids unloading door is located (being the back end of the vacuum container) and being the same end near to the conduit that conveys air from the vacuum container to the air filter. By extending the inlet vacuum conduit to a point just past the conduit that conveys air from the vacuum container to the filter and pointing the open end of the inlet vacuum conduit toward the vacuum container end opposite the solids unloading door (being the front end of the vacuum container), the velocity of the air flowing through the inlet vacuum conduit will propel any solids or liquid it is conveying to the front end of the vacuum container. Also the cross sectional area of the vacuum container is many times more than the cross sectional area of the inlet conduit, thus the velocity of the conveying air is also substantially reduced (as in a circular cyclone solids separator devise), thus the solids and liquid precipitate out of the air flow and settle on the bottom of the vacuum tank. The velocity of the conveying air slows even more as it reverses direction in a circular motion in order to exit the vacuum container and enter the filter housing through the exit conduit located near the back of the vacuum container. Thus performing a cyclone effect of circling and slowing the air velocity to facilitate removing a maximum of solids and liquid from the air before the air reaches the air filters. A baffle may be arranged around the inlet conduit that flows air from the vacuum container to the filter housing. This baffle may also be arranged so as to create an additional cyclone environment for further separating solids from the air. A housing with filters is adjacently mounted above the vacuum container in order to reduce the quantity of connecting conduit and facilitate a compact, efficient and clean interaction between the vacuum container and the filter housing. The filter housing and the vacuum container may share a common dividing wall. A 4 way valve arrangement may be used between the filter housing and the vacuum producing means to reverse the direction of air flow temporally for the purpose of back flow cleaning of the air filters. A compressible seal and conduit arrangement may be used as a quick disconnect between the vacuum producing means and the filter housing. The vacuum container access door and the filter housing access door may be adjacently placed in near proximity to each other for user friendly access to empty and clean the vacuum container and filter house. By inclining the vacuum tank and filter housing, they may be emptied by gravity. Vibrating the air filters creates a self cleaning effect. The vibration of the air filters may be created for example, by using tubular air filters that are mounted to the filter housing only by one end. Each movement of the vacuum filter housing vibrates solids from the filter and stores the solids in the filter housing until the housing is inclined and the access door is opened for emptying and cleaning. A pressurized water wash wand may be extended through the access door to wash the air filters. A baffle mounted within the filter housing adjacent to the filter housing air inlet conduit facilitates the efficiency of air flow & reduces sloshing of liquids into the air inlet conduit during mobile travel. The filter housing may also be designed to temporally store quantities of liquid carried over from the vacuum container, thus reducing the risk of liquid flowing through the filter to the vacuum pump. A vacuum conduit seal connector can be used to connect vacuum hoses that need to be separated temperately during the process of emptying solids from the vacuum tank. This invention generates an efficient compact mobile vacuum system having a minimum of interconnecting vacuum hoses to convey air from one step of the process to the next. Stacking the filter house above the vacuum container, reduces the square feet of mobile floor surface area requires to mount all the equipment. In other words this invention allows all the required equipment to be mounted on a skid, trailer or truck bed that is shorter and or more narrow than conventional state of the art equipment. In addition to reduced size, the invention has the advantage of operating more efficiently, have a cleaner, more simplistic look, be easier to perform maintenance on and even be more efficient to manufacture at a completive cost. The vacuum container may also have a means to separate a liquid from solids and dispense them from the vacuum container without eliminating the vacuum environment within the vacuum container.
[0049] The vacuum conduit used to transport debris into the vacuum container may have the added feature of being mounted on a powered remote operated articulated boom with sufficient structural strength to allow an operator to remotely move and control the location of the suction end of the vacuum conduit and may have one or more attachments adjacently attached to the boom arm or to the suction end of said vacuum conduit and said attachments being chosen from an earth digging bucket, a telescoping vacuum conduit, sensor to locate buried utilities, monitors and controls to operate the attachments and their function, water spray nozzle, vibrator, manhole cover remover, cutting tool, grinding tool, saw, blasting tool, surface cleaning tool, demolition tool, torque wrench, tractor to pull vacuum hose, jetter nozzle, or camera and power source to operate them.
[0050] This invention also includes the use if the described tool used in conjunction with each other and with or without the vacuum container. Such as a skid mounted, powered, remote control, articulated boom with an attached tool such as a torque wrench; and also having a fire hydrant system tester, a water diffuser and a de chlorinator as part of the skid mounted water utility servicing system and also having a quick coupler for attaching the skid mounted utility servicing system to the front loader arm of a skid steer.
[0051] The above described vacuum system may be mounted on a variety of mobile platforms, chosen from but not limited to a trailer, truck, skid steer, fork lift, track hoe, railroad car, air craft, space craft, boat, barge or zero turn radius vehicle which may have the added feature of being convertible between a powered vehicle & a trailer.
BRIEF DESCRIPTION OF THE DRAWINGS
[0052] FIG. 1 shows a vacuum container according to a first embodiment of the invention having both liquid and solid dispensers and means disposed within the container to separate liquids from solids.
[0053] FIG. 2 shows a side elevation of a vacuum container according to a second embodiment of the invention using a screen cylinder to separate liquids from solids and having a pump dispenser disposed within the screen and having a vibrator attached to the screen. Purification means are disposed within the vacuum container to remove contaminants from the liquids or solids. Purification means 55 , hydrocarbon absorbing means 56 and sterilization means 57 are shown disposed within the vacuum container although they can be attached to the container or conduits. Purification, hydrocarbon absorbs ion or sterilization means may chosen from, but are not limited to, zealite, ozone or activated carbon or ultra violet light or phasing or ultra sonic or chlorine or peat or diatomaceous earth.
[0054] FIG. 3 shows a vacuum container and liquid dispenser according to the second embodiment of the invention using a powered boom to articulate the vacuum conduit with vacuum conduit suction end attachments, sensors & controls.
[0055] FIG. 4 shows a vacuum container with liquid and solid dispensers according to a third embodiment of the invention using an articulated vacuum and jetter boom to reach into a lateral line of a drain pipe. A vacuum conduit tractor is shown pulling a vacuum conduit & the tractor is shown with a rotating vacuum nozzle, controls, light and camera. A jetter is also shown loosening debris to be vacuumed. The vacuum container is shown to separate solids & liquids. The liquid is shown to be dispensed and recycled. The solids are shown to be ground to a smaller size, and transported to a mobile container.
[0056] FIG. 5 shows a skid steer attachment being a platform with a vacuum excavation system, a water jetting system, a performance measuring, monitoring, data storage and documentation system, and an articulated boom arm system with tools attached to it and the tools are supported by the boom and secured in place during a service event such as exercising a valve or doing a repair to an in ground utility.
[0057] FIG. 5B is a side view of a skid mounted fire hydrant testing system quick coupled to a skid steer.
[0058] FIG. 6 is a side view of a vacuum hose guider support which is shown to be supported by a pivot ably mounted, articulated hose guider support boom arm, and said pivot ably mounted, articulated hose guider support boom arm is shown to be mounted adjacent to a jetter hose reel. The vacuum hose guider support can be a length of conduit or it can be a sleeve that the vacuum hose slides through or it can be an arrangement of rollers that serve to support and or guide the vacuum hose. Said rollers may be idler rollers or driven rollers used to assist in dispensing or retracting the vacuum hose. The suction end of the vacuum hose is shown to be vacuuming solids 45 or liquid 2 from a utility man hole basin 59 .
[0059] FIG. 6B is an end view of a vacuum hose reel which is shown to be pivot ably mounted adjacent to a vacuum container, but said vacuum hose reel is shown to be supported on a mobile vehicle platform by a vacuum hose reel support. A vacuum conduit connector is shown to connect the ridged vacuum conduit pipe to the vacuum conduit piping of the rotate able mounting attachment. The vacuum conduit connector can be a ridged fixed connector or it can be a quick release connector or a compression type seal connection which will separate in order to allow a vacuum container to be raised for unloading solids.
[0060] FIG. 7 shows an articulating boom with a multiple conduits 72 reaching into a drainage pipe lateral line to loosen & vacuum debris from the drainage pipe. The earthen material is vacuumed into the vacuum container and then conveyed out of the vacuum container via a screw conveyor 10 . At the discharge end of the conveyor 10 the discharge air from the vacuum producing means 11 is utilized to further convey the earthen materials 35 or debris 45 through a solids dispensing conduit boom. An air nozzle/orifice arrangement means 69 is illustrated as a means to direct the flow of air which is used to convey solids.
[0061] FIG. 8 shows an inclined slope vacuum container supported by a liquid storage container mounted under the slope of the vacuum tank. A filter housing containing filters is shown mounted adjacent to the debris tank. A single door is shown to access both the filter house and the debris tank simultaneously. A solids liquid vibrating screen separator is shown mounted to the debris tank portion of the access door. A powered telescoping cylinder or linear actuator is shown to open or close the access door. A powered articulating vacuum boom is shown with a manhole cover removal attachment.
[0062] FIG. 9 Shows a cross sectional view of an earth excavator digging a hole in the earth using a vacuum container mounted on a zero-turn radius vehicle & having a solids and liquid separation and unloading means. The Vacuum container is shown connected to an articulated vacuum conduit boom with an earth digging bucket attached in the retracted position. A telescoping section of the vacuum conduit is shown in the extended position vacuuming dirt that has been by water sprayed from a liquid spray nozzle which is shown mounted in the outside circumference of an indention in the suction end of the vacuum conduit. The indention reduces the size of solid that can enter the vacuum conduit, thus reducing the frequency of solids being clogged in the vacuum conduit. The earth excavator is shown to be convertible between a zero turn radius vehicle and a tow able trailer. The excavator is shown in the excavating configuration with the spreader blade being used as a jack. The debris access door is shown opening by a powered telescoping cylinder which in turn moves the pull bars and dried dirt out of the vacuum tank.
[0063] FIG. 10 Shows the earth excavator configuration as a trailer attached behind a truck. The trailer hitch has been lowered & the swivel front wheels have been raised. The articulated vacuum boom has been configured into a stored position and the combination dirt pushing blade and jack has been raised. A powered articulated boom is illustrated as mounted adjacent to the vacuum container and air filter housing. Said boom is illustrated to have a torque wrench tool 32 coupled to the attachment means of the telescoping boom arm. The hydraulics which could power the torque wrench tool are illustrated as supplying hydraulic power to a hydraulic driven submergible pump which has been lowered into a pit of water by the powered articulated boom arm. The water is being pumped from the pit by said submergible pump 7 . The pit could be a lift station such as a waste water utility lift station. A Jetter 26 or 39 could be used to break up any surface solids or a grinder pump 27 could be added to grind up solids so that they would be small enough to pump out or to vacuum up.
[0064] FIG. 11 shows a cross sectional side view of a trailer mounted vacuum excavator and surface cleaner with the filter housing 64 mounted above the vacuum container 12 . An air conduit 13 C allows air to flow from the vacuum container 12 to the filter housing 64 and then the air 77 flows through the air filter 65 , the air conduit 13 , through the conduit disconnect seal assembly 83 & 84 . The air 77 is then shown passing through a 4 way diverter valve 81 which may be used to temporarily reverse the flow of air back through the air filter 65 . The air flow reversing is important to assist in cleaning dirt from the filter 65 by blow dirt from the filter 65 to the cavity of the filter housing 64 . This process is especially useful when vacuuming dusty dry solids such as during the process of using air under pressure for excavating dirt. Vacuum suction hose 17 is shown vacuuming solids 6 into the vacuum container 12 through it's rear wall. This side elevation shows the air path and depicts the cyclone effect created by locating both the conduit 13 C and the vacuum hose 17 discharge adjacent to each other as well as being adjacent to the vacuum tank rear access door 12 . The air 77 is shown to slow in velocity, change directions and precipitate the solids it has been carrying adjacent to the bottom front of the vacuum container. The air filter housing 64 and the vacuum container 12 are also shown to be separated by a common dividing wall.
An air compressor 101 is shown to receive air 77 through an air filter 102 . The air 77 flows through conduit 103 , then through air compressor 101 then through conduit 104 then through air nozzle 105 just before air 77 impinges the earthen material 35 thus making the earthen solids 6 more vacuum able.
[0066] FIG. 12 shows a cross sectional end view of a trailer vacuum excavator like is shown in FIG. 14 . This view allows a better visualization of the relation ship between the air conduit 13 C, and the high level vacuum shut off ball 79 . The baffle 78 , the rear vacuum hose inlet 17 , an end view of the air filters 65 orientation relation ship is also shown. The air flow 77 is also shown dropping solids 6 .
[0067] FIG. 13 shows a cross sectional top view of a trailer vacuum excavator like is shown in FIG. 14 . This view allows a better visualization of the relation ship between the air conduit 13 C, and the rear vacuum hose inlet 17 , and the air filters 65 . The air flow 77 is also shown dropping solids 6 .
[0068] FIG. 14 shows a trailer 31 vacuum excavator side view with the vacuum tank laying horizontal during the process of filling it with solids or liquid. The air filter housing 64 is shown mounted horizontally above the vacuum container 12 . The filter housing door 18 F and the vacuum container rear access door 18 are both shown in the closed position during the vacuum filling of the vacuum container 12 . Vacuum filling hose 17 is shown to be vacuum air conveying solids 6 from the ground 35 into the vacuum container 12 . Water storage container 8 is shown as a saddle tank mounted adjacent to the trailer 31 finders & wheels.
[0069] FIG. 15 shows a trailer 31 vacuum excavator side view with the vacuum container 12 temporally raised to an inclined position for the purpose of unloading solids 6 from the vacuum container 12 . The vacuum container 12 read door 18 is shown in the open position with solids 6 flowing from the vacuum container 12 . The filter housing 64 rear access door 18 F is shown emptying solids 6 . The rear access door 18 F gives access to empty solids from the filter housing 64 by gravity as well as giving the operator a user friendly access to the air filters 65 . The open rear access door 18 F gives the operator easy access to insert a pressurized water nozzle within the filter housing 64 in order to wash clean both the air filters 65 and the filter housing 64 . The wash water and dirt flow freely by gravity from the filter housing 64 . The vacuum container can also be washed clean by the operator using a pressurized water nozzle & gravity. Permanent wash nozzles way be mounted and piped into the filter housing 64 or vacuum container 12 . Remote controls can be used to operate the water nozzles.
[0070] FIG. 16 shows a trailer mounted vacuum excavation machine EPI per the present invention showing its vacuum conduit 17 connecting a vacuum container 12 TP. The vacuum tank 12 TP is shown mounted on a trailer 30 TP being pulled by a truck 70 . Vacuum container 12 TP is shown getting it's vacuum source through conduit 17 . Conduit 17 TP is shown vacuuming earthen material 35 into the vacuum container 12 TP. Water 2 under pressure is shown passing through water conduit 5 & through water spray nozzle 26 in order to impinge the earthen material 35 and make it vacuum able. Vacuum excavation machine EPI is shown supplying the power, vacuum source, and pressurized water supply for the excavation. The larger vacuum container 12 TP is shown as a storage container for vacuumed solids & liquid. When it is filled, it will be hauled off to an unloading location by truck 70 . The EPI vacuum excavator will remain in place ready to fill another 12 TP vacuum container. Thus this arrangement functions like a track loader filling a dump trucks with dirt.
SOME DEFINITIONS
[0000]
31 —Mobile Platform—a moveable or transportable surface which may be used to support Things.
32 —Attachment tools—a tool which may be attached to something. Such as a tool that is attached to a boom arm
33 —Utility Sensor—an earth penetrating means for locating a buried utility
34 —Monitor and for Controller, which may include but not be limited to a GPS signal receiver, an RFID, a data logger, a PLC, a sensor, a wireless transmitter, a touch-screen interface, a phone, internet connection, a camera, or the like.
37 —Reel—is an object around which lengths of another material (usually long and flexible) are wound for storage. Generally a reel has a cylindrical core and walls on the sides to retain the material wound around the core.
74 —Skid Steer type vehicle—a skid steer is a vehicle maneuvered by skid steering, a method of steering through braking or engaging tracks or wheels on one side of a vehicle. The skid steering vehicle is turned by generating differential velocity at the opposite side of the vehicle, as the wheels or tracks are non-steer able. Skid steers can pivot steer which is the ability to change direction on the same place without going through any distance in forward or reverse direction. A zero turn radius vehicle and a skid loader are also a skid steer.
177 —a standard predetermined type skid steer quick connect type receiving attachment fastener means for connecting implements to a skid steer
178 —Lifting arm such as that of a skid steer or front loader.
184 —Hydraulic quick connects and associated hydraulic hoses.
88 —(Wireless communication) is the transfer of information over a distance without the use of electrical conductors or wires. It includes antennas for transmitting and receiving information.
89 —(GPS)—is any devise that receives Global Positioning System signals thus the devise may be known as a GPS signal receiver. The GPS signals include data which is use full to locate a present location, which may include time, latitude, longitude and elevation. The GPS signal receiver system may be hand held or mounted on the platform 31 .
90 —(RFID)—Radio-frequency identification is the use of an object (typically referred to as an RFID tag) applied to, incorporated into a product, or applied by a person for the purpose of identification using radio waves. Most RFID tags contain at least two parts. One is the integrated circuit for storing and processing information, modulating and demodulating a radio-frequency (RF) signal, and other specialized functions. There are generally three types of RFID tags, which contain a battery and can transmit signals autonomously, passive RFID tags, which have no battery and require an external source to provoke signal transmission, and battery assisted passive (BAP) which require an external source to wake up but have significant higher forward link capacity providing great read range. Item 90 RFID includes using the type RFID tag best suited for the specific field application. The RFID tag may be hand held or mounted on the platform 31 . The RFID tag may be mounted on a utility access opening, at a repair location, at a buried valve, mounted as part of the valve stem, valve stem adapter or the like for the purpose of finding an in ground valve, a junction point, a repair location or identifying information relative to a utility item, it's performance, maintenance history or the like.
91 —RFID antenna—for receiving and transmitting the signal. The RFID antenna may be hand held or mounted on the platform 31 .
92 —Data Logger—is an electronic devise that records data over time or in relation to location either with a built in instrument or sensor or via external instruments and sensors. Increasingly, but not entirely, they are based on a digital processor (or computer). The data logger may be small, battery operated, portable, or equipped with a microprocessor, internal memory for data storage, or sensors. The data logger may interface with a personal computer and utilize software to activate the data logger and view and analyze the collected data, or may have a local interface device (keypad, LCD) and can be used as a stand-alone device. One of the benefits of using the data logger is the ability to automatically collect data even on a 24-hour 7-day bases. Upon activation, the data logger may measure and record information for the duration of a monitoring period. This allows an accurate picture of the conditions being measured, such as RFID info.; GPS info.; hydraulic flow, pressure or temperature; water flow, pressure or temperature; air flow, pressure and temperature; evaluate process equipment system measurements against predetermined conditions and standards. A USB flash memory data storage device may be used for data storage. The data logger may include or be coupled to a display and soft ware in order to display gathered data in a meaningful, user friendly manor. The data logger may be hand held or mounted on the platform 31 .
93 —(PLC)—programmable logic controller—is a digital computer used for automation of electromechanical processes, such as opening or closing valves or turning switches on or off based or predetermined measurements. A PLC is a real time system wherein output results are produced in response to input conditions within a boundary time. The PLC may be hand held or mounted on the platform 31 .
94 —Sensor—a sensor is a device that measures a physical quantity and converts it into a signal which can be read by an observer or by an instrument such as a data logger, PLC or the like. Examples of a sensor included but are not limited to a volt meter, an amp meter, a flow sensor, a pressure sensor, a temperature sensor, a level sensor, a speed sensor or the like.
95 —Hand held electronic device. Is an electronic device which may be held in the hand of an operator. It may be a type of (PDA) Personal Digital Assistant which may include but not be limited to a GPS signal receiver, an RFID, a data logger, a PLC, a sensor, a wireless transmitter, a touch-screen interface, a phone, internet connection, a camera, or the like. It may be keep by the operator person or stored on the mobile platform.
96 —Camera—is a device that records images, either as a still photograph or as a moving image known as a video or movie. The camera may work with the visual spectrum or with other portions of the electromagnetic spectrum.
97 —Utility Mapping System—to include a GIS Mapping system—A Geological Information System captures, stores, analyzes, edits, manages, displays and presents data that links to location, to include a utility piping system displayed relative to geographic information. It includes merging of cartography and database technology. A GIS is a system which includes mapping software and its application to remote sensing, land surveying, water utility piping system surveying, aerial photography, mathematics, photo grammetry, geography, and tools that can be implemented with GIS software.
98 —Utility Valve—generally an in ground water valve
99 —Valve stem—generally the portion of a valve which is turned in order to open or close a valve.
100 —Valve stem extension rod—which may be telescoping.
120 —Water diffuser—a tool used when testing a fire hydrant for receiving pressurized water from a fire hydrant. The diffuser is configured so as to discharge the water it receives at a pressure and velocity that is less than the pressure and velocity at which the water entered the diffuser. The effectiveness of the diffuser is improved by improving the reduction of pressure or velocity.
121 —De Chlorinator—is a means for removing a chlorine chemical from water.
Data—means groups of information that represent the qualitative or quantitative attributes of a variable or set of variables. Data are typically the results of measurements and can be the basis of graphs, images, or observation of a set of variables. Data are often viewed as the lowest level of abstraction from which information and knowledge are derived.
Document—is to present data in a file or format which may be useable for representation of a body of information. To document (verb) is to produce an artifact of data by collecting and representing information.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0097] Using the drawings, preferred embodiments of the present invention will now be explained.
[0098] FIG. 1 shows the first embodiment of the invention, being one example of various possible arrangements of apparatus within a vacuum container 12 for the purpose of accomplishing a method of separating solids 6 or liquids 2 by predetermined category and then dispensing said solids 6 or liquids 2 using a dispensing means 1 without eliminating the vacuum environment within the vacuum container 12 . In FIG. 1 , the apparatus of the present invention include a vacuum container 12 , a vacuum producing means 11 , a conduit 13 to allow air to move from vacuum container 12 to vacuum producing means 11 , a second conduit 14 dispenses air from the vacuum producing means 11 . Vacuum container 12 has an access door 18 having a hinge 20 and a latching means 19 . Solids 6 or liquids 2 are vacuumed into vacuum container 12 by means of a vacuum conduit 17 . In FIG. 1 , the ground 35 is earthen dirt. Liquid 2 , which has been stored in container 8 , is pumped by pump 7 through pump discharge conduit 5 to a spray nozzle 26 . The pressurized liquid 2 dislodges and emulsifies the ground 35 so it becomes vacuum able. The vacuum able ground 35 and liquid 2 are vacuumed through conduit 17 and into vacuum container 12 . The solids 6 and liquids 2 fall onto a screen 21 which is vibrated by vibrator 23 . Screen 21 is mounted on springs 22 which are supported by support means 24 . Liquid 2 passes through screen 21 and is dispensed from the vacuum container 12 by means of a liquid dispenser means 1 which is shown as a rotary void style in this example. The solids 6 which are too large to pass through the vibrating screen 21 are vibrated to a solids dispensing means 10 which in this example is a rotary void style dispenser. The solids 6 are dispensed into solids conveyor 49 . The vacuum container 12 is supported by a pivot arm 28 and a cylinder 29 which may be extended to dump contents out of container access door 18 . The above system is mounted on a mobile platform 31 with wheels 30 . FIG. 1 is shown excavating ground 35 in order to locate a utility 15 without doing damage to said utility 15 .
[0099] In a second embodiment of the invention shown in FIGS. 2 and 3 , the screen 21 is formed in the shape of a cylinder. The solids 6 and liquids 2 which are vacuumed through conduit 17 , are deposited into vacuum container 12 around the vibrated screen well 21 . The solids 6 which cannot pass through the screen well 21 , remain in the vacuum container 12 to be dumped out through access door 18 when it is opened and cylinder 29 is extended. Liquid 2 passes through screen 21 thus dewatering the solids 6 which remain in vacuum container 12 . Liquid 2 , which passes through screen 21 , is dispensed from vacuum container 12 by means of liquid dispenser 1 , which in this example is a pump. The liquid 2 passes through conduit 16 and into hydro-cyclone 25 where the solids 6 and liquid 2 separation is further refined. The solids 6 are discharged through solids discharge conduit 4 into vacuum container 12 and liquids are discharged through conduit 3 which discharges into a liquid 2 storage container 8 thus providing a method to reclaim and recycle vacuumed liquids 2 . Purification elements 55 such as ozone, activated carbon or zealite, hydrocarbon absorbing means 56 and a sterilization means 57 is located within the vacuum container 12 . in order to purify, sterilize or remove hydrocarbons from the liquids 2 or solids 6 as they pass through vacuum container 12 . The sterilization means 57 , or purification means 55 or hydrocarbon means 56 may also be disposed within the suction conduit 17 or dispensing conduit 16 , or dispensing means 1 or 10 .
[0100] FIG. 3 has the added features of a mobilization means 36 being a powered mobile boom to articulate the movement of vacuum conduit 17 and vacuum conduit attachments 32 which may consist of cutters, demolition means, surface grinders, cleaners, air jets, water jets, scoops, etc. Utility location sensors 33 with monitor/controller means 34 are shown to assist in locating and accessing a utility 15 buried under ground 35 which may consist of dirt, stone, asphalt, concrete or a combination there of. The system of FIG. 3 is shown to also be recycling the liquid 2 as it locates, uncovers or avoids a utility 15 .
[0101] In a third embodiment of the invention shown in FIG. 4 , the solids 6 are passed through a solids grinder 27 in order to reduce the solids 6 size to a predetermined size before being dispensed by a solids dispenser 10 which in this example is a progressive cavity screw. The dispensed solids are collected in solids receiver container 9 to be hauled off. The liquid 2 is shown being dispensed by liquid dispenser means 1 , which in this example is a diaphragm pump. The recycled liquid 2 is pumped through hose reel 37 by transfer pump 7 to a water jetter 39 spraying a water jet 40 , thus cleaning drain pipe 38 with recycled water as it moves.
[0102] The recycled liquid 2 along with solids 6 washed from drain pipe 38 are vacuumed up by the vacuum conduit 17 which is shown as an articulated powered vacuum conduit boom 36 . The articulated powered boom 36 also has means to place the jetter 39 into location down a manhole 59 and into a lateral drainage conduit 38 and dispense the jetter conduit 58 . In this example, telescoping cylinder 41 is used to articulate the vacuum conduit boom 36 and jetter 39 . Vacuum boom structure 44 allows the vacuum conduit 17 to be rigid enough to move, support weight and force in order to articulate and operate attachments such as the vacuum conduit tractor 51 which is articulated into a starting position by the vacuum conduit boom 36 . Vacuum conduit powered tractor 51 then moves vacuum conduit 17 to debris 45 to be vacuumed. Vacuum hose reel 54 unreels and retracts vacuum hose 17 as needed. Vacuum conduit tractor 51 can have a sensor controller means 52 attached so as to monitor and control the vacuuming process. Vacuum conduit tractor 51 can also be fitted with an articulating suction head means 53 , which allows the vacuum conduit tractor to access debris 45 in multiple degrees. Although the articulating vacuum conduit boom 36 is shown vacuuming debris from a drain pipe, said vacuum conduit boom 36 works equally well vacuuming substances from railcars, barges, tankers, silos, or shavings and dung from the barn and stables.
[0103] FIG. 6 illustrate the vacuum hose reel 54 rotate ably mounted and supported by a vacuum container 12 and the vacuum hose reel 54 is also illustrated to rotate around a horizontal axis, however the vacuum hose reel 54 could also be mounted to rotate around a vertical axis instead or have an adjustable mount attached in such a way as to pivot said vacuum hose reel 54 from a horizontal to a vertical axis of rotation. The vacuum container 12 is illustrated to be of the incline slope design which is rigidly mounted and does not further incline in order to unload its contents. However, the vacuum hose reel 54 could be rotate ably mounted adjacently to a vacuum container 12 which is filled in a horizontal orientation and then inclined in order to unload its contents. The vacuum hose 17 is shown to be supported and guided by a support guider 17 B which is being supported by an articulated arm 36 which is mounted adjacent to a jetter hose reel 37 .
[0104] FIG. 6B illustrates a cross section end view of a vacuum hose reel 54 pivot ably attached to a vacuum container 12 by means of a ridged vacuum conduit pipe 17 A extending from the vacuum container 12 . In FIG. 6 the vacuum hose reel 54 is shown to rotate around a horizontal axes. The Vacuum container 12 is shown to give structural support to the ridged vacuum conduit pipe 17 A which in turn is shown to give structural support to a rotate able mounting attachment 303 which has bearings and seals. The rotate able mounting attachment 303 is shown to be supporting the vacuum hose reel 54 . The vacuum hose 17 is attached to the rotate able mounting attachment 303 by means of vacuum conduit connector 17 C. In this drawing, the rotate able mounting attachment 303 with its bearings and seals is shown to be an hourglass worm slewing ring gear drive 303 . An electric motor, a hydraulic motor or a handle may be used to rotate the hourglass worm slewing ring gear drive 303 which then turns the vacuum hose reel 54 in order to retract or dispense a length of vacuum hose 17 .
[0105] FIG. 5 is shown as a side view example of a mobile equipment means for servicing and repairing in ground utilities 15 . The mobile equipment means illustrated in this example is a mobile platform 31 which is connected 177 to a front loader lifting arm 178 of a skid steer 74 type vehicle via a skid steer coupling means 177 . The skid steer hydraulic system is illustrated as providing the power source for powering the vacuum producing means 11 , the water pump 7 , and the valve exerciser tool 32 which is attached to an in ground utility valve 98 via an extension arm 100 . The mobile platform 31 is illustrated to have multiple utility servicing systems mounted on it, which include a vacuum excavator system, a water jetter system, and a pivot ably mounted articulated boom arm 36 with a torque wrench utility servicing tool 32 mounted on it. In this example the torque wrench 32 is being used to exercise an in ground utility valve 98 via an extension rod 100 which is shown to couple the valve stem 99 to the torque wrench 32 . The torque wrench 32 may be used to open and close valves or loosen valve seats, bolts or the like. Camera 96 is illustrated as videoing the servicing of the utility valve 98 . The water jettering system is illustrated as supplying water 2 to a spray nozzle 26 for the purpose of improving the vacuum ability of earthen material 35 . The vacuum excavation system is illustrated as vacuuming up the earthen material 35 thus creating an access opening to an in ground utility 15 . The mobile platform 31 mounted systems are also illustrated to include process control and data documentation sensors 94 to measure the physical quantities of the service or repair operation. A data logger 92 , a PLC 93 , an RFID 90 , a camera 96 , a GPS signal receiver 89 , a utility mapping program 97 and wireless communication via antenna 88 are illustrated as being used for documenting, controlling, displaying and storing data related to a utility servicing or repair operation or the like. A hand held PDA 95 is shown to give a person access to remotely control, gather data and monitor the servicing and repair event. The person wishing to use the PDA 95 is shown to first activate the PDA 95 by means of a personalized RFID tag 90 . PDA 95 activation occurs when the person places his RFID tag 90 in communication with the RFID antenna 91 . The PDA 95 will be activated provided that the persons RFID tag is programmed to activate the system. In this way the PDA 95 is protected from persons not authorized to use or operate the PDA 95 . Use of the RFID tag 90 also documents personal data regarding who is using the system, what he used it for, for what period of time and what took place during his use of the PDA 95 . The described RFID system is also illustrated as being mounted to the mobile platform 31 controller 34 . The PDA 95 or the controller 34 are also illustrated to receive data from sensors 94 which measure physical quantities such as pressure, temperature, or flow of air, liquid, and solids, as well as measuring speed, counting rotations, measuring distance, counting time, measuring voltage, locate buried utilities and the like. The sensors 94 may send their data to a data logger 92 and or a PLC 93 which in turn may store the data, display it on a monitor screen for viewing by a person, use the data for process control, or generate archives of charts, graphs, and useful information formats for future evaluation such as storing the information onto a utility mapping program 97 and documenting. The utility mapping program 97 is illustrated as being displayed on the hand held devise 95 . A GPS signal receiver 89 is illustrated as being used for receiving data from GPS satellites in order to document the latitude, longitude, elevation, time and or date that a utility service was performed. The GPS 89 data may be stored onto a data logger 92 , a PLC 93 and a utility mapping program 97 . Thus the mobile utility servicing machine as illustrated in FIGS. 5 , 11 and 14 can access an in ground utility 15 with out mechanically damaging the utility 15 , perform a service on a utility valve 98 , and document who did the service, the physical location of the service, when the service started, what took place during the service event, when the service was completed, how the service event effected the overall utility system, update the utility data storage archives, and generate reports to those with a need to know. The system may also generate pictures and video of the service work. FIG. 5B illustrates another platform 31 mounted utility testing system quick coupled 77 to a skid steer 74 , similar to FIG. 5 . The fire hydrant tester illustrated in FIG. 5B could be included with the utility servicing systems illustrated in FIG. 5 . FIG. 5B illustrates a mobile platform 31 quick coupled 77 to a skid steer 74 with an articulated boom means 36 mounted on said mobile platform 31 . The remote controlled, powered, articulated boom means 36 is shown to have a linear actuator 41 illustrated a a powered means for lifting the telescoping boom arm. A torque wrench 32 is illustrated as being connected to and supported by the articulated boom means 36 . The Torque wrench 32 is also illustrated a being used for opening or closing a fire hydrant valve 98 . A water hose is illustrated for transporting water under pressure from the fire hydrant to a water diffuser 120 which is mounted on the mobile platform 31 . Sensors 94 are illustrated to be measuring the performance of a fire hydrant and of the utility supply system. The data gathering system is shown to be hand held and capable of wireless transmission of the data. A water diffuser 120 is illustrated as receiving water 2 from the fire hydrant. The Diffuser 120 is also illustrated as discharging the water 2 onto the ground 35 with a minimum of pressure and a minimum of velocity. A De chlorinator 121 is illustrated as a means of removing chlorine from the water 2 before it is released to the ground 35 .
[0106] FIG. 9 illustrates an earth excavator which can alternate between the use of vacuum excavation & bucket 43 excavation. This is illustrated in this example by a vacuum container 12 , with its components, mounted on a zero turn radius vehicle 31 . An articulated powered vacuum conduit boom 36 is also mounted to the zero turn radius vehicle 31 . The articulated powered vacuum conduit 17 boom 36 is constructed with sufficient strength to mount & operate an earth digging bucket 43 adjacent to the suction end of the vacuum conduit 17 . The added means of a telescoping 42 section of vacuum conduit 17 extended to vacuum excavate or may be retracted to allow use of a bucket 43 for digging. The suction end of the telescoping 42 vacuum conduit 17 is shown to have a liquid spray nozzle 26 attached to the outer circumference of an indention 75 in the suction end of the vacuum conduit 17 . The indention serves both to restrict the size of a solid entering vacuum conduit 17 to a size too small to get clogged in the conduit 17 & to serves as a location to mount the spray nozzle 26 at an orientation which will aim the s liquid 2 spray in a direction which will loosen & emulsify the earth 35 located at the suction end entrance of vacuum conduit 17 . Controller 34 represents the sensors & monitors used to automate the sequencing of the articulation of the vacuum conduit boom 36 into location, the locating of utilities 15 by earth penetrating utility sensor 33 , and the selection between & sequencing between earth digging bucket 43 & telescoping 42 vacuum conduit 17 & liquid spray nozzle 26 . In this illustration a liquid spray nozzle 26 is shown to be used to loosen the dirt, but an air pressure nozzle may be substituted for the liquid spray nozzle 26 to loosen dirt thus making it vacuum able. A liquid 2 supply conduit 5 is shown to be mounted adjacent to the vacuum conduit 17 boom 36 .
[0107] FIG. 8 shows a vacuum boring & mud recovery system preparing to clean a drainage pipe 38 . A manhole cover 46 is being removed to gain access to the drainage pipe 38 by a manhole cover 46 removal attachment 47 mounted to the articulated powered vacuum conduit boom 36 . A conduit 48 supplies power to the manhole cover removal attachment means 47 . The manhole cover removal attachment means 47 may be an electro magnet, a suction cup or a mechanical attachment means. FIG. 8 represents a fifth embodiment of the vacuum container 2 showing the vacuum container 2 mounted on an inclined slope, supported by a liquid container 8 located beneath the incline of the vacuum container 12 , and mounted on a generic mobile platform. The inclined angle is sufficient to allow the contents of the vacuum container to be removed by gravity when the door 18 is opened. A filter housing 64 having air filters disposed within it, is shown mounted adjacent to the vacuum container 12 in a configuration to allow simultaneous access to it & the debris tank 12 by a single door 12 . A powered telescoping cylinder 63 , chosen from a linear actuator or hydraulic, or air cylinder is shown mounted within the vacuum container 12 and to the access door 18 . This telescoping cylinder 63 opens or closes the access door 18 . A vibrating screen 21 is shown mounted to the access door 18 in this illustration. Mounting the vibrating screen 21 solids 6 liquids 2 separator to the access door 18 allows improved access for emptying & cleaning.
[0108] FIG. 7 shows an articulated powered jetter boom 60 having multiple boom sections 50 attached to a mobile platform. The boom 60 is shown loosening debris 45 from a drain pipe 38 . Telescoping jetter conduit 61 provides extension of water jetter's reach. Rotary structural support means 44 provide swivel and rotating means.
[0109] FIG. 9 Shows a cross sectional view of an vacuum boring & mood recovery unit digging a hole in the earth 35 using a vacuum container 12 mounted on a zero-turn radius vehicle 31 & having a solids 6 and liquid 2 separation means being a vibrating screen 21 and solids unloading drag bar 62 means. The Vacuum container 12 is shown connected to an vacuum conduit 17 which functions as part of the articulated boom 36 with has an earth digging bucket 43 attached in the retracted position. A telescoping section 42 of the vacuum conduit 17 is shown in the extended position vacuuming dirt 6 that has been emulsified by water 2 sprayed from a liquid spray nozzle 26 which is shown mounted in the outside circumference of an indention 75 in the suction end of the vacuum conduit 17 . The indention reduces the size of solid 6 that can enter the vacuum conduit 17 , thus reducing the frequency of solids 6 being clogged in the vacuum conduit 17 . Near the suction end of the vacuum conduit 17 is illustrated a hole or orifice 17 H in the side if the vacuum conduit 17 . The size of said hole 17 H and the number of said orifices 17 H and the location of said orifice 17 H is predetermined in order to allow a given quantity of air to enter the vacuum conduit for assisting in the air conveying of solids 6 or liquid 2 through said vacuum conduit 17 . Vacuum excavation depends on the velocity of air flowing through the vacuum conduit 17 for conveying solids 6 or liquid 2 . If the suction end of the vacuum conduit 17 becomes clogged then the air can no longer enter through the suction end of the vacuum conduit 17 , thus stopping the air conveying of solids 6 or water 2 , thus further clogging the vacuum conduit 17 along it's length. The addition of holes 17 H provides an alternate place for air to enter said vacuum conduit 17 , thus allowing the air conveying process to continue even if the suction end of said vacuum conduit 17 is clogged. Said hole 17 H may also be equipped with a check valve means which will remain closed until the vacuum value within said vacuum conduit 17 reaches a predetermined vacuum. The suction end of the vacuum conduit 17 is also restricted 17 R by rolling the sided of the suction inlet inward, which is commonly known as swedging the end of a pipe. The restriction 17 R may also be accomplished by placing an indention in the suction end of the vacuum conduit 17 . The restriction 17 R also increases the air velocity at the suction end of conduit 17 thus improving the ability to vacuum up solids 6 or liquid 2 . The earth excavator is shown to be secured in place during the excavation event by using the scrapper blade 66 as a jack to raise the front swivel wheels 68 off the ground 35 . As shown in FIG. 10 the front swivel wheels 68 may be raised and the tow bar tongue 67 may be lowered thus readying the unit for towing as shown in FIG. 10 . The excavator is shown in the excavating configuration. With the spreader blade 66 being used as a jack to sturdy the machine while digging. The debris access door 18 is shown opening by a powered telescoping cylinder 63 which in turn moves the pull bars 62 and dried dirt 6 out of the vacuum tank 12 . In this illustration the water tank 8 and the power plant 76 which may include an engine, hydraulic motor, vacuum pump, air compressor, water pump, muffler or controls, are both positioned beneath the slope of the inclined slope vacuum container 12 thus creating an even more compact vacuum boring & mud recovery system with an even greater concentration of weight. The water tank 8 in FIGS. 8 , 9 & 10 are shown supporting the vacuum container 12 . The operator controls the device from the operator seat 73 . Control center 34 includes means to control solids 6 liquid 2 separation & recycling, functions of excavation, location & avoidance of utilities, mapping of work area, recording of performance.
[0110] FIG. 10 shows the device position behind a towing vehicle 70 .
[0111] FIG. 11 shows a cross sectional side view of a trailer mounted vacuum excavator and surface cleaner with the filter housing 64 mounted above the vacuum container 12 . An air conduit 13 C allows air to flow from the vacuum container 12 to the filter housing 64 and then the air 77 flows through the air filter 65 , the air conduit 13 , through the conduit disconnect seal assembly 83 & 84 . The air 77 is then shown passing through a 4 way diverter valve 81 which may be used to temporarily reverse the flow of air back through the air filter 65 . The air flow reversing is important to assist in cleaning dirt from the filter 65 by blow dirt from the filter 65 to the cavity of the filter housing 64 . This process is especially useful when vacuuming dusty dry solids such as during the process of using air under pressure for excavating dirt. Vacuum suction hose 17 is shown vacuuming solids 6 into the vacuum container 12 through it's rear wall. This side elevation shows the air path and depicts the cyclone effect created by locating both the conduit 13 C and the vacuum hose 17 discharge adjacent to each other as well as being adjacent to the vacuum tank rear access door 12 . The air 77 is shown to slow in velocity, change directions and precipitate the solids it has been carrying adjacent to the bottom front of the vacuum container. The air filter housing 64 and the vacuum container 12 are also shown to be separated by a common dividing wall.
[0112] An air compressor 101 is shown to receive air 77 through an air filter 102 . The air 77 flows through conduit 103 , then through air compressor 101 then through conduit 104 then through air nozzle 105 just before air 77 impinges the earthen material 35 thus making the earthen solids 6 more vacuum able.
[0113] FIG. 12 shows a cross sectional end view of a trailer vacuum excavator like is shown in FIG. 14 . This view allows a better visualization of the relation ship between the air conduit 13 C, and the high level vacuum shut off ball 79 . The baffle 78 , the rear vacuum hose inlet 17 , an end view of the air filters 65 orientation relation ship is also shown. The air flow 77 is also shown dropping solids 6 .
[0114] FIG. 13 shows a cross sectional top view of a trailer vacuum excavator like is shown in FIG. 14 . This view allows a better visualization of the relation ship between the air conduit 13 C, and the rear vacuum hose inlet 17 , and the air filters 65 . The air flow 77 is also shown dropping solids 6 .
[0115] FIG. 14 shows a trailer 31 vacuum excavator side view with the vacuum tank laying horizontal during the process of filling it with solids or liquid. The air filter housing 64 is shown mounted horizontally above the vacuum container 12 . The filter housing door 18 F and the vacuum container rear access door 18 are both shown in the closed position during the vacuum filling of the vacuum container 12 . Vacuum conduit 17 is shown to be vacuum air conveying solids 6 from the ground 35 into the vacuum container 12 . Air 77 under pressure is shown to be discharged through air nozzle 105 for the purpose of loosening the earthen material thus making it vacuum able. A vibrator 17 V is also being used to loosen the earthen material in order to make it vacuum able. The vibrator 17 V is position adjacent to the suction end of the vacuum conduit 17 and may be attached to the suction end of the vacuum conduit via a flexible connection. The vibrator 17 V may be powered by air, electric, hydraulic or the like. A rod or blade or conduit may be attached to the vibrator 17 V for the purpose of attachment and for adding to the earth loosening process. The pressurized air conduit may be a part of the vibrator attachment means and may have orifices tragically placed in said pressurized air conduit for the purpose of loosening earthen material adjacent to the suction end of said suction end of said vacuum conduit 17 . Water 2 may be introduced into said pressurized air at a regulated rate so as to add mass to the air 77 excavation process. Greater mass increases the rate of making earthen material vacuum able. The water 2 volume may also be regulated proportionate to the amount of dust versus mud is desired. Water storage container 8 is shown as a saddle tank mounted adjacent to the trailer 31 finders & wheels. The suction end of the vacuum conduit 17 is being used for providing access to a buried valve 98 which has an RFID tag 90 positioned adjacent to a valve stem 99 adapter. The RFID tag 90 has been activated and used to locate the buried valve 98 . The RFID tag 90 may have data stored which saves and documents the events of this service activity. The RFID tag 90 in this illustration is imbedded within a valve stem 99 adapter so that the RFID tag 90 remains with the valve 98 for the purpose of assisting in the process of locating and identifying information relative to the maintenance and performance of said valve 98 . An RFID antenna 91 , sensors 94 and a data logger 92 may be used in conjunction with the RFID tag 90 .
[0116] FIG. 15 shows a trailer 31 vacuum excavator side view with the vacuum container 12 temporally raised to an inclined position for the purpose of unloading solids 6 from the vacuum container 12 . The vacuum container 12 read door 18 is shown in the open position with solids 6 flowing from the vacuum container 12 . The filter housing 64 rear access door 18 F is shown emptying solids 6 . The rear access door 18 F gives access to empty solids from the filter housing 64 by gravity as well as giving the operator a user friendly access to the air filters 65 . The open rear access door 18 F gives the operator easy access to insert a pressurized water nozzle within the filter housing 64 in order to wash clean both the air filters 65 and the filter housing 64 . The wash water and dirt flow freely by gravity from the filter housing 64 . The vacuum container can also be washed clean by the operator using a pressurized water nozzle & gravity. Permanent wash nozzles way be mounted and piped into the filter housing 64 or vacuum container 12 . Remote controls can be used to operate the water nozzles.
[0117] FIG. 16 shows a trailer mounted vacuum excavation machine EPI per the present invention showing its vacuum conduit 17 connecting a vacuum container 12 TP. The vacuum tank 12 TP is shown mounted on a trailer 30 TP being pulled by a truck 70 . Vacuum container 12 TP is shown getting it's vacuum source through conduit 17 . Conduit 17 TP is shown vacuuming earthen material 35 into the vacuum container 12 TP. Water under pressure 2 is shown passing through water conduit 5 & through water spray nozzle 26 in order to impinge the earthen material 35 and make it vacuum able. Vacuum excavation machine EPI is shown supplying the power, vacuum source, and pressurized water supply for the excavation. The larger vacuum container 12 TP is shown as a storage container for vacuumed solids & liquid. When it is filled, it will be hauled off to an unloading location by truck 70 . The EPI vacuum excavator will remain in place ready to fill another 12 TP vacuum container. Thus this arrangement functions like a track loader filling a dump trucks with dirt.
[0118] The preceding description has been presented to illustrate and describe the invention. It is not intended to be exhaustive or to limit the invention to any precise form disclosed. Many modifications and variations are possible in light of the above teaching.
[0119] The sample embodiments were chosen and described in order to explain the principles of the invention and its practical application. The preceding description is intended to enable others skilled in the art to best utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. The invention includes a variety of tools and processes. Further patent divisional and continuations of this patent application will be filed for the purpose of claiming each of the novel tools and process which have been taught and illustrated in this patent application. It is intended that this invention be defined by the following claims. | A compact mobile vacuum boring, and excavation method comprising a device which will create a vacuum condition within a vacuum container and having a vacuum conduit to air convey a liquid and or solid particles into the vacuum container. The vacuum container air inlet & outlet conduit arrangement may also facilitate the separation of solids from the vacuumed air flow by producing a cyclone effect within the vacuum container. A circular cyclone effect is created within the vacuum container by the arrangement relationship between the inlet and outlet vacuum air conduits and baffles. As the air velocity slows, the solids precipitate out of the air and settle in the vacuum container. A housing with filters disposed within it is also adjacently mounted near the vacuum container in order to reduce the quantity of connecting conduits and facilitate a compact, efficient and clean interaction between the vacuum container and the filter housing. The vacuum container access door and the filter housing access door may be adjacently placed in near proximity to each other for user friendly access to empty and clean the vacuum container and filter house or a common door may access both. A compressible seal and conduit arrangement may be used as a quick disconnect between the vacuum producing means and the filter housing. A reversing valve arrangement may be used to back flow air through the filter. Sensors, data gathering, data logging and documentation of a service event may be included. The above systems may be mounted on a variety of mobile platforms. | 4 |
BACKGROUND AND SUMMARY OF THE INVENTION
[0001] The present application relates to low-power portable fuel cells.
[0002] Background: Fuel Cells
[0003] A fuel cell is an electrochemical power source which is very attractive for many applications. A fuel cell may be regarded as a type of battery, but is significantly different from most common battery chemistries.
[0004] All batteries derive energy from a chemical reaction of some sort. In a fuel cell, the chemical reaction is the oxidation of a gaseous or liquid fuel (typically hydrogen), which may be supplied from an external supply. Thus, fuel cells can avoid the lifetime constraints of primary (non-rechargeable) batteries while also avoiding the degradation due to recharging and discharging which affects most rechargeable battery chemistries. The chemical reactions used in fuel cells are relatively energetic, and thus the amount of energy per unit weight is relatively high.
[0005] Much of the work on fuel cells has been directed towards larger fuel cells, in the range of a kilowatt to tens of kilowatts or more. However, the high energy density of fuel cell chemistries also makes them attractive for many portable applications, in which the energy requirements are far smaller. In particular, the development of gel-stabilized fuel cell technologies has made fuel cells much more attractive for portable applications. In such applications, the requirements of user convenience and comfort are crucial.
[0006] The oxidation of hydrogen produces water. Methanol and other hydrocarbon fuels have been proposed for fuel cells, but oxidation of any hydrocarbon fuel will produce water (as well as carbon dioxide, which is gaseous and not a problem). A fuel cell will also produce some heat, and some of the water produced will be water vapor rather than liquid water. However, some of the water vapor will condense as liquid water (either in the fuel cell plumbing, or shortly afterwards as the exhaust vapor cools). Thus liquid water will be generated.
[0007] The generation of liquid water is a significant problem: users do not want a computer which drips on their paperwork. The total flow of water is very small—on the order of one drop per minute, for 50W of power—but this is enough to be a serious nuisance in some applications.
[0008] [0008]FIG. 1 shows a typical small fuel cell for portable applications. This cell is supplied with air and hydrogen. A container 100 holds a proton transport membrane 102 . The transport membrane 102 can be, for example, a sulfonated styrene/ethylene/butylene-styrene triblock copolymer from DAIS. The membrane 102 is flanked by a porous cathode 104 and a porous anode 106 . (These are made of a porous conductive material, e.g. carbon fibers.) Hydrogen, supplied to fuel manifold 110 through inlet 114 , is catalytically ionized at the interface between anode 106 and membrane 102 . Hydrogen can then be transported through membrane 102 as protons (hydrogen ions). Similarly, oxygen is introduced through inlet 116 into oxidant manifold 112 , and is absorbed at the interface between membrane 102 and cathode 104 , to form oxygen ions within membrane 102 . The oxygen ions and protons react to form water, which is exuded into the oxidant manifold. Typically an excess of air is pumped into inlet 116 , so the exhaust port 118 carries air which is only partly deoxygenated, as well as moisture from the reaction. The free energy from the reaction can be extracted electrically at terminals V+ and V−. The voltage per cell will be in the neighborhood of 0.6V to 1.1V, depending on load characteristics and cell design.
[0009] The drawing of FIG. 1 is highly simplified. Since the membrane 102 generates only a small current per square inch, the membrane is typically folded back and forth many times. Thus the manifolds 110 and 112 will typically be long meandering passages, where condensed water can easily block gas flow. Additional pressure is therefore applied to the inputs occasionally, to produce a puff at the exhaust port which vents excess water.
[0010] Additional background on fuel cell technology can be found in Kordesh and Simader, FUEL CELLS AND THEIR APPLICATIONS (1996); the HANDBOOK OF BATTERIES AND FUEL CELLS (ed. Linden 1984); in the proceedings of the Grove Fuel Cell Symposia; and in the proceedings of the Annual Battery Conference on Applications and Advances; all of which are hereby incorporated by reference.
[0011] Innovative Portable Fuel Cell System
[0012] The present invention provides a portable fuel cell-powered system in which the water by-product is disposed of by ultrasonic vaporization. Users will object to the presence of liquid water (or to the presence of steam), but ultrasonic vaporization provides a very convenient way to expel H 2 O without the difficulties of handling liquid water in an office environment. Preferably a piezoelectric element is used to vaporize the water by-product, and a small port is used to eject the vapor thus produced.
[0013] In one class of embodiments, a heated airstream is combined with the water vapor exhaust port to reduce the chances of liquid water accumulating.
[0014] In another class of embodiments, the water byproduct is transported as a very-low-volume liquid flow to a vaporization orifice on the exterior of the system, where an ultrasonic transducer atomizes and expels the water.
BRIEF DESCRIPTION OF THE DRAWING
[0015] The disclosed inventions will be described with reference to the accompanying drawings, which show important sample embodiments of the invention and which are incorporated in the specification hereof by reference, wherein:
[0016] [0016]FIG. 1 shows a typical small fuel cell for portable applications.
[0017] [0017]FIG. 2 shows fuel cells and water discharge path in a first class of embodiments.
[0018] [0018]FIG. 3 shows fuel cells and water discharge path in a second class of embodiments.
[0019] [0019]FIG. 4 shows a block diagram of a portable computer system according to the presently preferred embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0020] The numerous innovative teachings of the present application will be described with particular reference to the presently preferred embodiment. However, it should be understood that this class of embodiments provides only a few examples of the many advantageous uses of the 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.
[0021] [0021]FIG. 2 shows a fuel cell and its water discharge path in a first class of embodiments. Fuel cell 210 is supplied (at inlet 114 ) by hydrogen from a hydrogen-storage reservoir 202 , and (at inlet 116 ) with air from air pump 204 . The exhaust port 118 releases moist air and water droplets.
[0022] An atomizer 220 includes a resonant piezoelectric transducer. The transducer is driven at an ultrasonic frequency, e.g. 100 KHz, which atomizes water droplets. Thus any liquid-phase water in the gas flow exiting the atomizer 220 will be in the form of very small droplets.
[0023] A heat exchanger 230 B preferably follows the atomizer 220 . This heat exchanger is coupled to the portable computer's CPU by a heat pipe, so it imparts a thermal rise to the gas flow exiting the atomizer. This helps to prevent condensation in or near the computer.
[0024] Alternatively a heat exchanger 230 A can be located before the atomizer, instead of or in addition to the following heat exchanger 230 B. Here too the primary purpose is to prevent condensation. However, a side benefit is that a small amount of extra cooling for the computer can be obtained.
[0025] The flow of moist air is finally discharged through an external exhaust port 240 .
[0026] [0026]FIG. 3 shows a fuel cell and its water discharge path in a second class of embodiments. In this class of embodiments the fuel cell 210 is followed by a separator 215 which extracts liquid water from the gas flow. (Alternatively, the separator 215 can be integrated into the fuel cell 210 , so that liquid water is produced at a separate outlet of the fuel cell 210 .) The small flow of liquid water is then fed directly to an atomizer 220 ′, which atomizes and expels the water. The gas flow is simply exhausted directly through an external port 240 .
[0027] [0027]FIG. 4 shows a portable computer including a power converter 800 to operate from AC power, when available, and from fuel cell 802 . The power converter is connected, through a full-wave bridge rectifier FWR, to draw power from AC mains. The fuel cell 802 (or the converter 800 ), connected through a voltage regulator 804 , is able to power the complete portable computer system, which includes. in this example:
[0028] user input devices (e.g. keyboard 806 and mouse 808 );
[0029] at least one microprocessor 810 which is operatively connected to receive inputs from said input device, through an interface manager chip 811 (which also provides an interface to the various ports);
[0030] a memory (e.g. flash memory 812 and RAM 816 ), which is accessible by the microprocessor;
[0031] a data output device (e.g. display 820 and display driver card 822 ) which is connected to output data generated by microprocessor; and
[0032] a magnetic disk drive 830 which is read-write accessible, through an interface unit 831 , by the microprocessor.
[0033] Optionally, of course, many other components can be included, and this configuration is not definitive by any means.
[0034] According to a disclosed class of innovative embodiments, there is provided: A portable electronic system, comprising: electronic operating circuits which perform one or more functions; a fuel cell operatively connected to provide power to said operating circuits; and an ultrasonic atomizer which uses ultrasonic energy to atomize any liquid water produced by said fuel cell.
[0035] According to another disclosed class of innovative embodiments, there is provided: A computer system, comprising: a user input device; a microprocessor operatively connected to detect inputs from said input device; memory which is connected to be read/write accessible by said microprocessor; a video controller connected to said microprocessor; a display operatively connected to display data generated by said video controller at a first refresh rate; a fuel cell;
[0036] a power supply connected to provide power from said fuel cell to said microprocessor, said memory, and said display; and an ultrasonic atomizer which uses ultrasonic energy to atomize any liquid water produced by said fuel cell.
[0037] According to another disclosed class of innovative embodiments, there is provided: A method for operating a fuel cell, comprising the steps of: (a.) supplying an oxidant and a fuel which contains hydrogen to a dry-electrolyte membrane; (b.) allowing an electrochemical reaction to occur at said membrane in which hydrogen is oxidized to form water; and (c.) atomizing any water condensate from the cell by applying ultrasonic energy thereto, and expelling atomized water into the ambient air.
[0038] Modifications and Variations
[0039] As will be recognized by those skilled in the art, the innovative concepts described in the present application can be modified and varied over a tremendous range of applications, and accordingly the scope of patented subject matter is not limited by any of the specific exemplary teachings given.
[0040] Optionally a reservoir can be used to buffer the flow of water, in combination with atomization, as described above, to get rid of it.
[0041] The disclosed inventions can be applied to a wide variety of dry portable fuel cells. For example, the disclosed inventions can also be applied to fuel cell technologies which use a solid-oxide transport medium. | A portable electronic system which obtains power from a dry-electrolyte fuel cell. Water which is produced by the fuel cell is atomized by an ultrasonic transducer, to avoid user inconvenience due to reservoirs or dripping. | 8 |
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